JP2013038932A - Manufacturing method for stator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for a stator which can efficiently manufacture a stator with a rectangular conductor coil.SOLUTION: A manufacturing method for a stator, includes forming a cylindrical coil basket 120 using a coil that is formed by winding a rectangular conductor D, and inserting a split core 111 into the coil basket 120 to manufacture a stator 100. A slider 22 arranged around the coil basket 120 and including an insulator holding part 22a at the tip of the slider advances toward an outer peripheral surface of the coil basket 120, and the insulator holding part 22a holds an insulator 125 inserted into a tooth insertion hole 121 of the coil basket 120. A split core 111 mounted on the slider 22 is pushed by a push block 25 arranged around the coil basket 120, and therefore the split core is inserted into the tooth insertion hole 121 to form the stator 100.

Description

  The present invention relates to a technique for assembling a split-type stator core with respect to a coil cage formed by winding a rectangular conductor used for a stator of a motor, and more specifically, from the outer peripheral side of a coil arranged in a cage shape. The present invention relates to a technique for automating a method of inserting a split stator core.

  In recent years, in view of environmental problems, there are an increasing number of cases in which a driving motor is mounted on an automobile. It is desirable that the drive motor mounted on the vehicle has a large output for moving the vehicle and is space-saving for being mounted on the vehicle. In particular, there is a high demand for miniaturization of a hybrid vehicle because the engine and the drive motor need to be housed in the engine room. In order to improve the output of the motor, a method for increasing the cross-sectional area of the coil used for the motor and increasing the space factor of the stator is being sought. On the other hand, with respect to miniaturization of motors, miniaturization has been studied by various approaches.

  As a method of increasing the cross-sectional area of the stator coil, a method of forming a coil by winding a flat rectangular conductor has been proposed. By forming a coil using a rectangular conductor having a rectangular cross section, the porosity can be lowered than when a conductor having a circular cross section is used when a part of the coil is placed in a rectangular slot, As a result, the space factor can be increased. However, when forming a coil using a rectangular conductor, the processing method becomes a little difficult. Further, when assembling a flat conductor coil, it is often difficult to assemble because the flat conductor is difficult to deform.

  There are some examples of methods for manufacturing a stator using concentrated winding coils that are relatively easy to assemble. There are examples of methods for forming a concentrated winding coil by performing edgewise bending using a rectangular conductor and then combining the coil with an insulator and assembling it as a cassette coil to a stator.

  Patent Document 1 discloses a technique related to a cassette coil, a split stator, and a stator. Assemblability is improved by placing resin coils on the split-type stator cores and inserting cassette coils with concavities and convexities on the joint surface, and arranging units that combine the stator cores and cassette coils in a cylindrical shape. .

  Patent Document 2 discloses a technique related to a stator and an assembly method thereof. After a conductor is edgewise bent to form a concentrated winding coil, a coil unit is formed by resin-molding the coil and then assembled to a split-type stator core. An embedded resin portion is provided between the teeth portion of the stator core and the inner peripheral portion of the coil unit, and after being assembled, the embedded resin portion is filled with resin so that the stator core and the coil unit are Suppresses backlash.

  Patent Document 3 discloses a technique related to a stator of a rotating electrical machine. By forming a coil made of edgewise bending of a rectangular wire in a bowl shape, inserting a split stator core from the outer periphery side, and fitting and fixing the outer periphery of the split stator core with an outer cylinder having a hook Constitutes the stator. By forming the outer cylinder thinly and providing the flange, it contributes to the downsizing of the stator while improving the rigidity of the outer cylinder.

JP 2009-153290 A JP 2009-254172 A JP 2010-259315 A

  However, the stators disclosed in Patent Documents 1 to 3 are considered to have the following problems.

  In both Patent Document 1 and Patent Document 2, a cassette type insulator is used for the coil. The method of forming a unit by combining a cassette type insulator with a split type stator core and arranging them in a cylindrical shape can be used only for a stator using concentrated winding coils. However, considering that the torque is increased by increasing the rotation speed of the motor, it is effective to increase the number of slots or change the winding method from concentrated winding to distributed winding in order to suppress the occurrence of cogging torque. In the methods of Patent Literature 1 and Patent Literature 2, there is a limit to increasing the number of stator core divisions, and it is considered that distributed winding cannot be handled.

  As in Patent Document 3, it is possible to deal with distributed winding coils by making a coil cage, but in this case, it is necessary to insert a split-type stator core from the outer periphery side. Also need to be inserted. However, such a manufacturing technique is not disclosed in Patent Document 3. This is because a coil using a flat conductor has not been used in a motor used to drive a car so far, and it can be automated when inserting a stator core from the outer peripheral side to a coil cage. Realization of production methods is eagerly desired.

  Accordingly, an object of the present invention is to provide a stator manufacturing method capable of more efficiently producing a stator using a rectangular conductor coil in order to solve such problems.

  In order to achieve the above object, a stator manufacturing method according to an aspect of the present invention has the following characteristics.

(1) In the stator manufacturing method of manufacturing a stator by forming a cylindrical coil cage using a coil formed by winding a flat rectangular conductor and inserting a split core into the coil cage, the coil cage A core carrier having an insulator holding portion at the tip disposed around the front of the coil rod advances toward the outer peripheral surface of the coil rod, and the insulator holding portion holds the insulator inserted into the tooth insertion hole of the coil rod. The split core placed on the core carrier is pushed by a pressing mechanism disposed around the coil rod and inserted into the teeth insertion hole, whereby the stator is formed. To do.

(2) In the stator manufacturing method according to (1), the insulator is inserted into the teeth insertion hole by an insulator insertion mechanism installed on the outer peripheral side of the coil rod, and the insulator is pressed and held. One end of the insulator is pressed by a claw, the other end of the insulator is pressed by the insulator holding part of the core carrier, the split core is inserted into the teeth insertion hole by the pressing mechanism, and the stator is formed. It is characterized by being.

(3) In the stator manufacturing method according to (1) or (2), the insulator holding portion has two convex portions to be inserted into the teeth insertion hole, and includes three pressing portions for pressing the insulator, A plurality of insulators are pressed by the insulator holding portion.

  The following operations and effects can be obtained by the stator manufacturing method according to one aspect of the present invention having such characteristics.

  In the aspect described in (1) above, a stator is manufactured by forming a cylindrical coil cage using a coil formed by winding a rectangular conductor and inserting a split core into the coil cage. In the method, an insulator having a core carrier having an insulator holding portion at a tip disposed around the coil rod advances toward an outer peripheral surface of the coil rod, and the insulator holding portion is inserted into a tooth insertion hole of the coil rod. The split core placed on the core carrier is pushed by a pressing mechanism arranged around the coil cage and inserted into the teeth insertion hole, thereby forming a stator.

  When inserting the split core into the coil rod with the insulator inserted, it is necessary to hold the insulator in order to prevent the insulator from being displaced by being dragged by the split core. For this reason, an insulator holding part is provided at the tip of the core carrier prepared for inserting the split core, and the core carrier is brought close to the coil cage, and the insulator holding part is used to hold the insulator. When the core is inserted into the coil cage by the pressing mechanism, it is possible to suppress the deviation of the insulator. And since it is a mechanism which extends a core conveyance stand and makes it an insulator holding | maintenance part, it can serve as a guide of a split core simultaneously with holding | maintenance of an insulator.

  In this way, it is possible to assemble the split core using the core carrier and the pressing mechanism with the insulator inserted into the coil cage, and the structure of the core carrier and the pressing mechanism corresponds to automation. A stator manufacturing method capable of more efficiently producing a stator using a coil can be provided.

  The aspect described in (2) above is the stator manufacturing method described in (1), in which the insulator is inserted into the teeth insertion hole by an insulator insertion mechanism installed on the outer peripheral side of the coil rod, and the insulator is pressurized. Hold one end of the insulator with the holding claw, hold the other end of the insulator with the insulator holding part of the core carrier, insert the split core into the teeth insertion hole with the pressing mechanism, and the stator is formed is there.

  The insulator can be prevented from being displaced by pressing one end of the insulator with a holding claw and the other end with an insulator holding portion provided in the core carrier. By increasing the holding points of the insulator, the insulator becomes more difficult to shift. As a technique for suppressing the generation of cogging torque when the motor is in operation, there is a method of increasing the number of slots. However, when the number of slots is increased, it is desirable to increase the number of means to be pressed because the insulator is elongated, and it can be expected that displacement will be more difficult by pressing one end and the other end on the coil end side of the coil cage.

  Moreover, the aspect as described in said (3) is the stator manufacturing method as described in (1) or (2), The insulator holding part has two convex parts inserted in a teeth insertion hole, and suppresses an insulator. Three pressing parts are provided, and a plurality of insulators are pressed by the insulator holding part.

  Since the insulator holding portion has two convex portions to be inserted into the tooth insertion holes and has three pressing portions for pressing the insulator, the three insulators can be pressed by the adjacent insulator holding portions. The stator core can be designed to reduce iron loss by providing two teeth, but by making the insulator holding part provided in the core carrier stand corresponding to this, the stator core can be inserted smoothly. I can do things.

It is a perspective view of the stator of this embodiment. It is a perspective view of a coil cage of this embodiment. It is a perspective view of a mode that a split core is inserted in a coil cage of this embodiment. It is a perspective view of a mode that an outer cylinder of this embodiment is fitted in the perimeter of a split core. It is a perspective view of the stator which provided the terminal block of this embodiment. It is side surface sectional drawing of the assembly apparatus of this embodiment. It is the elements on larger scale of the assembly apparatus of this embodiment. It is a perspective view of the unit for coil cage transfer of this embodiment. It is a top view containing a lower clamp unit of this embodiment. It is a perspective view of the assembly apparatus of this embodiment. It is a simple flow at the time of forming a stator of this embodiment. It is a flow regarding the insulator insertion process of this embodiment. It is a flow regarding the division | segmentation core insertion process of this embodiment. It is side surface sectional drawing which shows a mode that an insulator is hold | gripped by the upper clamp unit of this embodiment. It is side surface sectional drawing which shows a mode that an insulator is re-gripped by the upper clamp unit of this embodiment. It is side surface sectional drawing which shows a mode that the split core has been arrange | positioned to the split core insertion mechanism of this embodiment. It is side surface sectional drawing which shows a mode that a split core is inserted with the split core insertion mechanism of this embodiment.

  First, an embodiment of the present invention will be described with reference to the drawings.

  In FIG. 1, the perspective view of the stator 100 of this embodiment is shown. In FIG. 2, the perspective view of the coil cage | basket 120 is shown. In FIG. 3, the perspective view of a mode that the split core 111 is inserted in the coil cage | basket 120 is shown. FIG. 4 is a perspective view showing a state in which the outer cylinder 130 is fitted to the outer periphery of the split core 111. FIG. 5 is a perspective view of a stator provided with the external terminals 140. The stator 100 includes a split core 111, a coil rod 120, and an outer cylinder 130, and is used for an in-vehicle motor or the like. The split core 111 has a substantially fan shape with a convex portion, and is formed by stacking a plurality of electromagnetic steel plates punched and formed by press working. As shown in FIG. 3, the split core 111 is provided with two teeth 111a protruding toward the inner peripheral side of the stator 100 and one slot 111b between the teeth 111a. Twenty-four divided cores 111 are prepared and arranged in a cylindrical shape to form a stator core 110, which is used for the stator 100.

  The coil rod 120 is formed by stacking 48 concentric coils in a cylindrical shape, and has 48 teeth insertion holes 121 arranged radially to open toward the outer peripheral surface. The concentric coil is formed by edgewise bending a rectangular conductor having a rectangular cross section. As shown in FIG. 2, the in-slot conductor portion 122 indicates a rectangular conductor D aligned on the radiation from the axial center, and a tooth insertion hole 121 is provided between the adjacent in-slot conductor portions 122. . The in-slot conductor portion 122 is arranged inside the slot 111b of the split core 111 in the state of the stator 100, and the ten in-slot conductor portions 122 are arranged in the slot 111b.

  In addition, as shown in FIG. 3, the split core 111 is arranged in a cylindrical shape in the coil rod 120 by inserting the teeth 111 a into the teeth insertion holes 121. When the teeth 111a are inserted into the teeth insertion hole 121, an insulator 125 described later is inserted into the teeth insertion hole 121 and held. The insulator 125 is a resin or paper insulator prepared to ensure insulation between the in-slot conductor portion 122 and the split core 111. And the stator 100 is formed by fitting the outer cylinder 130 in the outer periphery of the split core 111 as shown in FIG.

  The outer cylinder 130 is an annular metal part and has a structure in which a rib is provided around it. The rib is provided with a hole for passing a bolt, and is used for the purpose of engaging the trunk axle case or providing a cover for the motor. The inner diameter of the outer cylinder 130 is set to a size that fits tightly with the outer diameter of the split core 111, and the split core 111 is held on the outer periphery of the split core 111 by heating and shrinking the outer cylinder 130. Things will be possible.

  The lead side of the coil ends of the coil rod 120 is joined using TIG welding or the like. The U-phase, V-phase, and W-phase are each welded to the neutral point and the external terminal 140 at the coil end, and finally fixed as shown in FIG. 5, with the external terminal 140 connected to the lead-side coil end. A child 100 is formed. The coil end is insulated by resin coating, varnish coating, electrodeposition coating, or the like as necessary to protect and insulate the welded portion.

  FIG. 6 shows a side sectional view of the assembling apparatus 10. In FIG. 7, the elements on larger scale of the assembly apparatus 10 are shown. FIG. 8 shows a perspective view of the coil cage transfer unit 50. In FIG. 9, the top view regarding a lower clamp unit is shown. FIG. 10 shows a perspective view of the assembling apparatus 10. The AA cross section in FIG. 9 corresponds to the side cross section shown in FIG. Moreover, although the assembling apparatus 10 shown in FIGS. 6 to 10 shows a test jig whose structure is easy to understand for the sake of explanation, it is possible to assemble using an apparatus of the same principle in an automated line.

  As shown in FIG. 10, the assembling apparatus 10 includes a split core insertion mechanism 20 and an upper clamp unit 30 and inserts the split core 111 into the coil rod 120. As shown in FIG. 7, the split core insertion mechanism 20 has a predetermined shape with respect to the slider 22 corresponding to the core transport base on which the split core transport base 21 and the split core 111 formed in a disk shape are placed directly on the slider 22 A compression spring 23 and a spring guide 24 for urging the pressure are provided, and the spring guide 24 is fixed to the divided core conveyance base 21.

  The slider 22 is provided to slide in the radial direction with respect to the coil rod 120 using an LM guide 26 including a guide rail 26a and a guide block 26b. Accordingly, the slider 22 is moved in the radial direction of the coil rod 120 by the urging force of the compression spring 23, and the insulator 125 having the tip of the insulator holding portion 22 a provided to extend the slider 22 is provided in the insulator 125. Can be pressed with an appropriate force. The push block 25 is disposed so as to engage with the slider 22, and has a function of moving the split core 111 in the radial direction of the coil rod 120. Three sets of such split core insertion mechanisms 20 are arranged with respect to the split core transport base 21. However, in the automated line, 24 sets, that is, the same number as the number of the split cores 111 inserted into the coil cage 120 are prepared.

  As shown in FIG. 9, the insulator holding portion 22 a of the slider 22 has a two-end split shape, and each is disposed so as to be inserted into the teeth insertion hole 121 of the coil rod 120. Yes. At the tip of the insulator holding portion 22a, there are two protrusions 22b, two shoulder portions 22c on both sides, and a central portion 22d at the center. The protrusion 22b is inserted into the tooth insertion hole 121 and plays a role of pressing the insulator 125 at the shoulder 22c and the center 22d.

  The upper clamp unit 30 is a unit disposed on the coil rod 120, and as shown in FIG. 7, a clamp claw 31 corresponding to a holding claw, a clamp post 36 that rotatably supports the clamp claw 31, and a clamp A clamp rod 35 having a function of lifting the clamp claw 31 in combination with the claw 31, an upper compression spring 33 provided on the clamp rod 35 and biasing downward, and the clamp rod 35 penetrating through the clamp claw 31 and the system A clamp bracket 32 to be joined and a disc-shaped guide plate 34 to which the clamp bracket 32 is attached are provided. Six sets of upper clamp units 30 are prepared and fixed on the circular base 41. The circular base 41 is attached to the center post 40. In the automated line, 48 sets of upper clamp units 30 are prepared which are the same number as the slots 111b.

  The split core 111 is inserted into the coil cage 120 using such an assembling apparatus 10. The coil cage 120 is disposed in a coil cage transfer unit 50 as shown in FIG. The coil rod transfer unit 50 includes a transfer plate 51 and a coil rod guide 52. As shown in FIG. 7, after the coil rod 120 is fitted on the outer periphery of the coil rod guide 52, By fitting the outer ring 53 on the upper and lower sides of the outer periphery of the coil rod 120, the coil rod 120 is held. The outer ring 53 has a function of holding the coil rod 120 from being deformed from the outer peripheral side of the coil rod 120 by expanding and contracting the diameter of the outer ring 53.

  Next, the procedure for inserting the split core 111 into the coil rod 120 and the movement of the assembly apparatus 10 will be briefly described.

  FIG. 11 shows a simplified flow when forming the stator. In FIG. 12, the flow regarding an insulator insertion process is shown. FIG. 13 shows a flow relating to the split core insertion process. In forming the stator 100, it is necessary to go through a coil cage forming process, an insulator inserting process, a split core inserting process, and an outer cylinder fitting process as described in the flow of FIG. Among these, the insulator insertion process and the split core insertion process which are largely related to the present invention will be briefly described below. In the automation process, since each process is performed at a different station, it is necessary to transfer the process. However, the description is only supplementarily described here.

  FIG. 14 is a side cross-sectional view showing how the insulator 125 is gripped by the upper clamp unit 30. FIG. 15 is a side sectional view showing how the insulator 125 is re-gripped by the upper clamp unit 30. FIG. 16 shows a side cross-sectional view of the split core 111 arranged in the split core insertion mechanism 20. FIG. 17 is a side sectional view showing how the split core 111 is inserted by the split core insertion mechanism 20. Note that in FIGS. 14 to 17, portions unnecessary for explanation are omitted and simplified. 14 to 17 show the assembling apparatus 10 shown in FIG. 7 for each movement so that a specific movement can be seen.

  In S1, the coil cage 120 is formed in the coil cage forming step. Specifically, it is a step of assembling the coils wound concentrically, and the cylindrical coil rod 120 is assembled on the coil rod transfer unit 50 shown in FIG. Details of how to assemble the coil have been described in detail in another application, and will be omitted. Then, the process proceeds to S2.

  In S <b> 2, the outer periphery of the coil rod 120 is held by the outer ring 53. Since the coil rod 120 is simply a state in which the coil is assembled in an annular shape, after the coil is assembled in an annular shape to form the shape of the coil rod 120, the outer ring 53 as shown in FIG. It arrange | positions to hold | maintain so that the coil which forms the coil cage | basket 120 may not fall apart. Then, the process proceeds to S3. At this point, the automated line needs to be transferred from the coil cage forming station to the insulator insertion station. In order to transfer, the coil rod 120 is held in the coil rod transfer unit 50 and then transferred to the next station.

  In S <b> 3, the insulator 125 is inserted into the teeth insertion hole 121 of the coil rod 120 from the outer peripheral side of the coil rod 120 in the insulator insertion step. Then, the process proceeds to S4.

  In S <b> 4, the insulator 125 is held on the coil rod 120 by clamping the insulator 125 with the clamp claws 31 of the upper clamp unit 30. As shown in FIG. 14, after the insulator 125 is inserted, the guide plate 34 is lowered to lower the clamp pawl 31 interlocked with the clamp rod 35, and the insulator 125 is clamped. The clamp claw 31 is disposed at a position where the in-slot conductor portion 122 of the coil rod 120 can be pressed. The clamp pawl 31 is urged by the upper compression spring 33 provided on the clamp rod 35, and the insulator 125 is held with an appropriate force. Then, the process proceeds to S5. At this point, the automated line needs to be transferred from the insulator insertion station to the core assembly process. To transfer, the upper clamp unit 30 is fixed to the coil cage transfer unit 50, and the insulator 125 is held by the upper clamp unit 30 on the coil cage 120 held by the coil cage transfer unit 50. Then, it will be transferred to the next station.

  In S5, the insulator 125 is held by the split core insertion mechanism 20 serving as an insulator holder. Accordingly, the lower portion of the insulator 125 is pressed by moving the slider 22 forward toward the coil rod 120 as shown in FIG. Then, the process proceeds to S6.

  In S <b> 6, the split core 111 is inserted into the teeth insertion hole 121 of the coil rod 120. The split core 111 is disposed on the slider 22 and moved so as to move forward with respect to the coil rod 120. Thereafter, the push block 25 moves forward to the coil rod 120, so that the split core 111 is moved into the tooth insertion hole 121. insert. Then, the process proceeds to S7. In addition, it is necessary to transfer to an outer cylinder fitting process from a core assembly | attachment process at this time in an automation line. In order to transfer, the coil rod 120 and the split core 111 are held in the coil rod transfer unit 50 and transferred to the next station.

  In S <b> 6, the outer cylinder 130 is fitted to the outer periphery of the split core 111. A heated outer cylinder 130 is arranged on the outer periphery of the split core 111 and cooled to form a tight fit, and the split core 111 is held by the outer cylinder 130. And it transfers to the next process.

  Next, the insulator insertion process shown in FIG. 10 will be described. In the insulator insertion process, the insulator 125 is inserted into the coil rod 120 at the insulator insertion station.

  In S10, the coil cage 120 provided in the coil cage transfer unit 50 is held in the station of the insulator insertion process. The coil rod transfer unit 50 is provided with a coil rod 120 formed in the coil rod forming process, which is a previous process, and an outer ring 53 is fitted therein to maintain the shape of the coil rod 120. Then, the process proceeds to S11.

  In S <b> 11, the upper clamp unit 30 serving as an insulator holder is disposed on the upper side of the coil rod 120. The upper clamp unit 30 is attached to the upper part of the coil cage transfer unit 50, and the clamp pawl 31 of the upper clamp unit 30 is in an open state as shown by a two-dot chain line in FIG. Then, the process proceeds to S12.

  In S <b> 12, the insulator 125 is inserted into the teeth insertion hole 121 of the coil rod 120. Although the details regarding the insertion process of the insulator 125 are omitted, the substantially U-shaped insulator 125 is disposed so as to cover the in-slot conductor portion 122 of the coil rod 120. Then, the process proceeds to S13.

  In S13, the coil rod 120 in which the insulator 125 is inserted is held by the clamp pawl 31 as shown by a solid line in FIG. The clamp pawl 31 presses around the center of the insulator 125, and the clamp pawl 31 is biased by the upper compression spring 33 via the clamp rod 35. Therefore, the clamp pawl 31 exerts a force for holding the insulator 125 by the upper compression spring 33. And it moves to the next process. In the automation process, the coil cage 120 is transferred to the next process while holding the insulator 125 inserted in the coil cage 120 with the upper clamp unit 30 in the coil cage transfer unit 50.

  Next, the split core insertion process shown in FIG. 11 will be described. In the split core insertion step, the split core 111 is inserted into the coil cage 120 at the split core insertion station.

  In S20, the upper clamp unit 30 that is an insulator holding jig is used for gripping. As shown in FIG. 14, the clamp pawl 31 of the upper clamp unit 30 presses around the center of the insulator 125 at the start of the split core insertion process. However, since the insertion of the split core 111 is obstructed as it is, gripping is performed so that the upper end of the insulator 125 is pressed by the clamp pawl 31 as shown in FIG. In FIG. 15, the clamp claw 31 is largely opened for easy understanding. However, it is desirable to reduce the opening amount of the clamp claw 31 in consideration of the displacement of the insulator 125 and to replace it. Then, the process proceeds to S21.

  In the automation process, a step of holding the coil cage 120 is required before S20. The unit in which the insulator 125 is held and conveyed by the coil rod 120 by the coil rod transfer unit 50 and the upper clamp unit 30 from the station of the insulator insertion step is set in the core insertion station. By holding the upper clamp unit 30 in the coil cage transfer unit 50, the insulator 125 can be suppressed with respect to the coil cage 120, and the insulator 125 is prevented from being displaced due to movement between stations. Is possible.

  In S <b> 21, the split core 111 is disposed on the slider 22. The split core 111 is arranged on the upper part of the slider 22 of the split core insertion mechanism 20 to prepare for insertion of the split core 111. A total of three divided cores 111 are arranged around the coil rod 120, one on the slider 22 respectively. Then, the process proceeds to S22. In the automated process, 24 pieces are arranged in each of the 24 divided core insertion mechanisms 20 in total.

  In S22, the slider 22 serving as a core carrier is advanced. By moving the slider 22 forward, the insulator holding portion 22 a of the slider 22 is brought close to the outer peripheral surface of the coil rod 120. In addition, since the split core 111 is placed on the slider 22, the split core 111 also approaches the coil rod 120 as the slider 22 advances. Then, the process proceeds to S23.

  In S23, the insulator holding portion 22a is inserted into the teeth insertion hole 121 of the coil rod 120, and the insulator 125 is pressed. As shown in FIG. 9, the insulator holding portion 22 a has two protrusions 22 b that are inserted into the tooth insertion holes 121, respectively. Then, the lower end of the insulator 125 is pressed by the shoulder portion 22c and the central portion 22d of the insulator holding portion 22a. Since the upper end portion of the insulator 125 is pressed by the clamp claws 31 of the upper clamp unit 30, the insulator 125 is pressed from both ends. Then, the process proceeds to S24.

  In S24, the push block 25 serving as a pressing mechanism is advanced and the split core 111 is inserted. By pressing the outer peripheral surface of the split core 111 with the tip of the push block 25, the split core 111 is advanced into the teeth insertion hole 121 as shown in FIG. Then, the process proceeds to S25.

  In S25, the clamp pawl 31 that presses the end of the insulator 125 is opened. Since the insulator 125 is pressed by the split core 111 by inserting the split core 111 into the teeth insertion hole 121, the clamp pawl 31 is opened. Then, the process proceeds to S26.

  In S26, the slider 22 as the core carrier is moved backward. As the slider 22 moves backward, the coil cage 120 becomes free and can be transferred to the next step. In the next step, it is necessary to remove the upper clamp unit 30 and the outer ring 53 in order to fit the outer cylinder 130. In the automation process, the upper clamp unit 30 is removed from the coil cage transfer unit 50 and transferred to the next station.

  In addition, although the position of the clamp nail | claw 31 was changed by S20 and the slider 22 which is a core conveyance stand is advanced by S22, this procedure may be reverse. The clamp claw 31 is shaped to hold the in-slot conductor portion 122, and one slider 22 does not directly interfere with the clamp claw 31. The split core 111 placed on the slider 22 may interfere with the clamp pawl 31. The split core 111 is provided with a slot 111b, and the clamp pawl 31 is designed to enter the gap. Therefore, interference can be avoided. Therefore, after the step of arranging the split core 111 on the slider 22 which is the procedure of S21, the slider 22 which is the procedure of S22 is advanced, the lower part of the insulator 125 is pressed by the insulator holding portion 22a, and then the clamp which is the procedure of S20 When the nail 31 is re-held, the insulator 125 is less likely to be displaced. However, it is necessary to solve the problem that it is difficult to place the split core 111 due to the presence of the clamp claws 31.

  Through these steps, the split core 111 is inserted into the coil rod 120, the outer cylinder 130 is fitted, the welded portion JV is formed, and the external terminal 140 is welded as shown in FIG. 100 is formed. Although the automation process has been briefly described in the middle, the stator 100 is formed by the same principle and procedure.

  Since the manufacturing method of the stator 100 of this embodiment is the said structure, there exists an effect | action and effect which are demonstrated below.

  First, since the manufacturing method of the stator 100 can cope with the automation process, production can be performed more efficiently. In the method for manufacturing the stator 100 according to the present embodiment, a cylindrical coil rod 120 is formed using a coil formed by winding a flat conductor D, and the split core 111 is inserted into the coil rod 120, whereby the stator In the stator manufacturing method for manufacturing 100, the slider 22 having the insulator holding portion 22a at the tip disposed around the coil rod 120 advances toward the outer peripheral surface of the coil rod 120, and the insulator holding portion 22a is moved to the coil rod 120. The insulator 125 inserted in the tooth insertion hole 121 of 120 is pressed, and the split core 111 placed on the slider 22 is pushed by the push block 25 arranged around the coil rod 120 to enter the teeth insertion hole 121. Inserted, the stator 100 is formed.

  Further, the insulator 125 is inserted into the teeth insertion hole 121 by the split core insertion mechanism 20 installed on the outer peripheral side of the coil rod 120, and one end of the insulator 125 is pressed by the clamp pawl 31 that pressurizes and holds the insulator 125, and the slider The other end of the insulator 125 is pressed by the insulator holding portion 22a of the arm 22 and the split core 111 is inserted into the teeth insertion hole 121 by the push block 25, whereby the stator 100 is formed.

  The circumferential width of the teeth insertion hole 121 of the coil rod 120 is designed so that there is almost no margin with respect to the circumferential width of the teeth 111a of the split core 111 in consideration of the thickness of the insulator 125. This is necessary to improve the space factor of the stator 100. If the width of the circumferential tooth insertion hole 121 is set wide in consideration of the assembling property of the split core 111 and the coil rod 120, the space factor is increased. In order to reduce the rate, it is necessary to set the gap as small as possible.

  For this reason, when the insulator 125 is disposed so as to cover the in-slot conductor portion 122 of the coil rod 120 and then the teeth 111a of the split core 111 are inserted, a deviation is likely to occur. However, the teeth 111a are inserted in a state where both ends of the insulator 125 are pressed by the insulator holding portion 22a and the clamp claw 31, and the clamp claw 31 is attached by the upper compression spring 33 and the insulator holding portion 22a by the compression spring 23. In this state, the split core 111 is moved forward in the radial direction of the coil rod 120, so that the insulator 125 is dragged by the split core 111 to cause a displacement, or the insulator 125 is damaged. It becomes possible to prevent.

  The split core insertion mechanism 20 can be arranged in 24 sets on the outer periphery of the coil rod 120, and the upper clamp unit 30 can be arranged in 48 sets on the outer periphery of the coil rod 120. For this reason, it is possible to use the structure equivalent to the split core insertion mechanism 20 and the upper clamp unit 30 in an automation process. By using the split core insertion mechanism 20 and the upper clamp unit 30, the insulator 125 can be prevented from being damaged or displaced, and the yield of the stator 100 can be improved.

  In addition, by providing the split core insertion mechanism 20 with the insulator holding portion 22a at the tip of the slider 22, the center of gravity of the split core 111 is held by the insulator when the split core 111 disposed on the slider 22 is moved. The accuracy of the insertion position of the split core 111 can be increased without being detached from the tip of the portion 22a.

  This is because the slider 22 is provided on the LM guide 26 so as to be movable in the radial direction of the coil rod 120, and the insulator holding portion 22a at the tip of the slider 22 has a protrusion 22b, a shoulder portion 22c, and a central portion 22d. It is. The protrusion 22 b is inserted into the teeth insertion hole 121 when the split core 111 is inserted into the teeth insertion hole 121 of the coil rod 120. When the split core 111 is arranged at a predetermined position as the stator 100, the center of gravity of the split core 111 remains on the slider 22 so that the tip of the split core 111 does not hang downward due to the influence of gravity. Thus, the length of the protrusion 22b is determined.

  Further, the slider 22 is urged by the compression spring 23 to the slider 22, and as shown in FIG. 17, when the slider 22 moves forward, the insulator holding portion 22 a comes into contact with the outer periphery of the coil rod 120, and a part of the teeth is teeth. It is inserted into the insertion hole 121. The slider 22 is biased by the compression spring 23. As shown in FIG. 9, the tip of the insulator holding portion 22a has a protrusion 22b, a shoulder portion 22c and a central portion 22d at the tip of the insulator holding portion 22a, and the in-slot lead portion 122 has a shoulder portion 22c and a shoulder portion 22c. The central portion 22d contacts.

  Accordingly, the protrusion 22b is inserted into the tooth insertion hole 121, and the shoulder portion 22c and the central portion 22d are urged by the compression spring 23 to press the in-slot conductor portion 122 disposed on the outermost periphery of the coil rod 120. As a result, the insulator holding portion 22a is in a state in which the protrusion 22b protrudes into the tooth insertion hole 121 with respect to the coil rod 120, and the shoulder portion 22c and the central portion 22d protrude from the in-slot conductor portion 122. Since the split core 111 is moved in this state, the split core 111 is pushed by the push block 25. As a result, even when the split core 111 is inserted into the coil cage 120, the center of gravity of the split core 111 remains on the slider 22, so that the tip of the split core 111 does not sag. In addition, the accuracy of inserting the split core 111 into the tooth insertion hole 121 can be improved.

  This means that the variation in the insertion position of the teeth 111a of the split core 111 can be reduced, and the split core 111 can be inserted smoothly. The tip of the teeth 111a has a purpose of reducing cogging torque when the stator 100 is used for a motor, and therefore it is difficult to perform R chamfering or C chamfering. Therefore, increasing the insertion position accuracy of the split core 111 is essential in the assembly of the stator 100, and the teeth 111a of the split core 111 are urged while abutting the insulator holding portion 22a of the slider 22 against the coil rod 120. The insertion position accuracy can be increased by inserting. As a result, it is possible to contribute to the yield improvement in the manufacture of the stator 100.

  Further, by providing the upper clamp unit 30 with a mechanism that can be gripped, the insulator 125 can be held at a more appropriate position.

  In forming the coil cage 120, it is assumed that the assembly process of the coil cage 120, the inserting process of the insulator 125, and the inserting process of the split core 111 each have a higher production efficiency if the stations are divided. Actually, in the perspective view of the assembling apparatus 10 in FIG. 10, it is described that two split core insertion mechanisms 20 are drawn and arranged on the split core transport base 21. However, it is desirable that all the divided cores 111 are inserted simultaneously from the entire circumference of the coil rod 120. Further, the split core insertion mechanism 20 interferes with a mechanism for inserting the insulator 125 to be disposed opposite to the split core insertion mechanism 20 in FIG. 10 and a mechanism for assembling a coil (not shown) as the coil rod 120.

  For this reason, in the automated line assumed by the applicant, the coil cage forming process, the insulator inserting process, the core assembling process, and the outer cylinder fitting process are performed by providing separate stations. Therefore, when moving the station, the assembled coil rod 120 is fixed on the coil rod transfer unit 50, and the insulator 125 is pressed by the upper clamp unit 30 fixed to the coil rod transfer unit 50. Thus, it is possible to move between the stations so that the coil rod 120 and the insulator 125 do not shift when the coil rod 120 is transferred.

  In addition, the coil rod 120 is placed on the coil rod transfer unit 50 in a state where the middle part of the insulator 125 is pressed by the clamp claws 31 of the upper clamp unit 30 and moved between stations, and then the upper end portion of the insulator 125 is clamped. The nail 31 can be re-gripped. For this reason, it becomes possible to keep pressing the insulator 125 while avoiding interference between the split core 111 and the clamp pawl 31 in the core assembling step.

  Further, since the upper clamp unit 30 is unitized and can be fixed to the coil cage transfer unit 50, the displacement of the insulator 125 is suppressed when transferring between stations for each process. Is possible. By using the split core insertion mechanism 20 and the upper clamp unit 30 as described above, a compact production line for the stator 100 can be realized. For this reason, it can contribute to cost reduction.

  Although the invention has been described according to the present embodiment, the invention is not limited to the embodiment, and by appropriately changing a part of the configuration without departing from the spirit of the invention. It can also be implemented.

  For example, the coil rod 120 described in the present embodiment is described as being formed by stacking concentric coils. However, if the stator 100 has a configuration in which the coils are arranged in the shape of the coil rod 120, for example, a wave winding coil or the like The present invention can also be applied to. Therefore, the use of the present invention for the stator 100 having the coil rod 120 is not prevented. Moreover, it does not prevent changing the connection method of the coil rod 120 shown in this embodiment and the shape of the coil end. Moreover, the apparatus configuration of the assembly apparatus 10 does not prevent changing within the range of design matters.

DESCRIPTION OF SYMBOLS 10 Assembling apparatus 20 Split core insertion mechanism 21 Split core conveyance base 22 Slider 22a Insulator holding part 30 Upper clamp unit 31 Clamp claw 32 Clamp bracket 50 Coil cage transfer unit 53 Outer ring 100 Stator 110 Stator core 111 Split core 111a Teeth 111b Slot 120 Coil rod 121 Teeth insertion hole 122 In-slot conductor portion 125 Insulator 130 Outer tube 140 External terminal

Claims (3)

In the stator manufacturing method of manufacturing a stator by forming a cylindrical coil rod using a coil formed by winding a flat conductor, and inserting a split core into the coil rod,
A core carrier having an insulator holding part at the tip disposed around the coil cage,
Advance toward the outer peripheral surface of the coil cage,
The insulator holding part holds the insulator inserted in the teeth insertion hole of the coil rod,
The split core placed on the core carrier is inserted into the teeth insertion hole by being pushed by a pressing mechanism disposed around the coil cage,
A stator manufacturing method, wherein the stator is formed. In the stator manufacturing method according to claim 1,
The insulator is inserted into the teeth insertion hole by an insulator insertion mechanism installed on the outer peripheral side of the coil rod,
Holding one end of the insulator with a holding claw that pressurizes and holds the insulator,
Holding the other end of the insulator at the insulator holding part of the core carrier,
The split core is inserted into the teeth insertion hole by the pressing mechanism,
A stator manufacturing method, wherein the stator is formed. In the stator manufacturing method according to claim 1 or 2,
The insulator holding portion has two convex portions to be inserted into the teeth insertion hole, and has three pressing portions for pressing the insulator,
A method of manufacturing a stator, wherein a plurality of insulators are pressed by the insulator holding portion.

Images