JP2012115002A - Stator coil manufacturing method and preforming apparatus used in the manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator coil manufacturing method which makes it possible to achieve stable normal winding in a wind-up process without driving a core member to rotate and obtain surely a wound body which is wound around a desired roll diameter.SOLUTION: The manufacturing method of the present invention comprises a coil wire rod formation step 101 in which a plurality of coil wire rods 50 are formed by forming an electric conductive wire into a prescribed shape, an integration step 102 in which the plurality of coil wire rods 50 are integrated to form a belt-like integrated body 47, and a winding step 103 in which the integrated body 47 is disposed in place, with its tip part inner surface aligned along the outer peripheral surface of a freely rotatable core member 81, and a plurality of feed arrows 82a are inserted in prescribed clearances between straight overlapping portions 41, adjacent to each other, of the integrated body 47, and, while the tips thereof are engaged with the core member 81, the feed arrows 82a are intermittently rotated in the circumferential direction, whereby the core member 81 is rotated and the integrated body 47 is wound around it.

Description

  The present invention relates to a method for manufacturing a stator coil used in a rotating electrical machine and a preforming apparatus used in the manufacturing method.

  In recent years, rotating electrical machines used as electric motors and generators have been required to have small size, high output, and high quality. For example, in a rotating electrical machine mounted on a vehicle, the space for mounting the rotating electrical machine is becoming smaller, while an improvement in output is required. As a conventional rotating electrical machine, a stator coil used for a stator is formed by continuous winding (for example, see Patent Document 1).

  The manufacturing method of the stator coil described in patent document 1 has the winding-up process which winds up the assembly body formed by incorporating a some coil wire around a core member. And in this winding-up process, while inserting and aligning an alignment member in each gap formed between adjacent straight overlapping portions of the embedded body supplied to the core member, the embedded body is used as the core member. I'm trying to wind it up. As a result, the integrated body can be aligned and wound.

JP 2010-75035 A

  However, in the method of manufacturing a stator coil described in Patent Document 1, since the rotation of the core member and the supply and positioning of the built-in body are controlled synchronously, the quality of the coil wire rod is formed and the built-in body being wound up If the behavior is small, synchronization deviation (positional deviation) is likely to occur, and the operation rate becomes unstable. In addition, since the core member is driven to rotate, the built-in body easily swells radially outward during winding due to centrifugal force, and variations in the final winding diameter are likely to occur. For this reason, restrictions on speeding up by preventing swelling are added.

  The present invention has been made in view of the above circumstances, and in the winding process, stable aligned winding can be performed without driving and rotating the core member, and the winding wound to a desired winding diameter. It is an object to be solved to provide a method of manufacturing a stator coil that can stably obtain a workpiece, and a winding device used in the manufacturing method.

  The invention according to claim 1, which has been made to solve the above-mentioned problems, is a method for manufacturing a stator coil in which a plurality of coil wires are wound, in which electric conductor wires are formed and are directly parallel to each other. A plurality of slot accommodating portions extending in parallel with each other in the longitudinal direction, and a plurality of turn portions alternately connecting the adjacent slot accommodating portions at one end side and the other end side of the slot accommodating portions. A coil wire material forming step for forming a coil wire material, and a plurality of the coil wire materials are arranged with a predetermined pitch shift in the longitudinal direction, and a plurality of the linearly overlapped portions formed by superimposing the slot accommodating portions on each other are elongated. An assembly process for forming a strip-shaped integrated body in a direction, and a winding process for winding the integrated body around a core member to form a wound body, the winding process being freely rotatable The inner end of the built-in body is arranged along the outer peripheral surface of the supported core member, and a plurality of feeds are fed into a predetermined gap formed between the adjacent straight overlapping portions of the built-in body. The core member is rotated by intermittently rotating the feed arrow within a predetermined range in the circumferential direction of the core member with the arrow inserted and the tip of the feed arrow engaged with the core member. The built-in body is wound around the core member.

  According to the first aspect of the present invention, the winding step includes inserting a plurality of feed arrows into a predetermined gap formed between adjacent straight overlapping portions of the built-in body, and moving the tips of the feed arrows. By rotating the feed arrow intermittently within a predetermined range in the circumferential direction of the core member while being engaged with the core member, the built-in body is wound around the core member while rotating the core member. That is, in the present invention, since the core member is not driven and rotated, the core member is wound around the core member while rotating the core member with the feed arrow, so that the rotation of the core member and the supply and positioning of the core body are performed. There is no need for synchronous control. Therefore, the occurrence of synchronization deviation (position deviation) and instability of the operation rate are eliminated. Further, since the core member is not driven and rotated, the built-in body does not bulge outward in the radial direction due to the centrifugal force during winding of the built-in body, and thus the diameter of the formed wound body is less likely to vary. . Further, during winding of the built-in body, a feed arrow whose tip is engaged with the core member is always inserted into a predetermined gap formed between adjacent straight overlapping portions of the built-in body. Therefore, it is possible to ensure a good alignment state of the built-in bodies. Therefore, according to the present invention, in the winding process, it is possible to perform stable aligned winding of the built-in body, and it is possible to stably obtain a wound body wound up to a desired winding diameter.

  In the invention according to claim 2, in the winding process, when the feeding arrow is extracted from a predetermined gap formed between the straight overlapping portions adjacent to each other in the built-in body, The linear overlapping portion is positioned by inserting a positioning arrow into another predetermined gap.

  According to the invention described in claim 2, when the feed arrow is extracted from the predetermined gap of the built-in body and returned from the winding stop position to the winding start position, it is inserted into another predetermined gap of the built-in body. With the positioning arrows, it is possible to reliably maintain a good alignment state of the straight overlapping portions.

  According to a third aspect of the present invention, in the winding step, a plurality of first feed arrows inserted into one side of a predetermined gap formed between the adjacent straight overlapping portions of the built-in body. And a plurality of second feed arrows inserted on the other side of the predetermined gap, and the first feed arrow and the second feed arrow are alternately inserted into the predetermined gap, and The assembled body is wound around the core member while rotating the core member alternately in the circumferential direction of the core member.

  According to the third aspect of the present invention, when the built-in body is wound with the first feed arrow, the second feed arrow returns to the winding start position, and when the built-up body is wound with the second feed arrow, the first feed arrow is It is possible to return to the winding start position. Therefore, since the loss of time for the first feed arrow and the second feed arrow to return to the winding start position can be reduced, it is possible to speed up winding of the built-in body. Moreover, since the 1st feed arrow and the 2nd feed arrow are inserted alternately in the predetermined clearance gap formed between the adjacent linearly overlapped parts of the built-in body, The positioning arrow used in the invention can be made unnecessary.

  The invention described in claim 4 is characterized in that the winding step is performed while pressing the turn portions on both sides of the slot housing portion of the built-in body to be wound from the outer peripheral side with a pressing member.

  According to the invention described in claim 4, since the turn portion can be prevented from bulging radially outward and twisted during winding of the built-in body, the turn portion is well aligned and desired. It is possible to stably obtain a wound body wound to a winding diameter of.

  According to a fifth aspect of the present invention, the pressing member has a pair of rollers arranged in parallel in the circumferential direction of the core member, and the pair of rollers are installed to be swingable in the circumferential direction of the core member. It is characterized by that.

  According to the invention described in claim 5, since the pair of rollers can always come into contact with the turn portion of the built-in body at two points, the built-in body being wound up is bulged outward, twisted, etc. Occurrence can be prevented more reliably.

  In the invention according to claim 6, the pressing member constantly presses the turn portion with either one of the first pressing force and the second pressing force smaller than the first pressing force, While the winding operation of the built-in body by the feed arrow is stopped, the pressing is performed with the first pressing force.

  According to the invention described in claim 6, while the winding operation of the built-in body by the feed arrow is stopped, the turn portion is bulged outward in the radial direction by pressing with a relatively large first pressing force. It can be surely prevented. Further, during the winding operation of the built-in body by the feed arrow, even if there is a step in the turn part of the built-in body by pressing with a relatively small second pressing force, the turn part can be stably held by the pressing member. It is possible to prevent the occurrence of damage to the insulating coating covering the surface of the coil wire.

  According to a seventh aspect of the present invention, the pressing member presses the first pressing member that presses the turn portion on one end side of the slot accommodating portion, and the turn portion on the other end side of the slot accommodating portion. And the first pressing member and the second pressing member are alternately rotated by a predetermined pitch in the circumferential direction.

  According to the invention of claim 7, during winding of the built-in body, the first pressing member and the second pressing member can alternately press the turn portions on both ends of the slot accommodating portion. It is possible to appropriately prevent the turn portion from bulging outward in the radial direction. Thereby, the winding body wound up by the desired winding diameter can be obtained more reliably.

  The invention according to claim 8 is characterized in that the first pressing member and the second pressing member independently advance and retract to press the turn portion with an arbitrary force.

  According to the invention described in claim 8, since the timing and pressing force of the first pressing member and the second pressing member can be switched appropriately according to the situation, the spring back (elasticity generated in the turn portion) Winding corresponding to the resistance force due to the returning action) and other external factors becomes possible.

  A ninth aspect of the present invention is a winding device used in the method for manufacturing a stator coil according to the first aspect, wherein the core member is pivotally supported so as to be freely rotatable, and is wound around the outer peripheral side of the core member. A plurality of feed arrows arranged in parallel in the direction, a first drive member for moving the feed arrow forward and backward with respect to the outer peripheral surface of the core member, and an inner surface of the tip portion along the outer peripheral surface of the core member In the circumferential direction of the core member, the feed arrow is inserted into a predetermined gap formed between adjacent straight overlapping portions of the built-in bodies arranged in a row and the tip thereof engages with the core member. And a second drive member to be rotated.

  According to the ninth aspect of the present invention, it is possible to easily achieve a winding device that can perform stable aligned winding and reliably wind to a desired winding diameter without driving and rotating the core member. Can be realized.

  In the invention according to claim 10, when the feeding arrow is extracted from a predetermined gap formed between the adjacent straight overlapping portions of the built-in body, another predetermined gap is formed in the built-in body. It is provided with a positioning arrow that is inserted to position the straight overlapping portion.

  According to the invention described in claim 10, when the feeding arrow is returned from the winding stop position to the winding start position, the positioning arrow is inserted into the predetermined gap of the built-in body, thereby Good alignment can be reliably maintained.

  According to an eleventh aspect of the present invention, the feed arrow includes a plurality of first feed arrows that are inserted into one side of a predetermined gap formed between the straight overlapping portions adjacent to each other of the built-in body. And a plurality of second feed arrows inserted on the other side of the predetermined gap.

  According to the eleventh aspect of the invention, when the built-in body is wound up by the first feed arrow, the second feed arrow returns to the winding start position, and when the built-in body is wound up by the second feed arrow, the first feed arrow is It can be configured to return to the winding start position. Therefore, since the loss of time for the first feed arrow and the second feed arrow to return to the winding start position can be reduced, a winding device that can wind up the built-in body at high speed can be easily realized. it can.

  The invention described in claim 12 is characterized by comprising a pressing member that presses the built-in body wound around the core member from the outer peripheral side.

  According to the twelfth aspect of the present invention, it is possible to prevent the occurrence of bulging or twisting of the built-in body in the radial direction during winding, so that the turn portions are well aligned and stably desired. It is possible to more reliably obtain a wound body wound to a winding diameter of.

It is an axial direction sectional view showing typically the composition of the rotary electric machine concerning an embodiment. 1 is an overall perspective view of a stator of a rotating electrical machine according to an embodiment. It is a top view of the stator of the rotary electric machine which concerns on embodiment. It is a side view of the stator of the rotary electric machine which concerns on embodiment. It is a top view of the stator core which concerns on embodiment. It is a top view of the split core which concerns on embodiment. It is a whole perspective view of the stator coil which concerns on embodiment. It is a side view of the stator coil which concerns on embodiment. It is a top view of the stator coil which concerns on embodiment. It is a bottom view of the stator coil which concerns on embodiment. (A) (B) is sectional drawing of the coil wire used in embodiment. (A) is a top view of the coil wire used in the embodiment, and (B) is a front view of the coil wire. (A) is a perspective view which shows the shape of the turn part of the conducting wire used in embodiment, (B) is a perspective view which shows the several turn part adjacent. It is a connection diagram of a stator winding used in the embodiment. It is explanatory drawing which shows the arrangement position of the 1st slot accommodating part of each conducting wire arrange | positioned at the outermost diameter side of each slot in embodiment. It is explanatory drawing which shows the arrangement position and locus | trajectory of the slot accommodating part of one conducting wire (U1-4 ') in the stator winding | coil of embodiment. It is a coil | winding specification figure which shows the connection state of the coil | winding of V phase in embodiment. It is a block diagram which shows the manufacturing process of the manufacturing method of embodiment. It is a front view of the integration body formed in the integration process of an embodiment. It is a top view of the winding apparatus used for the winding process of Embodiment 1. It is a front view of the winding device used for the winding process of Embodiment 1. It is a figure which shows the core member of the winding apparatus used for the winding process of Embodiment 1, Comprising: (A) is a top view of the core member divided into four, (B) is the side view. It is a front view of the winding apparatus used for the winding process of Embodiment 2. It is the top view which looked at the 1st rotation table of the winding device used for the winding process of Embodiment 2 from the upper part. It is the top view which looked at the 2nd rotation table of the winding device used for the winding process of Embodiment 2 from the upper part.

  Hereinafter, embodiments of a method for manufacturing a stator coil according to the present invention will be described in detail. The embodiment to be described is merely an example of the embodiment, and the method for manufacturing the stator coil of the present invention is not limited to the following embodiment. The method for manufacturing a stator coil of the present invention can be implemented in various forms that have been modified or improved by those skilled in the art without departing from the scope of the present invention.

  First, the structure of the rotary electricity using the stator coil obtained by the stator coil manufacturing method of the present embodiment will be described. FIG. 1 is an axial cross-sectional view schematically showing the configuration of the rotating electrical machine according to the embodiment. 2 is an overall perspective view of the stator of the rotating electrical machine according to the present embodiment, FIG. 3 is a plan view of the stator, and FIG. 4 is a side view of the stator.

  The rotating electrical machine 1 according to the present embodiment is used as, for example, a rotating electrical machine that also serves as a motor and a generator of a vehicle, and a pair of substantially bottomed cylindrical housing members 10a and 10b are joined at openings. A housing 10, a rotor 14 fixed to a rotary shaft 13 rotatably supported on the housing 10 via bearings 11, 12, and a position surrounding the rotor 14 inside the housing 10. A fixed stator 20.

  The rotor 14 is formed with a plurality of magnetic poles having different magnetities alternately in the circumferential direction by permanent magnets on the outer peripheral side facing the inner peripheral side of the stator 20. The number of magnetic poles of the rotor 14 is not limited because it varies depending on the rotating electrical machine. In this embodiment, an 8-pole rotor (N pole: 4, S pole: 4) is used.

  As shown in FIGS. 2 to 4, the stator 20 includes a stator core 30 and a three-phase stator coil 40 formed of a plurality (48 in the present embodiment) of coil wire rods 50. . Note that insulating paper may be disposed between the stator core 30 and the stator coil 40.

  FIG. 5 is a plan view of the stator core according to the present embodiment. FIG. 6 is a plan view of the split core according to the present embodiment.

  As shown in FIG. 5, the stator core 30 has an annular shape in which a plurality of slots 31 are formed on the inner periphery. The plurality of slots 31 are provided in the circumferential direction so that the depth direction thereof coincides with the radial direction. The number of slots 31 formed in the stator core 30 is formed at a ratio of two per one phase of the stator coil 40 with respect to the number of magnetic poles of the rotor (eight magnetic poles). In this embodiment, since 8 × 3 × 2 = 48, the number of slots is 48.

  The stator core 30 is formed by connecting a predetermined number (24 in this embodiment) of the split cores 32 shown in FIG. 6 in the circumferential direction. An outer cylinder 37 is fitted on the outer periphery of the split core 32 (see FIGS. 2 to 4). The split core 32 has a shape in which one slot 31 is defined and one slot 31 is defined between the adjacent split cores 32 in the circumferential direction. Specifically, the split core 32 has a pair of teeth portions 33 that extend radially inward, and a back core portion 34 that connects the teeth portions 33 radially outward.

  The split core 32 constituting the stator core 30 is formed by laminating a plurality of electromagnetic steel plates. An insulating thin film is disposed between the laminated electrical steel sheets. The split core 32 may be formed not only from the laminated body of electromagnetic steel sheets but also using a conventionally known metal thin plate and insulating thin film.

  7 is an overall perspective view of the stator coil according to the present embodiment, FIG. 8 is a side view of the stator coil, FIG. 9 is a plan view of the stator coil, and FIG. 10 is the stator. It is a bottom view of a coil.

  As shown in FIGS. 7 to 10, the stator coil 40 is formed in a cylindrical shape by a plurality of coil wires 50, and includes a straight overlapping portion 41 accommodated in the slot 31 of the stator core 30, Coil end portions 42 disposed outside the slot 31 are provided at both ends of the straight overlapping portion 41. On the end face of one coil end portion 42, the output line and the neutral point protrude in the axial direction, and the end of the coil wire 50 protruding from the inner diameter side is connected to the end of the coil wire 50 protruding from the outer diameter side. A crossover 70 is provided.

  As shown in FIG. 11A, the coil wire 50 constituting the stator coil 40 includes a copper conductor 67 and an insulating film 68 comprising an inner layer 68a and an outer layer 68b covering the outer periphery of the conductor 67 and insulating the conductor 67. Formed from. The thickness of the insulating coating 68 including the inner layer 68a and the outer layer 68b is set between 100 μm and 200 μm. As described above, since the insulating coating 68 composed of the inner layer 68a and the outer layer 68b is thick, it is not necessary to sandwich insulating paper or the like between the coil wires 50 in order to insulate the coil wires 50 from each other. Insulating paper may be provided between 50 or between the stator core 30 and the stator coil 40.

  The outer layer 68b is formed of an insulating material such as nylon, and the inner layer 68a is formed of an insulating material such as a thermoplastic resin or a polyamideimide having a glass transition temperature higher than that of the outer layer 68b. Accordingly, the outer layer 68b is crystallized faster than the inner layer 68a by the heat generated in the rotating electrical machine 1, so that the surface hardness of the outer layer 68b is increased and the coil wire 50 is not easily damaged. For this reason, the insulation of the coil wire 50 which performed the process which forms a step part in the turn part 52 mentioned later is securable.

  Further, as shown in FIG. 11B, the coil wire 50 may cover the outer periphery of the insulating coating 68 made of the inner layer 68a and the outer layer 68b with a fusion material 69 made of epoxy resin or the like. As a result, the fusion material 69 is melted faster than the insulating coating 68 by the heat generated in the rotating electrical machine, so that the plurality of coil wire materials 50 accommodated in the same slot 31 are thermally bonded by the fusion material 69. . As a result, a plurality of coil wire rods 50 accommodated in the same slot 31 are integrated and the coil wire rods 50 are cured, so that the mechanical strength of the coil wire rods 50 in the slots 31 is improved. A film made of polyphenylene sulfide (PPS) may be used for the outer layer 68b of the insulating film 68.

  FIG. 12 is a development view when the coil wire 50 is developed on a plane. As shown in FIG. 12, the coil wire 50 has a plurality of slot accommodating portions 51 accommodated in the slots 31 of the stator core 30, and protrudes out of the stator core 30 from the slots 31, and is formed into different slots in the circumferential direction. And a plurality of turn portions 52 connecting the slot accommodating portions 51 accommodated therein. In the case of this embodiment, each coil wire 50 is provided with 12 slot accommodating parts 51A-51L and 11 turn parts 52A-52K.

  Specifically, the slot accommodating portions 51 in the present embodiment are respectively accommodated in slots 31 spaced apart in the circumferential direction of the stator core 30 in order from the first slot accommodating portion 51A located at the left end of FIG. The slot accommodating portion 51B, the third slot accommodating portion 51C,..., And the twelfth slot accommodating portion 51L. Further, the turn portion 52 is a first turn portion 52A that connects the slot accommodating portions 51 alternately between the outside of the slot 31 on one end side of the stator core 30 and the outside of the slot 31 on the other end side of the stator core 30. , Second turn part 52B,..., Tenth turn part 52J, and eleventh turn part 52K connecting the eleventh slot accommodating part 51K and the twelfth slot accommodating part 51L.

  The spacing distance X in the circumferential direction (arrow Y direction) between adjacent slot accommodating portions 51 of the coil wire 50 is made different at all locations. In this case, the separation distance X is gradually shortened from the first slot accommodating portion 51A side of the coil wire 50 toward the twelfth slot accommodating portion 51L side. That is, the separation distance X is X1> X2> X3> X4> X5> X6> X7> X8> X9> X10> X11. The separation distance X is appropriately set in consideration of the separation distance (slot pitch) between the slots 31 adjacent in the circumferential direction of the stator core 30.

  At both ends of the coil wire 50, lead-out portions 53a and 53b for connecting to the other coil wire 50 and the like are provided. One of the drawer portions 53a is a turn portion formed to be approximately half the length of the turn portion 52 between the slot accommodating portions 51 so as to return from the end of the first slot accommodating portion 51A to the inside (the right side in FIG. 12). 52M. Therefore, one drawer part 53a is located in the place which approached the inner side (right side of FIG. 11) by the length of the turn part 52M from the 1st slot accommodating part 51A. The other drawer part 53b is a turn part formed to have a length approximately half of the turn part 52 between the slot accommodating parts 51 so as to return from the end of the twelfth slot accommodating part 51L to the inside (left side in FIG. 12). 52N is formed. Therefore, the other drawer portion 53b is located at a position closer to the inside (left side in FIG. 12) than the twelfth slot accommodating portion 51L by the length of the turn portion 52N. Between the other lead-out portion 53b and the turn portion 52N, there is provided a crossover portion 70 that is bent on the axial end surface of the stator coil 40 and arranged radially outward of the stator core 30.

  A crank portion 54 for shifting the radial position of the slot accommodating portion 51 connected to both ends of the turn portion 52 is provided at a substantially central portion of the turn portion 52. Specifically, the crank portion 54 is configured so that each of the first to twelfth slot accommodating portions 51A to 51L is orthogonal to the longitudinal direction of the coil wire 50 and the extending direction of the slot accommodating portion 51 (stator core 30). It is formed in a crank shape so as to be sequentially displaced in the radial direction). As a result, the coil wire 50 has a stepped shape as shown in FIG.

  FIGS. 13A and 13B are perspective views showing the shape of the turn portion 52 when the cylindrical stator coil 40 is formed using the coil wire 50 shown in FIG. As shown in FIG. 13A, the turn portion 52 has a crank portion 54 that is displaced in the radial direction of the stator core 30 and extends along the end surface 30 a of the stator core 30. The amount of displacement of the crank portion 54 due to the crank shape (the amount of displacement of the stator core 30 in the radial direction) is the thickness of the turn portion 52 in the radial direction. Thereby, the slot accommodating parts 51 connected by the turn part 52 are displaced by the radial thickness of the turn part 52. Thus, by providing the crank part 54 in the turn part 52, as shown in FIG.13 (B), the turn parts 52 of the coil wire 50 adjacent in the circumferential direction can be wound closely. Further, as shown in FIG. 13B, the turn parts 52 adjacent in the circumferential direction have the same shape and prevent the turn parts 52 from interfering with each other.

  In addition, along the end surfaces 30a on both sides in the axial direction of the stator core 30 toward the slots where the coil wire material 50 is placed across the projecting portion of the turn portion 52 projecting out of the stator core 30 from the slot 31. A stepped portion 55 is formed. Thus, the coil wire 50 is installed across the interval between the protruding portions of the turn portion 52 of the coil wire 50 protruding from the slot 31, in other words, the length of the base of the triangular portion formed by the turn portion 52. It is narrower than the interval between slots. As a result, the height of the coil end portion 42 is lowered.

  Further, d1 ≦ d2 is satisfied, where d1 is the length of the step portion 55 along the end surface 30a of the stator core 30 and d2 is the distance between the slots 31 adjacent in the circumferential direction. Thereby, it can prevent that the step part 55 of the coil wire 50 interferes with the coil wire 50 which protrudes from the slot 31 adjacent to the circumferential direction. Thereby, in order to avoid that the coil wire 50 (turn part 52) which protrudes from the slot 31 adjacent to the circumferential direction mutually interferes, the height of the coil end part 42 becomes high, or the coil end part 42 of It is possible to prevent the radial width from becoming large. As a result, the height of the coil end portion 42 is lowered. Furthermore, since the radial width of the coil end portion 42 is reduced, the stator coil 40 is prevented from projecting outward in the radial direction.

  Further, two step portions 56 are formed on the coil wire 50 between a crank portion 54 at a substantially central portion of the turn portion 52 and a step portion 55 formed at a protruding portion of the turn portion 52. . That is, one crank portion 54 and a total of six step portions 55 and 56 are formed in the turn portion 52 of the coil wire 50 on the side of one axial end face 30 a of the stator core 30. Thereby, the height of the turn part 52 becomes lower than the height of the triangular turn part in which the crank part 54 and the step parts 55 and 56 are not formed. The crank shape of the crank portion 54 is also formed along the end surface 30 a of the stator core 30, similarly to the step portions 55 and 56. Therefore, both sides of the turn portion 52 of the coil wire 50 are formed stepwise with the crank portion 54 interposed therebetween.

  The stator coil 40 is formed using 48 coil wire members 50 shown in FIG. However, in order to provide an output line, a neutral point, etc. in the stator coil 40, the coil wire 50 which does not provide the crossover part 70 may be mixed appropriately. Therefore, in the present embodiment, all of the 48 coil wires 50 are formed in the same shape between the drawn portions 53 a and 53 b formed at both ends of each coil wire 50.

  The coil wire 50 constituting the stator coil 40 is provided with a crank portion 54 that is displaced in the radial direction by the radial thickness of the turn portion 52 at a substantially central portion of the turn portion 52. The slot accommodating parts 51 connected to each other are different in radial distance from the central axis of the stator core 30 by the radial thickness of the slot accommodating part 51. Further, the coil wire 50 is configured such that the separation distance X between the adjacent slot accommodating portions 51 gradually decreases as the coil wire 50 moves from the first slot accommodating portion 51A side to the twelfth slot accommodating portion 51L side. Are substantially different at all points (see FIG. 12B). Accordingly, the stator coil 40 has a shape closer to a true cylindrical shape because the slot accommodating portions 51 that overlap in the radial direction are aligned in a straight line in the radial direction without being displaced in the circumferential direction. (See FIGS. 7 and 8).

  In the stator coil 40, the first slot accommodating portions 51A, the second slot accommodating portions 51B,..., The twelfth slot accommodating portions 51L of the plurality of coil wires 50 are arranged in the circumferentially continuous slots. In addition, the first slot accommodating portions 51A, the second slot accommodating portions 51B,..., The twelfth slot accommodating portions 51L are arranged so that the radial distances from the central axis O of the stator core are equal. Thus, the outer diameter and inner diameter of the stator coil 40 can be made uniform in the circumferential direction. As shown in FIG. 14, the stator coil 40 is a three-phase winding in which each phase winding 43 (U, V, W) in which each phase has 16 coil wires 50 connected in series is Y-connected. Is formed.

  FIG. 15 is an explanatory diagram showing an arrangement position of the first slot accommodating portion of each coil wire arranged on the outermost diameter side of each slot in the present embodiment. In FIG. 15, the slot accommodating portion 51 of each coil wire 50 is arranged at a position where twelve broken line circles and a broken line extending in the radial direction intersect, and only the outermost diameter side and the innermost diameter side are rectangular in cross-sectional shape. It is represented by Corresponding slot numbers 1 to 48 are assigned to the outsides of the slot accommodating portions 51 arranged in a line in the radial direction (hereinafter, the same applies to FIG. 16). Further, on the outer side of the slot number, the number of the coil wire 50 in which the first slot accommodating portion 51A serving as the winding start end side is arranged on the outermost diameter side (the twelfth layer) of each slot is attached. Yes.

  The sixteen coil wires 50 constituting the winding of each phase are different from the eight coil wires 50 in which the slot accommodating portions 51 are accommodated in the eight identical slots 31 and the eight slots 31. It is divided into eight coil wires 50 in which the slot accommodating portions 51 are accommodated in eight identical slots 31. For example, in the case of the U phase, the eight coil wires (U1-1) to (U1-4) and (U1-1 ′) to (U1-4 ′) are warped from the outer diameter side toward the inner diameter side. Each slot accommodating portion 51 is wound clockwise and accommodated in the 1st slot, 7th slot, 13th slot, 19th slot, 25th slot, 31st slot, 37th slot and 43rd slot. The Further, the other eight coil wires (U2-1) to (U2-4) and (U2-1 ′) to (U2-4 ′) are wound counterclockwise from the outer diameter side toward the inner diameter side. As a result, the slot accommodating portions 51 are accommodated in the 2nd slot, the 8th slot, the 14th slot, the 20th slot, the 26th slot, the 32nd slot, the 38th slot and the 44th slot.

  In FIG. 15, the locus of the coil wire (U1-1) is shown as a representative. In FIG. 15, a portion indicated by a black square indicates that the slot accommodating portion 51 of the coil wire (U1-1) is arranged, and a thick line extending in the circumferential direction of the coil wire (U1-1) is a stator. The two-dot chain line extending in the circumferential direction of the coil wire (U1-1) is shown on the other side in the axial direction of the stator core 30. The turn portion 52 is located on one side in the axial direction of the core 30 (front side in FIG. 15). The turn part 52 located in the (rear side of the paper surface of FIG. 15) is shown (hereinafter the same in FIG. 16).

  As shown in FIG. 15, the stator coil 40 is in a state in which, in each slot 31, the slot accommodating portions 51 of the eight coil wire members 50 are laminated in 12 layers in the radial direction. In the coil wire (U1-1), the first slot accommodating portion 51A on the start end side is positioned in the outermost layer (the twelfth layer) of the first slot, and the twelfth slot accommodating portion 51L on the end side is the innermost layer of the nineteenth slot. It is located in (first layer).

  In addition, the 48 coil wires 50 constituting the stator coil 40 are arranged so as to be shifted by one slot pitch in the longitudinal direction (circumferential direction), so that the first slot housing portion serving as the start end side of each coil wire 50 51A are sequentially accommodated in the outermost layer (the twelfth layer) of each of the 48 slots 31. Table 1 below summarizes the numbers of the coil wire 50 located in the outermost layer and the numbers of the coil wire 50 located in the innermost layer in each of the slots 1 to 48.

  The coil wire 50 that constitutes the stator coil 40 is arranged so that the coil wire 50 of the slot housing portion 51 moves from one end side (the first slot housing portion 51A side) to the other end side (the 12th slot housing portion 51L side). The radial distance from the central axis O of the stator core 30 is sequentially reduced. In the case of this embodiment, each coil wire 50 is different in the radial distance from the central axis O of the stator core 30 between the slot accommodating portions 51 connected by the turn portion 52 by the radial thickness of the slot accommodating portion 51. Yes.

  FIG. 16 is a diagram showing a trajectory of one coil wire (U1-4 ′) when the stator coil 40 is viewed from the back side of FIG. 15. In the coil wire (U1-4 ′), the first slot accommodating portion 51A on the start end side is arranged in the 12th layer (outermost layer) of the 43rd slot, and the second slot accommodating portion 51B is the 11th of the 1st slot. The third slot accommodating portion 51C is disposed in the tenth layer of the seventh slot, the fourth slot accommodating portion 51D is disposed in the ninth layer of the thirteenth slot, and the final twelfth slot accommodating portion 51L It is arranged in the first layer (innermost layer) of the thirteenth slot. That is, in the coil wire (U1-4 ′), the radial distance from the central axis O of the stator core 30 of the slot accommodating portion 51 gradually decreases from the start end (outer diameter side) toward the end side (inner diameter side). It has become.

  Therefore, the radial distance r43 from the central axis O of the stator core 30 to the first slot accommodating part 51A, the radial distance r1 to the second slot accommodating part 51B, and the radial distance r7 to the third slot accommodating part 51C The radial distance r13 to the fourth slot accommodating portion 51D is sequentially reduced by the radial thickness of the slot accommodating portion 51. Similarly, the radial distance is successively increased until reaching the twelfth slot accommodating portion 51L. The thickness is reduced by 51 in the radial direction. That is, from the first slot accommodating portion 51A to the twelfth slot accommodating portion 51L, the radial distance only decreases sequentially, and the radial distance does not increase midway.

  Next, among the phase windings 43 (U, V, W) formed by connecting the 16 coil wires 50 in series, the connection state of the V-phase windings 43 is representatively shown in FIGS. 17 and Table 1 above. The U-phase and W-phase windings are also connected in the same way as the V-phase.

  As shown in Table 1 and FIG. 17, the coil wire rod (V1-1) positioned at the start end of the output line V in FIG. 16 has the first slot accommodating portion 51A on the start end side as the outermost layer (12th layer). ) And the end side twelfth slot accommodating portion 51L is arranged in the innermost layer (first layer) of the 23rd slot. On the terminal end side of the coil wire (V1-1), the first slot accommodating portion 51A on the starting end side is disposed in the 12th layer of the 17th slot, and the 12th slot accommodating portion 51L on the terminal end is the first slot in the 35th slot. The starting end side of the coil wire (V1-2) arranged in the layer is connected.

  On the terminal end side of the coil wire (V1-2), the first slot accommodating portion 51A on the starting end side is disposed in the 12th layer of the 29th slot, and the 12th slot accommodating portion 51L on the terminal end is the first slot 47th slot. The starting end side of the coil wire (V1-3) arranged in the layer is connected. On the terminal end side of the coil wire (V1-3), the first slot accommodating portion 51A on the starting end side is disposed in the twelfth layer of the 41st slot, and the twelfth slot accommodating portion 51L on the terminal end is the first slot of the eleventh slot. The starting end side of the coil wire (V1-4) arranged in the layer is connected. On the terminal side of the coil wire (V1-4), the first slot accommodating portion 51A on the starting end side is arranged in the twelfth layer of the sixth slot, and the twelfth slot accommodating portion 51L on the terminal end is the first of the twenty-fourth slot. The starting end side of the coil wire (V2-1) arranged in the layer is connected.

  On the terminal side of the coil wire (V2-1), the first slot accommodating portion 51A on the starting end side is disposed in the twelfth layer of the 18th slot, and the twelfth slot accommodating portion 51L on the terminal end is the first slot of the 36th slot. The starting end side of the coil wire (V2-2) arranged in the layer is connected. On the terminal end side of the coil wire (V2-2), the first slot accommodating portion 51A on the starting end side is arranged in the 12th layer of the 30th slot, and the 12th slot accommodating portion 51L on the terminal end is the first slot in the 48th slot. The starting end side of the coil wire (V2-3) arranged in the layer is connected. On the terminal side of the coil wire (V2-3), the first slot accommodating portion 51A on the starting end side is arranged in the twelfth layer of the 42nd slot, and the twelfth slot accommodating portion 51L on the terminal end is the first of the twelfth slot. The starting end side of the coil wire (V2-4) arranged in the layer is connected.

  On the terminal side of the coil wire (V2-4), the first slot accommodating portion 51A on the starting end side is arranged in the twelfth layer of the 48th slot, and the twelfth slot accommodating portion 51L on the terminal end is the first slot in the eighteenth slot. The terminal side of the coil wire (V2-4 ′) arranged in the layer is connected. On the starting end side of the coil wire (V2-4 ′), the first slot accommodating portion 51A on the starting end side is arranged in the twelfth layer of the 36th slot, and the twelfth slot accommodating portion 51L on the terminal end is the sixth slot in the sixth slot. The terminal side of the coil wire (V2-3 ′) arranged in one layer is connected. On the starting end side of the coil wire (V2-3 ′), the first slot accommodating portion 51A on the starting end side is arranged in the twelfth layer of the 24th slot, and the twelfth slot accommodating portion 51L on the end side is located on the 42nd slot. The terminal side of the coil wire (V2-2 ′) arranged in one layer is connected. On the starting end side of the coil wire (V2-2 ′), the first slot accommodating portion 51A on the starting end side is arranged in the twelfth layer of the 12th slot, and the twelfth slot accommodating portion 51L on the end side is the 30th slot. The terminal side of the coil wire (V2-1 ′) arranged in one layer is connected.

  On the starting end side of the coil wire (V2-1 ′), the first slot accommodating portion 51A on the starting end side is arranged in the 12th layer of the 47th slot, and the twelfth slot accommodating portion 51L on the end side is the 17th slot No. The terminal side of the coil wire (V1-4 ′) arranged in one layer is connected. On the starting end side of the coil wire (V1-4 ′), the first slot accommodating portion 51A on the starting end side is disposed in the twelfth layer of the 35th slot, and the twelfth slot accommodating portion 51L on the end side is the fifth slot in the fifth slot. The terminal side of the coil wire (V1-3 ′) arranged in one layer is connected. On the starting end side of the coil wire (V1-3 ′), the first slot accommodating portion 51A on the starting end side is arranged in the 12th layer of the 23rd slot, and the 12th slot accommodating portion 51L on the end side is the 41st slot of the 41st slot. The terminal side of the coil wire (V1-2 ′) arranged in one layer is connected. On the starting end side of the coil wire (V1-2 ′), the first slot accommodating portion 51A on the starting end side is arranged in the twelfth layer of the 11th slot, and the twelfth slot accommodating portion 51L on the end side is located on the 29th slot. The terminal side of the coil wire (V1-1 ′) arranged in one layer is connected. The starting end side of the coil wire (V1-1 ′) is connected to the neutral point V.

  Next, the connection state of each coil wire 50 will be described with reference to Table 1, FIG. 12, and FIG. Here, the connection state of two coil wire materials (V1-1) (V1-2) will be described as a representative. In one coil wire (V1-1), the first slot accommodating portion 51A on the start end side is arranged in the outermost layer (the twelfth layer) of the fifth slot, and the twelfth slot accommodating portion 51L on the end side is the 23rd Arranged in the innermost layer (first layer) of the slot. The lead-out part 53b (inner peripheral side end part) provided on the terminal side of the coil wire (V1-1) is the length of the turn part 52N from the 23rd slot where the 12th slot accommodating part 51L is arranged. It is located in the return place (near the 20th slot).

  In the other coil wire (V1-2), the first slot accommodating portion 51A on the start end side is arranged in the outermost layer (the twelfth layer) of the 17th slot, and the twelfth slot accommodating portion 51L on the end side is arranged. It is arranged in the innermost layer (first layer) of the 35th slot. The lead-out portion 53a (outer end portion) provided on the starting end side of the coil wire (V1-2) returns by the length of the turn portion 52M from the 17th slot where the first slot accommodating portion 51A is disposed. It is located somewhere (near the 20th slot). As shown in FIGS. 7 to 10, the lead portion 53b (inner peripheral side end portion) of the coil wire (V1-1) is bent at a substantially right angle outward in the radial direction, and then the tip is fixed. The coil coil (V1-2) is located at the outer peripheral end of the child coil 40 and is connected by welding to the tip of the lead-out portion 53a (outer peripheral end).

  This weld joint is connected by welding on the outer diameter side of the turn portion 52 located on the outermost diameter side of the stator coil 40. In this case, the bent portion of the lead portion 53b (inner peripheral side end portion) of the coil wire (V1-1) passes through the transition portion 70 passing on the axial end surface of the stator coil 40 (the axial outer surface of the turn portion 52). The two coil wire rods (V1-1) (V1-2) are connected via the crossover part 70. Thereby, since the 12th slot accommodating part 51L located in the inner diameter side can be more effectively prevented from bulging inward in the radial direction, it is possible to avoid interference with the rotor located on the inner diameter side. It becomes possible.

  As shown in FIGS. 3 and 9, the crossover portion 70 has both ends in the radial direction of the crossover portion 70 along a straight line extending radially from the central axis O of the stator core 30 (stator coil 40). It is formed to extend. By making the shape of the crossover portion 70 in this way, the coil wire 50 can be easily bent and welded joining can be facilitated.

  Further, as shown in FIG. 3 and FIG. 9, the crossover portion 70 is provided in a region in a range of approximately 3/4 round in the circumferential direction on the axial end surface of the stator coil 40. In addition, the remaining quarter of the region on the axial end face of the stator coil 40 includes a neutral point V, an output line W, a neutral point U, an output line V, a neutral point W, and an output line U. Are provided in order. That is, on the end face in the axial direction of the stator coil 40, the output lines U, V, and W are provided in the same region as the neutral points U, V, and W, and the crossover 70 is provided. The region is separated from the regions where the neutral points U, V, and W and the output lines U, V, and W are provided.

  The stator coil 40 configured as described above is assembled with the stator core 30 by inserting the teeth portion 33 of the split core 32 from the outer peripheral side (see FIGS. 2 to 4). Thereby, the coil wire 50 which comprises the stator coil 40 is assembled | attached in the state wound by the inner peripheral side of the stator core 30 along the circumferential direction. The slot accommodating portions 51 connected by the turn portion 52 of the coil wire 50 are accommodated in the slots 31 separated by a predetermined slot pitch (in this embodiment, 3 phases × 2 pieces = 6 slot pitch). The turn portions 52 that connect adjacent slot accommodating portions 51 protrude from both end surfaces of the stator core 30 in the axial direction, and a coil end portion 42 is formed by the aggregate of the protruding turn portions 52. Yes.

Embodiment 1
Next, the manufacturing method of the stator coil 40 of Embodiment 1 is demonstrated. As shown in FIG. 18, the method for manufacturing the stator coil 40 of the present embodiment includes a coil wire forming process 101, an assembling process 102, and a winding process 103. Hereinafter, each process is demonstrated in order.

<Coil wire forming step 101>
In the coil wire forming step 101, the coil wire 50 is formed by forming an electric conductor wire into a predetermined shape. In the present embodiment, 48 coil wires 50 are prepared for one stator coil 40. The coil wire 50 formed here includes 12 slot accommodating portions 51 extending in parallel to each other and arranged in parallel in the longitudinal direction of the coil wire 50, and adjacent slot accommodating portions 51 are connected to one end side and the other end of the slot accommodating portion 51. 11 turn portions 52 that are alternately connected to each other (see FIG. 12). In addition, a conventionally well-known thing can be employ | adopted as a shaping | molding apparatus which shape | molds an electrical conductor wire.

<Incorporation process 102>
In the assembling step 102, the coil wire 50 formed in the coil wire forming step 101 is incorporated by 24 in a predetermined method, thereby forming the band-like incorporated body 47 shown in FIG. The built-in body 47 is assembled by superimposing the 24 coil wires 50 in the longitudinal direction of the built-in body 47 in a state shifted by one slot pitch, and is formed in a substantially planar shape. This built-in body 47 has a plurality of straight overlapping portions 41 formed in a longitudinal direction in which the slot accommodating portions 51 of the coil wire members 50 are overlapped with each other. A gap having a size substantially the same as a gap formed between the adjacent slot accommodating portions 51 is formed between the adjacent straight overlapping portions 41.

<Winding process 103>
In the winding process 103, the winding device shown in FIGS. 20 and 21 is used to wind the two sets of built-in bodies 47 formed in the assembling process 102 around the core member 81 to form a wound body. First, the configuration of the winding device used here will be described. As shown in FIGS. 20 and 21, the winding device includes a core member 81, a pair of feed arrow devices 82, a pair of positioning arrow devices 83, a pair of first pressing members 84, and a pair of second members. A pressing member 85 and a pair of pressing members 86 are provided, and these are installed on the base 80.

  As shown in FIG. 22A, the core member 81 is formed into a cylindrical shape by being divided into four in the circumferential direction. As shown in FIG. 21, the core member 81 is coaxially fitted to the outer periphery of the upper end portion of the rotary shaft 81b that is erected so as to be rotatable with respect to the base 80 via a bearing 81a, and is fitted on the inner peripheral side. It is fixed by the taper pin 81c inserted. Thus, the core member 81 is pivotally supported with respect to the base 80 so as to be freely rotatable. As shown in FIG. 22B, a plurality of engaging grooves 81d extending in the axial direction are formed on the outer peripheral surface of the core member 81. The tip of a feed arrow 83a described later is engaged with the engagement groove 81d.

  The pair of feed arrow devices 82 are disposed on the outer peripheral side of the core member 81 so as to be opposed to positions that are axially symmetric with the core member 81 interposed therebetween. Each feed arrow device 82 includes six feed arrows 82 a arranged in parallel in the circumferential direction, a cam plate 82 b that holds the six feed arrows 82 a, and the cam plate 82 b that moves forward and backward with respect to the outer peripheral surface of the core member 81. A first cylinder (first drive member) 82c to be moved. The six feed arrows 82 a are arranged radially so that their tips are directed to the rotation axis of the core member 81. In the present embodiment, since the adjacent slot accommodating portions 51 of the coil wire 50 are accommodated in the slots 31 separated by a 6-slot pitch, the number of feed arrows 82a is set to six. Thereby, when the built-in body 47 is wound up by rotating the feed arrow 82a, it is possible to transport all the coil wire members 50 of the built-in body 47 with the six feed arrows 82a. This feed arrow device 82 is driven by a second cylinder (second drive member, only one of which is shown in FIG. 20) 82d between a predetermined range in the circumferential direction of the core member 81 (the position of the solid line and the position of the two-dot chain line in FIG. (Range) can be intermittently rotated (reciprocated).

  The pair of positioning arrow devices 83 are disposed on the outer peripheral side of the core member 81 so as to be opposed to positions that are axially symmetric with the core member 81 interposed therebetween. In this case, the pair of positioning arrow devices 83 are arranged at positions that are shifted by about 80 ° in the counterclockwise direction with respect to the pair of feed arrow devices 82 in FIG. Each positioning arrow device 83 includes six positioning arrows 83 a that are arranged in parallel in the circumferential direction, a cam plate 83 b that holds the six positioning arrows 83 a, and the cam plate 83 b that moves forward and backward with respect to the outer peripheral surface of the core member 81. And a cylinder 83c as a driving member to be moved. The six positioning arrows 83 a are arranged radially so that the tips thereof face the rotation axis of the core member 81.

  As shown in FIG. 21, the pair of first pressing members 84 are disposed below the positioning arrow 83 a, and the turn portion 52 located on one end side (lower side) of the slot housing portion 51 of the built-in body 47 to be wound up. Is to press. Each first pressing member 84 includes a support portion 84b that supports a pair of first rollers 84a arranged in parallel in the circumferential direction of the core member 81 so as to be swingable in the circumferential direction, and an arm portion 84c to which the support portion 84b is attached. And a cylinder 84d as a drive member that moves forward and backward with respect to the outer peripheral surface of the core member 81.

  The first pressing member 84 is configured to constantly press the turn portion 52 with either one of the first pressing force and the second pressing force smaller than the first pressing force. In this case, while the winding operation of the built-in body 47 by the feed arrow device 82 is stopped, the first pressing force is pressed, and during the winding operation of the built-in body 47 by the feed arrow device 82 is pressed by the second pressing force. To do.

  As shown in FIG. 21, the pair of second pressing members 85 are arranged above the positioning arrow 83 a and are turn portions on the other end side (upper side) of the slot accommodating portion 51 of the built-in body 47 to be wound up. 52 is pressed. Each second pressing member 85 has the same basic configuration as the first pressing member 84, and includes a pair of second rollers 85a, a support portion 85b, an arm portion 85c, and a cylinder 85d. The second pressing member 85 is configured to always press the turn portion 52 with either one of the first pressing force and the second pressing force, similarly to the first pressing member 84.

  The pair of second rollers 85a of the second pressing member 85 moves forward synchronously when the pair of first rollers 84a of the first pressing member 84 moves forward by a control unit (not shown) that controls the cylinders 84d and 85d. When the pair of first rollers 84a of the first pressing member 84 move and move backward, the movement is controlled to move backward synchronously.

  As shown in FIG. 20, the pair of pressing members 86 are disposed on the outer peripheral side of the core member 81 at positions that are axially symmetric with the core member 81 interposed therebetween. In this case, the pair of pressing members 86 are disposed at intermediate positions between the feed arrow device 82 and the positioning arrow device 83, respectively. Specifically, the pair of pressing members 86 are disposed at positions shifted by about 10 ° in the counterclockwise direction with respect to the pair of positioning arrow devices 83 in FIG. Each pressing member 86 includes a holding portion 86b that holds a pair of rollers 86a arranged in parallel in the horizontal direction, and a cylinder (driving member) 86d that moves the slide base portion 86c that holds the holding portion 86b in a swingable manner in the horizontal direction. It has.

  Each pressing member 86 presses the built-in body 47 supplied to the outer peripheral surface of the core member 81 with a pair of rollers 86 a, so that the built-in body 47 supplied to the core member 81 has a wider area on the outer peripheral surface of the core member 81. Thus, the feeding arrow 82a is easily inserted into the gap formed between the adjacent straight overlapping portions 41 of the built-in body 47.

  Next, the winding process 103 of this embodiment performed using the winding apparatus comprised as mentioned above is demonstrated. In the initial state, the winding device of the present embodiment includes six feeding arrows 82a of each feeding arrow device 82, six positioning arrows 83a of each positioning arrow device 83, and first and second pressing members 84 and 85. The first and second rollers 84a and 85a and the pair of rollers 86a of the pressing member 86 are all on standby at the retracted positions. In this state, as shown in FIG. 20, the two sets of built-in bodies 47 are in contact with the outer peripheral surface of the core member 81 at the position where the outer peripheral surface of the core member 81 is 180 ° out of phase. Set to state. At this time, the built-in body 47 is set so that the lead-out portion 53b of each coil wire 50 becomes the tip side, and the outer surface of the tip portion faces the tips of the six feeding arrows 82a of each feeding arrow device 82.

  Next, the first and second rollers 84a and 85a of the first and second pressing members 84 and 85 are advanced toward the outer peripheral surface of the core member 81, and at least one of the first and second pressing members 84 and 85 is reached. The turn part 52 of the front-end | tip part of the incorporating body 47 is pressed with the rollers 84a and 85a. Thereby, the front-end | tip part of the incorporating body 47 is hold | maintained in the state positioned on the outer peripheral surface of the core member 81. FIG. At this time, the pressing force of the first and second pressing members 84 and 85 that press the built-in body 47 is a relatively large first pressing force.

  Further, the pair of rollers 86a of the pressing member 86 is advanced toward the outer surface of the built-in body 47, and the outer surface of the built-in body 47 is pressed by the pair of rollers 86a. Thus, the feed arrow 82a is easily inserted into the gap formed between the adjacent straight overlapping portions 41 of the built-in body 47.

  Next, the first cylinder 82 c of each feed arrow device 82 is operated to advance the six feed arrows 82 a toward the outer peripheral surface of the core member 81. Thereby, the six feed arrows 82 a are respectively inserted into predetermined six gaps formed between the adjacent straight overlapping portions 41 of the built-in body 47, and the tips thereof are the outer periphery of the core member 81. The six engaging grooves 81d provided on the surface engage with each other. As a result, the straight overlapping portions 41 sandwiched between adjacent feed arrows 82a among the six feed arrows 82a are aligned in a state in which the slot accommodating portions 51 are aligned in a row in the radial direction.

  In this state, the second cylinder 82d of each feed arrow device 82 is operated to rotate each feed arrow device 82 in the circumferential direction of the core member 81 (direction of arrow A in FIG. 20) by a predetermined distance. That is, each feed arrow device 82 is rotated from the position of the solid line (rotation start position) in FIG. 20 to the position of the two-dot chain line (rotation stop position). As a result, the core member 81 with which the tips of the six feed arrows 82a are engaged rotates together with the feed arrow 82a and rotates by a predetermined angle, and is conveyed by the feed arrow 82a as the core member 81 rotates. The built-in body 47 is wound around the core member 81.

  When each feed arrow device 82 rotates and the built-in body 47 is wound, the pressing force of the first pressing member 84 that presses the built-in body 47 is changed to a relatively small second pressing force. ing. Thereby, even if the step (crank portion 54) is formed in the turn part 52 of the built-in body 47, the turn part 52 of the built-in body 47 to be conveyed can be stably pressed by the first pressing member 84.

  After each feed arrow device 82 is rotated to the rotation stop position and stopped, the cylinder 83c of each positioning arrow device 83 is operated to advance the six positioning arrows 83a toward the outer peripheral surface of the core member 81. . Thereby, the six positioning arrows 83a are respectively inserted into predetermined six gaps formed between the adjacent straight overlapping portions 41 of the built-in body 47. Thus, the straight overlapping portion 41 sandwiched between the adjacent positioning arrows 83a among the six positioning arrows 83a is aligned in a state in which the slot accommodating portions 51 are aligned in a row in the radial direction, and the core Good alignment of the integrated body 47 wound around the member 81 is maintained.

  In this state, the first cylinder 82c of each feed arrow device 82 is operated to retract the six feed arrows 82a outward in the radial direction of the core member 81, and between the adjacent straight overlapping portions 41. Extract from the formed gap. Next, the second cylinder 82d of each feed arrow device 82 is operated to rotate each feed arrow device 82 in the direction opposite to the winding direction to return from the rotation stop position to the rotation start position.

  After each feed arrow device 82 returns to the rotation start position, the first cylinder 82c of each feed arrow device 82 is actuated again to advance the six feed arrows 82a toward the outer peripheral surface of the core member 81. Then, the built-in body 47 is inserted into a predetermined gap formed between the adjacent straight overlapping portions 41, and the tip thereof is engaged with the engaging groove 81 d of the core member 81. In this state, the second cylinder 82d of each feed arrow device 82 is operated, and each feed arrow device 82 is rotated by a predetermined distance in the circumferential direction of the core member 81 (the direction of arrow A in FIG. 20). The winding operation of the built-in body 47 by the similar feed arrow 82a is started. Thereafter, each feeding arrow device 82, each positioning arrow device 83, each first pressing member 84, each second pressing member 85, and each pressing member 86 repeats the same operation as described above, so that two sets are incorporated. The body 47 is wound around the core member 81 to the rear end.

  Thus, when the winding up to the rear end of the built-in body 47 is completed, the six feeding arrows 82a of each feeding arrow device 82, the six positioning arrows 83a of each positioning arrow device 83, the first and second The first and second rollers 84a and 85a of the pressing members 84 and 85, and the pair of rollers 86a of the pressing member 86 are returned to the initial position before the start of winding and wait. In this state, the taper pin 81c inserted on the inner peripheral side of the core member 81 is extracted, and in a state where the diameter of the core member 81 is reduced, the winding body wound in a cylindrical shape is removed from the core member 81, The winding process 103 is completed.

  Thereafter, among the 48 coil wires 50 of the formed wound body, the drawn portions 53a and 53b of the predetermined coil wire 50 are connected by welding, whereby the stator coil 40 shown in FIGS. 7 to 10 is completed. To do.

  As described above, according to the method for manufacturing the stator coil 40 of the present embodiment, in the winding process 103, a plurality of gaps are formed in the predetermined gaps formed between the adjacent straight overlapping portions 41 of the built-in body 47. In a state where the feed arrow 82 a is inserted and the tip of the feed arrow 82 a is engaged with the core member 81, the feed arrow 82 a is intermittently rotated within a predetermined range in the circumferential direction of the core member 81. The built-in body 47 is wound around the core member 81 while rotating the core member 81 at 82a.

  For this reason, since the core member 81 is not driven and rotated, there is no need to control the rotation of the core member 81 and the supply and positioning of the built-in body 47. Can be resolved. Further, during winding of the built-in body 47, the feeding arrow 82a is always inserted into a predetermined gap formed between the adjacent straight overlapping portions 41 of the built-in body. Can be ensured. Therefore, according to the method for manufacturing the stator coil 40 of the present embodiment, the aligned body 47 can be stably aligned and wound in the winding step 103, and the wound body wound to a desired winding diameter. Can be obtained stably.

  Moreover, in the winding process 103 of this embodiment, when the feed arrow 82a is extracted from a predetermined gap formed between the adjacent straight overlapping portions 41 of the built-in body 47, the built-in body 47 The straight overlapping portion 41 is positioned by a positioning arrow 83a inserted into another predetermined gap. Therefore, when the feed arrow 82a is extracted from the predetermined gap of the built-in body 47 and returned from the winding stop position to the winding start position, the positioning arrow 83a ensures the good alignment state of the straight overlapping portion 41. Can be maintained.

  In addition, the winding process 103 is performed while pressing the turn parts 52 on both sides of the slot accommodating part 51 of the built-in body 47 to be wound by the first pressing member 84 from the outer peripheral side. Therefore, it is possible to prevent the turn portion 52 from bulging radially outward and twisting during the winding of the built-in body 47, so that the turn portion 52 can be well aligned and stably wound up. A wound body wound to a diameter can be obtained.

  The first pressing member 84 has a pair of first rollers 84 a arranged in parallel in the circumferential direction of the core member 81, and the pair of first rollers 84 a is installed to be swingable in the circumferential direction of the core member 81. . Thus, the pair of first rollers 84a can always come into contact with the turn portion 52 of the built-in body 47 at two points, so that the built-in body 47 during winding is bulged outward or twisted. It can prevent more reliably.

  Further, the first pressing member 84 always presses the turn portion 52 with either one of the first pressing force and the second pressing force smaller than the first pressing force, and is assembled by the feed arrow 82a. While the winding operation of the body 47 is stopped, the body 47 is pressed with the first pressing force. Therefore, while the winding operation of the built-in body 47 by the feed arrow 82a is stopped, the turn portion 52 can be reliably prevented from bulging outward in the radial direction by pressing with a relatively large first pressing force. it can. Further, during the winding operation of the built-in body 47 by the feed arrow 82a, a step (crank portion 54) is formed in the turn portion 52 of the built-in body 47 by pressing with a relatively small second pressing force. In addition, the turn part 52 can be stably pressed by the first pressing member 84. Thereby, the occurrence of damage to the insulating coating 68 that covers the surface of the coil wire 50 can also be prevented.

  Then, according to the winding device used in the winding process 103 of the present embodiment, stable aligned winding can be performed without driving and rotating the core member 81, and the coil has been wound to a desired winding diameter. It is possible to easily realize a winding device that can reliably obtain a wound body.

[Embodiment 2]
Next, the manufacturing method of the stator coil 40 of Embodiment 2 is demonstrated. The manufacturing method of the stator coil 40 according to the present embodiment includes the coil wire forming process 101, the assembling process 102, and the winding process 103 as in the manufacturing method of the first embodiment. Is different from the manufacturing method of the first embodiment. Therefore, description of the coil wire forming process 101 and the assembling process 102 is omitted, and only the winding process 103 will be described. In the following description, the same reference numerals are used for common members such as the embedded body 47 used in the description of the first embodiment prior to the assembling step 102.

<Winding process 103>
The winding process 103 of this embodiment is performed using the winding apparatus shown in FIGS. As shown in FIG. 23, this winding device is configured by dividing the feeding arrow 82a used in the winding device of the first embodiment into two vertically, A first feed arrow device 94 having a plurality of (six) first feed arrows 94a inserted into one side (lower side) of a predetermined gap formed between the overlapping parts 41, and the predetermined feed It differs in that it has a second feed arrow device 97 having a plurality of (six) second feed arrows 97a inserted on the other side (upper side) of the gap.

  The winding device of the present embodiment includes a substantially cylindrical cylindrical base portion 90a that is erected with a lower end portion fitted and fixed in a through hole of the bed substrate 90. A cylindrical column 90b is fitted and erected on the inner side of the cylindrical base 90a. A core member 91 that is rotatable relative to the support column 90b via a bearing (not shown) is pivotally supported on the upper end of the support column 90b coaxially with the support column 90b. Like the core member 81 of the first embodiment, the core member 91 is formed by being divided into four in the circumferential direction, and a plurality of engagement grooves (not shown) extending in the axial direction are formed on the outer circumferential surface (FIG. 22B). Reference) is engraved. The engaging grooves engage with tips of first and second feed arrows 94a and 97a, which will be described later. Similarly to the core member 81 of the first embodiment, the core member 91 is fitted on the outer periphery of the upper end of the support column 90b and is coaxially fixed by a taper pin 91c inserted on the inner peripheral side.

  A cylindrical first drive shaft 92 is coaxially fitted between the column 90b and the cylindrical base 90a so as to be rotatable relative to the column 90b and the cylindrical base 90a. The first drive shaft 92 is rotatable relative to the cylindrical base 90a via a pair of upper and lower bearings 92a, and is driven and rotated by a drive motor 92b connected to the lower end thereof. The drive motor 92b is driven and controlled by a control unit (not shown).

  A first rotation table 93 that rotates integrally with the first drive shaft 92 in the circumferential direction of the core member 91 is attached to the upper end of the first drive shaft 92. The first rotation table 93 has a pair of support substrates 93 a that spread horizontally in the outward direction on both sides of the first drive shaft 92 at a position descending downward from the upper end of the first drive shaft 92. On each support substrate 93a, a first unit including a first feed arrow device 94 and a first pressing member 95 is installed.

  As shown in FIG. 24, the pair of first feed arrow devices 94 are disposed to face axially symmetrical positions across the core member 91 on the outer peripheral side of the core member 91 (first drive shaft 92). Yes. Each first feed arrow device 94 includes six first feed arrows 94 a arranged in parallel in the circumferential direction, a cam plate 94 b that holds the six first feed arrows 94 a, and the cam plate 94 b of the core member 91. A drive motor 94c and a ball screw 94d that move forward and backward with respect to the outer peripheral surface are provided.

  The six first feed arrows 94 a are arranged radially at positions facing the outer peripheral surface of the core member 91 at a predetermined distance so that their tips face the rotation axis of the core member 91. Then, when the six first feed arrows 94a are moved forward by the operation of the drive motor 94c, their tip ends are engaged between the center and the lower end of the engagement grooves provided on the outer peripheral surface of the core member 91. Is configured to do. In FIG. 24, the six first feed arrows 94a are shown at positions retracted from the core member 91.

  Each first pressing member 95 includes a support portion 95b that supports a pair of first rollers 95a arranged in parallel in the circumferential direction of the core member 91 so as to be swingable in the circumferential direction, and an arm portion 95c to which the support portion 95b is attached. And a drive motor 95d that moves forward and backward with respect to the outer peripheral surface of the core member 91. The first pressing member 95 is disposed so that the pair of first rollers 95a faces the outer peripheral surface of the core member 91 at a position below the six first feed arrows 94a. When the built-in body 47 is wound around the outer peripheral surface of the core member 91, the pair of first rollers 95 a are moved forward by the operation of the drive motor 95 d and are on one end side (lower end side) of the slot accommodating portion 51. The turn part 52 is configured to be pressed by a pair of first rollers 95a.

  And between the bed board | substrate 90 and the 1st rotation table 93, the 2nd rotation table 96 which can be relatively rotated via the bearing 96a with respect to the cylindrical base part 90a is provided. The second turning table 96 has a pair of plate-like base portions 96 a that extend further outward than the outer peripheral ends of the support substrates 93 a of the first turning table 93. Each plate-like base 96a is rotatably supported by support rollers 90c provided at a plurality of locations on the bed substrate 90. A pair of support legs 96c having a pair of support substrates 96b positioned above the first unit are erected on the upper surface of the outer peripheral side end of each plate-like base 96a. On the pair of support substrates 96b, second units each including a second feed arrow device 97 and a second pressing member 98 are installed.

  As shown in FIG. 25, the pair of second feed arrow devices 97 are disposed so as to face axially symmetrical positions with the core member 91 on the outer peripheral side of the core member 91 interposed therebetween. Each second feed arrow device 97 includes six second feed arrows 97 a arranged in parallel in the circumferential direction, a cam plate 97 b that holds the six second feed arrows 97 a, and the cam plate 97 b of the core member 91. A drive motor 97c that moves forward and backward with respect to the outer peripheral surface and a ball screw 97d are provided. The six second feed arrows 97 a are arranged radially at positions facing the outer peripheral surface of the core member 91 at a predetermined distance with their tips facing the rotation axis of the core member 91. Then, when the six second feed arrows 97a are moved forward by the operation of the drive motor 97c, their tip portions are engaged between the center and the upper end of the engagement groove provided on the outer peripheral surface of the core member 91. Is configured to do.

  Note that the six first feed arrows 94a of each first unit and the six second feed arrows 97a of each second unit are fed to either one by a control unit (not shown) that controls the drive motors 94c and 97c. When the arrow moves forward, the other feeding arrow moves backward after stopping the forward movement, and when one of the other feeding arrows moves forward, the other moving arrow is controlled to move backward after stopping the forward movement. The Thus, at least one of the first feed arrow 94a and the second feed arrow 97a is always stopped at the forward movement stop position.

  Each of the second pressing members 98 includes a support portion 98b that supports a pair of second rollers 98a and 98a arranged in parallel in the circumferential direction of the core member 91 so as to be swingable in the circumferential direction, and an arm portion to which the support portion 98b is attached. And a drive motor 98d for moving 98c forward and backward with respect to the outer peripheral surface of the core member 91. The second pressing member 98 is disposed such that the pair of second rollers 98a faces the outer peripheral surface of the core member 91 at a position below the six second feed arrows 97a. When the built-in body 47 is wound around the outer peripheral surface of the core member 91, the pair of second rollers 98 a is moved forward by the operation of the drive motor 98 d, and is moved to the other end side (upper end side) of the slot accommodating portion 51. The turn part 52 is configured to be pressed by a pair of second rollers 98a.

  The pair of second rollers 98 a of the second pressing member 98 moves forward synchronously when the pair of first rollers 95 a of the first pressing member 95 moves forward, and the pair of first rollers of the first pressing member 95. When the roller 95a moves backward, the roller 95a is controlled to move backward synchronously. In other words, the pair of first rollers 95a of the first pressing member 95 and the pair of second rollers 98a of the second pressing member 98 independently advance and retract to press the turn portion 52 with an arbitrary pressing force. It is like that.

  The second rotary table 96 on which the pair of second feed arrow devices 97 and the pair of second pressing members 98 are installed is driven by the second drive shaft 99. The second drive shaft 99 is provided to be relatively rotatable with respect to the bed substrate 90 via a pair of upper and lower bearings 99a. The first gear 99a attached to the upper end of the second drive shaft 99 and the gear 96d attached to the lower surface side of the second rotating table 96 are meshed and connected. Thereby, the second rotation table 96 can be rotated in the circumferential direction of the core member 91 by the rotational drive of the second drive shaft 99.

  Further, the second drive shaft 99 is attached with a gear 92c attached to the lower end portion of the first drive shaft 92 and a second gear 99b engaged and connected via an idle gear (not shown). Thus, the second drive shaft 99 is driven to rotate in the opposite direction to the first drive shaft 92 when the first drive shaft 92 is driven and rotated by the drive motor 92b. That is, when the first drive shaft 92 and the second drive shaft 99 are synchronously rotated in opposite directions, the first rotation table 93 and the second rotation table 96 are moved to the first drive shaft 92 (core member 91). ) Around the rotation axis, and so as to rotate in the opposite directions.

  Next, the winding process 103 of this embodiment performed using the winding apparatus comprised as mentioned above is demonstrated. In the initial state of the winding device of the present embodiment, the six first feeding arrows 94 a of each first feeding arrow device 94 and the pair of first rollers 95 a of each first pressing member 95 are wound around the built-in body 47. The six second feed arrows 97a of each second feed arrow device 97 and the pair of second rollers 98a of each second pressing member 98 wait at the winding stop position of the built-in body 47. ing. Further, the first and second feed arrows 94a and 97a of the first and second feed arrow devices 94 and 97, and the first and second rollers 95a and 98a of the first and second pressing members 95 and 98 are all provided. Waiting in the retracted position.

  In this state, as shown in FIG. 24 and FIG. Set it in contact. At this time, the built-in body 47 is set so that the lead-out portion 53b of each coil wire 50 becomes the tip side, and the tip portion faces the tips of the six first feed arrows 94a of the first feed arrow device 94. .

  Next, by operating the drive motors 95d and 98d of the first and second pressing members 95 and 98 to advance the first and second rollers 95a and 98a toward the outer peripheral surface of the core member 91, The turn part 52 of the assembly 47 is pressed by the second rollers 95a and 98a. Thereby, the front-end | tip part of the incorporating body 47 is hold | maintained in the state positioned in the predetermined position of the outer peripheral surface of the core member 91. FIG.

  Next, the drive motor 94 c of the first feed arrow device 94 is operated to advance the six first feed arrows 94 a toward the outer peripheral surface of the core member 91, and the adjacent straight overlapping portions of the built-in body 47. It is inserted into a predetermined gap formed between 41 and its tip is engaged between the center and the lower end of the engagement groove provided on the outer peripheral surface of the core member 91. Thus, the straight overlapping portion 41 sandwiched between the adjacent first feed arrows 94a among the six first feed arrows 94a is in a state where the slot accommodating portions 51 are arranged in a row in the radial direction. Aligned. It should be noted that the six second feed arrows 97a of the second feed arrow device 97 that is retracted and waiting at the winding stop position are still waiting at the retracted position.

  In this state, the first drive shaft 92 is driven and rotated by the drive motor 92b, and the first drive shaft 92 and the second drive shaft 99 are rotated in synchronization with each other by a predetermined amount. As a result, the first rotation table 93 driven by the first drive shaft 92 rotates in the direction of arrow B in FIGS. 24 and 25, and at the same time, the second rotation table 96 driven by the second drive shaft 99. Rotates in the direction of arrow C in FIGS.

  At this time, the six first feed arrows 94 a of the first feed arrow device 94 installed on the first turning table 93 and the pair of first rollers 95 a of the first pressing member 95 are connected to the first turning table 93. At the same time, it rotates by a predetermined pitch in the direction of arrow B, and stops at the position where the six second feed arrows 97a of the second feed arrow device 97 are waiting. As a result, the core member 91 with which the tips of the six first feed arrows 94a are engaged rotates together with the first feed arrow 94a and rotates by a predetermined angle, and the first feed is accompanied by the rotation of the core member 91. The built-in body 47 conveyed by the arrow 94 a is wound around the outer peripheral surface of the core member 91.

  At this time, the built-in body 47 to be wound up maintains a good alignment state by the straight overlapping portion 41 being held between the six first feed arrows 94a. In addition, since the assembled body 47 to be wound is turned on the outer peripheral surface of the core member 91 by the first and second rollers 95 a and 98 a of the first and second pressing members 95 and 98, and the turn parts 52 on both the upper and lower sides are pressed. Bulging outward in the radial direction is prevented.

  On the other hand, the six second feed arrows 97 a of the second feed arrow device 97 installed on the second rotary table 96 and the pair of second rollers 98 a of the second pressing member 98 are together with the second rotary table 96. A predetermined pitch is turned in the direction of arrow C, and the rotation start positions of the six first feed arrows 94a of the first feed arrow device 94 and the pair of first rollers 95a of the first pressing member 95 (of the first feed arrows 94a). Rotate to the winding start position) and stop. Accordingly, the six second feed arrows 97a of the second feed arrow device 97 and the pair of second rollers 98a of the second pressing member 98 are returned to the winding start position of the built-in body 47 by the second feed arrows 97a. .

  After the stop, the drive motor 97c of the second feed arrow device 97 is operated to advance the six second feed arrows 97a toward the outer peripheral surface of the core member 91, so The tip 41 is inserted into a predetermined gap formed between the portions 41, and the tip is engaged between the center and the upper end of the engagement groove provided on the outer peripheral surface of the core member 91. Thereafter, the drive motor 94c of the first feed arrow device 94 is operated, and the six first feed arrows 94a whose tips are engaged with the engaging grooves of the core member 91 are moved backward, and are put on standby at the retracted position. Thereby, the preparation for starting the next winding operation is completed.

  In this state, the first drive shaft 92 is driven and rotated in the opposite direction to the previous time by the drive motor 92b, and the first drive shaft 92 and the second drive shaft 99 are rotated in the opposite directions in synchronization with each other by a predetermined amount. As a result, the second rotation table 96 driven by the second drive shaft 99 rotates by a predetermined pitch in the direction of arrow B in FIGS. 24 and 25, and at the same time, the first rotation driven by the first drive shaft 92. The table 93 rotates by a predetermined pitch in the direction of arrow C in FIGS.

  At this time, the six second feed arrows 97 a of the second feed arrow device 97 installed on the second turning table 96 and the pair of second rollers 98 a of the second pressing member 98 are connected to the second turning table 96. At the same time, it rotates in the direction of arrow B, and stops at the position where the six first feed arrows 94a of the first feed arrow device 94 are waiting. As a result, the core member 91 with which the tips of the six second feed arrows 97a are engaged is rotated with the second feed arrow 97a by a predetermined angle, and the second feed is accompanied by the rotation of the core member 91. The built-in body 47 conveyed by the arrow 97a is wound around the outer peripheral surface of the core member 91.

  At this time, the assembled body 47 to be wound up is maintained in a good alignment state by the straight overlapping portion 41 being held between the six second feed arrows 97a. In addition, since the assembled body 47 to be wound is turned on the outer peripheral surface of the core member 91 by the first and second rollers 95 a and 98 a of the first and second pressing members 95 and 98, and the turn parts 52 on both the upper and lower sides are pressed. Bulging outward in the radial direction is prevented.

  On the other hand, the six first feed arrows 94 a of the first feed arrow device 94 installed on the first turning table 93 and the pair of first rollers 95 a of the first pressing member 95 together with the first turning table 93. Rotating in the direction of arrow C, the rotation start positions of the six second feed arrows 97a of the second feed arrow device 97 and the pair of second rollers 98a of the second pressing member 98 (winding of the second feed arrow 97a) Rotate to the starting position and stop. Thereby, the six first feed arrows 94a of the first feed arrow device 94 and the pair of first rollers 95a of the first pressing member 95 are returned to the winding start position of the built-in body 47 by the first feed arrows 94a. .

  After the stop, the drive motor 94c of the first feed arrow device 94 is actuated to advance the six first feed arrows 94a toward the outer peripheral surface of the core member 91, so The tip 41 is inserted into a predetermined gap formed between the portions 41, and the tip is engaged between the center and the upper end of the engagement groove provided on the outer peripheral surface of the core member 91. Thereafter, the drive motor 97c of the second feed arrow device 97 is operated, and the six second feed arrows 97a whose tips are engaged with the engaging grooves of the core member 91 are moved backward, and are put on standby at the retracted position. Thereby, the preparation for starting the next winding operation is completed.

  In this state, the first drive shaft 92 is driven and rotated in the opposite direction to the previous time by the drive motor 92b, and the first drive shaft 92 and the second drive shaft 99 are rotated in the opposite directions in synchronization with each other by a predetermined amount. As a result, the first rotary table 96 is rotated by a predetermined pitch in the direction of the arrow B, and simultaneously, the first rotary table 93 is rotated by the predetermined pitch in the direction of the arrow C. In addition to starting the winding operation of the built-in body 47 by the first feed arrow 94a, the operation of returning the second feed arrow 97a of each second feed arrow device 97 to the winding start position is started. Thereafter, the first and second feed arrows 94a and 97a of the first and second feed arrow devices 94 and 97, and the first and second rollers 95a and 98a of the first and second pressing members 95 and 98 are respectively described above. By repeating the same operation as above, the two sets of built-in bodies 47 are wound around the core member 81 to the rear end.

  Thus, when the winding up to the rear end of the built-in body 47 is completed, the first and second feed arrows 94a and 97a of the first and second feed arrow devices 94 and 97, and the first and second pressing members. The first and second rollers 95a and 95a are returned to their initial positions before the start of winding, and wait. In this state, the taper pin 91c inserted on the inner peripheral side of the core member 91 is extracted, and in a state where the diameter of the core member 91 is reduced, the winding body wound in a cylindrical shape is removed from the core member 91, The winding process 103 is completed.

  Thereafter, among the 48 coil wires 50 of the formed wound body, the drawn portions 53a and 53b of the predetermined coil wire 50 are connected by welding, whereby the stator coil 40 shown in FIGS. 7 to 10 is completed. To do.

  As described above, according to the method of manufacturing the stator coil 40 of the present embodiment, in the winding step 103, the predetermined gap formed between the adjacent straight overlapping portions 41 of the built-in body 47 is In a state where a plurality of first feed arrows 94a and second feed arrows 97a are alternately inserted and the tips of the feed arrows 94a and 97a are engaged with the core member 91, the first feed arrows 94a and the second feed arrows 97a Are alternately rotated within a predetermined range in the circumferential direction of the core member 81, whereby the built-in body 47 is wound around the core member 91 while rotating the core member 91.

  Therefore, similarly to the case of the first embodiment, in the winding process 103, the assembled body 47 can be stably aligned and wound without rotating the core member 91, and wound to a desired winding diameter. A winding body can be obtained reliably.

  In particular, in the present embodiment, the first feed arrow 94 is used by using a winding device that includes the first feed arrow device 94 having the first feed arrow 94a and the second feed arrow device 97 having the second feed arrow 97a. 94a and second feed arrows 97a are alternately inserted into the predetermined gaps of the built-in body 47, and alternately rotate in the circumferential direction of the core member 91 to rotate the core member 91 while rotating the built-in body 47 into the core member 91. I am trying to wind it up. That is, when the built-in body 47 is wound up by the first feed arrow 94a, the second feed arrow 97a returns to the winding start position, and when the built-in body 47 is wound up by the second feed arrow 97a, the first feed arrow 94a starts winding. It tries to return to the position.

  For this reason, it is possible to reduce the loss of time required for the first feed arrow 94a and the second feed arrow 97a to return to the winding start position, so that the winding speed can be increased. Moreover, the positioning arrow 83a used in Embodiment 1 can be made unnecessary.

  The winding device used in the present embodiment includes the first feeding arrow 94a and the second feeding arrow 97a, so that a winding device capable of winding the built-in body 47 at high speed is easily realized. be able to. Moreover, since the winding device used in the present embodiment includes the first and second pressing members that press the built-in body 47 wound around the core member 91 from the outer peripheral side, the built-in body 47 during winding. It is possible to prevent the occurrence of bulging or twisting in the radially outward direction. Therefore, it is possible to more reliably obtain a wound body in which the turn portions 52 are well aligned and stably wound to a desired winding diameter.

[Other Embodiments]
The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the present invention.

  For example, in the winding process 103 according to the first and second embodiments, when the stator coil 40 in which 48 coil wires 50 are wound is manufactured, two sets of built-in bodies 47 made of 24 coil wires 50 are used. However, the number of coil wire members 50 incorporated in the assembly 47 may be changed as appropriate. For example, three sets of built-in bodies 47 made up of 16 coil wires 50 may be wound up, or four sets of built-in bodies 47 made up of 12 coil wires 50 may be taken up.

  However, as the number of coil wires 50 of one set of built-in bodies 47 is reduced, the required number of sets of built-in bodies 47 is increased, and accordingly, necessary feed arrows 82a, 94a, 97a (feed arrow devices 82, 94). 97) also increases. Further, when the number of the feed arrows 82a, 94a, 97a (feed arrow devices 82, 94, 97) is increased, the winding amount (the transport distance of the built-in body 47) by one winding operation of the feed arrows 82a, 94a, 97a. ) Is reduced, it is difficult to increase the winding speed. Therefore, the number of coil wires 50 to be incorporated into the built-in body 47 may be determined in consideration of the balance of these points.

  Further, the winding device of the second embodiment is not provided with the pair of pressing members 86 and 86 provided in the winding device of the first embodiment. However, the winding device of the second embodiment is also necessary. Accordingly, a pair of pressing members 86, 86 may be provided.

  DESCRIPTION OF SYMBOLS 1 ... Rotary electric machine, 14 ... Rotor, 20 ... Stator, 30 ... Stator core, 31 ... Slot, 40 ... Stator coil, 41 ... Straight overlap part, 42 ... Coil end part, 43 ... Each phase winding Wire: 47 ... Built-in body, 50 ... Coil wire material, 51 ... Slot housing portion, 52 ... Turn portion, 54 ... Crank portion, 55, 56 ... Step portion, 67 ... Conductor, 68 ... Insulating film, 81 ... Core member, 82 ... Feeding arrow device, 82a ... Feeding arrow, 82c ... First cylinder (first driving member), 82d ... Second cylinder (second driving member), 83 ... Positioning arrow device, 83a ... Positioning arrow, 84 ... First presser 84a ... first roller 85 ... second pressing member 85a ... second roller 86 ... pressing member 91 ... core member 92 ... first drive shaft 92b ... drive motor (second drive unit) 94... First feed arrow device, 94 a... First feed arrow, 94 c... Drive motor (first drive member), 95... First press member, 95 a... First roller, 97. ... second feed arrow, 97c ... drive motor (first drive member), 98 ... second pressing member, 98a ... second roller, 99 ... second drive shaft.

Claims (12)

A method for manufacturing a stator coil in which a plurality of coil wires are wound,
A plurality of slot accommodating portions that are formed in an electric conductor wire and extend in a straight line parallel to each other in parallel in the longitudinal direction, and adjacent slot accommodating portions are alternately arranged at one end side and the other end side of the slot accommodating portion. A coil wire forming step of forming a plurality of the coil wire materials having a plurality of turn portions to be connected;
A plurality of coil wire rods are arranged with a predetermined pitch shift in the longitudinal direction, and an assembly that forms a strip-like incorporation body having a plurality of straight overlapping portions formed in the longitudinal direction formed by superimposing the slot accommodating portions on each other is formed. Process,
A winding step of winding the built-in body around a core member to form a wound body, and
In the winding process, the inner surface of the built-in body is disposed along the outer peripheral surface of the core member that is pivotally supported so as to be freely rotatable, and between the adjacent straight overlapping portions of the built-in body. In a state where a plurality of feed arrows are inserted into a predetermined gap formed in the front and the tips of the feed arrows are engaged with the core member, the feed arrows are intermittently moved within a predetermined range in the circumferential direction of the core member. A method of manufacturing a stator coil, wherein the built-in body is wound around the core member while rotating the core member by rotating the core member.   In the winding process, when the feeding arrow is extracted from a predetermined gap formed between the adjacent straight overlapping portions of the built-in body, a positioning arrow is placed in another predetermined gap of the built-in body. The stator coil manufacturing method according to claim 1, wherein the linearly overlapped portion is positioned by insertion.   The winding step includes a plurality of first feed arrows inserted on one side of a predetermined gap formed between the adjacent straight overlapping portions of the built-in body and the other side of the predetermined gap. A plurality of second feed arrows inserted into the first feed arrow and the second feed arrow are alternately inserted into the predetermined gap, and alternately in the circumferential direction of the core member The method for manufacturing a stator coil according to claim 1, wherein the built-in body is wound around the core member while rotating to rotate the core member.   The said winding-up process is performed while pressing the said turn part in the both sides of the said slot accommodating part of the said integration body wound up with a pressing member from the outer peripheral side, respectively. The manufacturing method of the stator coil as described in any one of Claims 1-3.   The said pressing member has a pair of roller paralleled in the circumferential direction of the said core member, A pair of this roller is installed so that rocking | fluctuation is possible in the circumferential direction of the said core member. The manufacturing method of the stator coil of description.   The pressing member always presses the turn portion with either one of the first pressing force and the second pressing force smaller than the first pressing force, and the integrated body is wound by the feed arrow. 6. The method of manufacturing a stator coil according to claim 4, wherein pressing is performed by the first pressing force while the take-off operation is stopped.   The pressing member includes a first pressing member that presses the turn portion on one end side of the slot housing portion, and a second pressing member that presses the turn portion on the other end side of the slot housing portion. 5. The method of manufacturing a stator coil according to claim 4, wherein the first pressing member and the second pressing member are alternately rotated by a predetermined pitch in the circumferential direction.   The method for manufacturing a stator coil according to claim 7, wherein the first pressing member and the second pressing member independently advance and retract to press the turn portion with an arbitrary force. . A winding device used in the method of manufacturing a stator coil according to claim 1,
A core member pivotally supported for free rotation;
A plurality of feed arrows arranged in parallel in the circumferential direction on the outer peripheral side of the core member;
A first drive member for moving the feed arrow forward and backward with respect to the outer peripheral surface of the core member;
The core member is inserted into a predetermined gap formed between adjacent straight overlapping portions of the built-in body arranged along the inner surface of the tip portion along the outer peripheral surface of the core member, and the tip end engages with the core member. A second drive member that rotates the feed arrow in the circumferential direction of the core member;
A take-up device comprising:   When the feed arrow is extracted from a predetermined gap formed between the adjacent straight overlapping portions of the built-in body, the straight overlapping portion is inserted into another predetermined gap of the built-in body. The winding device according to claim 9, further comprising a positioning arrow for positioning the position.   The feed arrows are provided on the other side of the predetermined gap and a plurality of first feed arrows inserted on one side of the predetermined gap formed between the adjacent straight overlapping portions of the built-in body. The winding device according to claim 9, comprising a plurality of second feeding arrows to be inserted.   The winding device according to any one of claims 9 to 11, further comprising a pressing member that presses the built-in body wound around the core member from an outer peripheral side.

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