JP2014073058A - Method for manufacturing coil assembly - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for efficiently manufacturing a hardly deformed coil assembly for a rotary electric machine.SOLUTION: A method for manufacturing a coil assembly comprises the steps of: arranging three coil wires 20A, 20B and 20C; setting a predetermined position as a stitch starting point; moving the second coil wire 20B and the third coil wire 20C upward; jumping a lower turn part 22Dat the predetermined position over an upper side turn part 22U; lowering the second coil wire 20B; jumping a lower turn part 22Dat the predetermined position over the upper side turn parts 22Uand 22U; lowering the third coil wire 20C; moving the first coil wire 20A and the second coil wire 20B upward; jumping the lower turn part 22Dat the predetermined position over an upper side turn part 22U; lowering the second coil wire 20B; jumping a lower turn part 22Dat the predetermined position over the upper side turn parts 22Uand 22U; and lowering the first coil wire 20A.

Description

  The present invention relates to a method of manufacturing a coil assembly used for a stator of a rotating electrical machine used as an electric motor or a generator in a vehicle or the like.

Conventionally, various methods have been proposed for manufacturing a coil assembly for a rotating electrical machine. The coil assembly for a rotating electrical machine is formed by braiding a plurality of coil wires having a plurality of turn portions, and is installed and wound in a plurality of slots provided in a stator core.
Patent Document 1 discloses a method for manufacturing such a coil assembly of a rotating electrical machine, in which a first coil wire and a second coil wire are arranged at predetermined positions, and the first coil wire is provided. And at least one of the second coil wire rod is moved in a direction perpendicular to the longitudinal direction of the first coil wire rod and the second coil wire rod, and the turn portion of the first coil wire rod and the second coil wire rod are An engagement step of engaging the turn portions of the two-coil wire rod, and the arranging step includes the step of placing the second coil wire rod between the two turn portions adjacent in the longitudinal direction of the first coil wire rod. A method of manufacturing a coil assembly for a rotating electrical machine is disclosed, wherein the first coil wire and the second coil wire are shifted in the longitudinal direction so that the center of the turn portion is located.
In the coil assembly manufacturing method disclosed in Patent Document 1, the first coil wire and the second coil wire are engaged with each other from the longitudinal center of the two coil wires toward both sides. By arranging the coil wire and the second coil wire, it is possible to prevent the turn portions of the first coil wire and the second coil wire from interfering with each other, and to prevent deformation of each coil wire. Can be included.

However, in the manufacturing method of Patent Document 1, when a plurality of coil wires are knitted, a wire bundle in which the first coil wire and the second coil wire are knitted is regarded as one coil wire, and the first coil wire is obtained. When the third coil wire is knitted in accordance with the same procedure as the procedure for knitting the second coil wire and the number of coils is sequentially increased, the knitting operation is repeated, and the rigidity of the coil wire bundle gradually increases as the number of knitted wires increases. Since the difference in rigidity between the coil wire rod and the one coil wire rod knitted into the coil wire increases, a coil wire bundle in which a plurality of coil wire rods are knitted and one coil wire rod knitted into the coil wire rod during the knitting operation Are twisted evenly, making it difficult to get entangled, and applying excessive force exceeding the yield value to the coil wire on the braided side with relatively low rigidity causes plasticity. There was a risk of sexual deformation.
Furthermore, in the manufacturing method of Patent Document 1, it is necessary to switch the apparatus every time the number of coil wires increases, which may cause an increase in equipment costs.

  Therefore, in view of such circumstances, the present invention reduces the number of processes by knitting three long coil wires at the same time, improves work efficiency, and makes it difficult for deformation of the coil wire to occur. An object is to provide a manufacturing method.

  According to the first aspect of the present invention, a plurality of turn portions that are used for a stator of a rotating electric machine and are periodically turned back and forth alternately with a predetermined amplitude and a predetermined turning pitch with respect to the axial direction are formed to have a substantially waveform. A method of manufacturing a coil assembly in which a plurality of coil wires are knitted together, a coil wire arranging step of arranging and arranging three coil wires by shifting a predetermined distance in the longitudinal direction, and the three Among the coil wires, a predetermined position of the first coil wire is set as a starting point, the second coil wire and the third coil wire are moved upward in the amplitude direction, and the upper turn portion of the first coil wire The lower turn portion of the second coil wire rod and the lower turn portion of the third coil wire rod are pulled up to the position, and first, the lower turn portion of the second coil wire rod adjacent to the weaving start point After jumping over the upper turn portion of the first coil wire, the second coil wire is moved downward in the amplitude direction, and then the third coil wire adjacent to the weaving start point The lower turn portion is jumped over the upper turn portion of the first coil wire and the upper turn portion of the second coil wire, and then the third coil wire is lowered in the amplitude direction. And moving the first coil wire and the second coil wire toward the upper side in the amplitude direction to move the upper side of the third coil wire. The lower turn part of the first coil wire and the lower turn part of the first coil wire are pulled up to the position of the turn part and adjacent to the part knitted by the first knitting process After the lower turn portion of the second coil wire not knitted is jumped over the upper turn portion of the third coil wire, the second coil wire is moved downward in the amplitude direction. Next, the lower turn portion of the first coil wire that is adjacent to the portion knitted by the first braiding step and is not knitted is connected to the upper turn portion of the second coil wire, and the first turn portion. And a second weaving step of forming a braided portion by moving the first coil wire toward the lower side in the amplitude direction after jumping over the upper turn portion of the three coil wire rods. The coil wire is made by repeating the first knitting step and the second knitting step using a predetermined position of the first coil wire not knitted as a new knitting start point. A coil assembly (three bundles) forming step for forming three bundles is provided.

  According to a second aspect of the present invention, the coil assembly is configured so that the knitting starting point is the center of the upper turn portion positioned substantially at the center of the first coil wire, and is symmetrical to both sides in the longitudinal direction of the coil wire. (3 bundles) The formation process proceeds.

  According to a third aspect of the present invention, the predetermined distance is set to a quarter of the turn-back pitch of the coil wire rod, and a crank is formed in the radial direction of the stator at a substantially central portion of the upper turn portion and the lower turn portion of the coil wire rod. A bent portion that is bent in a shape is provided, and a slot accommodating portion of another coil wire adjacent to the bent portion of the coil wire is brought into contact with the coil wire to be used as a guide for relative movement of the coil wire.

  In the invention of claim 4, the three coil wire rods obtained by the coil assembly (three bundle) forming step are regarded as one set of coil assemblies, and two sets of coil assemblies are knitted to form the coil wire 6 A coil assembly (6 bundles) forming step for forming a bundle of coil assemblies is provided.

According to the present invention, three coil wires can be knitted simultaneously, so that the working efficiency can be remarkably increased as compared with the conventional method of knitting one by one, and the number of necessary production lines can also be reduced. Therefore, it becomes possible to greatly reduce the manufacturing cost.
Moreover, it is possible to easily jump over the upper turn portion by pulling up the coil wire material to be knitted upward and slightly bending the lower turn portion at a predetermined position. There is no invitation.
In addition, when forming a bundle of six coil wires, two bundles of coil wires having equal rigidity are knitted, so that it is relatively rigid with a coil wire bundle having increased rigidity as in the prior art. By knitting one coil wire having a low thickness, stress concentration is not caused and deformation does not occur.

The perspective view which shows the outline | summary of the stator for rotary electric machines to which the coil assembly manufactured by the manufacturing method of this invention is applied. 1B is a side view of FIG. 1A. FIG. The principal part enlarged plan view which shows the coil end of FIG. 1A. The perspective view of the coil assembly manufactured by the manufacturing method of this invention. Sectional drawing of a coil wire. The perspective view of a coil wire. The front view which shows the whole coil wire shape. The figure for demonstrating the manufacturing method of the coil assembly in embodiment of this invention later on in order of a process, and the top view which shows the arrangement | positioning method of three coil wires. FIG. 4A is a longitudinal cross-sectional view of FIG. 4A. The perspective view which shows a part of braiding process of the coil wire which concerns on the manufacturing method of the coil assembly in embodiment of this invention. The top view which shows the principal part of the manufacturing method of the coil assembly in embodiment of this invention later on in order of the process of (A)-(G). The top view which shows the process of completing a coil assembly (3 bundles) in order of (A)-(E) according to the manufacturing method of the coil assembly of this invention. The top view which shows the process until it completes the bundle of six coil wire rods following FIG. 6 in order of (A)-(D). The flowchart which shows the manufacturing line of the coil assembly of this invention shown as Example 1 The flowchart which shows the manufacturing line of the conventional coil assembly shown as the comparative example 1 The flowchart which shows the manufacturing line of the other conventional coil assembly shown as the comparative example 2

The method for manufacturing a coil assembly according to the present invention is used for manufacturing a coil assembly 2 incorporated in a stator 1 of a rotating electrical machine as shown in FIG. 1A.
First, an outline of the stator 1 to which the manufacturing method of the present invention is applied will be described.
For convenience, in the following description, the traveling direction of the arrow is the upper side and the reverse direction is the lower side with respect to the axial direction of the stator 1 indicated by the arrow in FIG. 1A.

The stator 1 rotatably accommodates a rotor (not shown) on the inner side to constitute a rotating electrical machine.
As shown in FIG. 1A, the stator 1 is formed by forming a coil assembly 2 by bundling a predetermined number of coil wires 20 after forming a coil wire 20 in a substantially waveform in advance, and then forming a stator core 10. This is a so-called distributed winding structure housed in the slot 11.
As the stator core 10, a laminated core formed by laminating magnetic steel plates having a predetermined thickness in the axial direction and formed in a substantially annular shape, a dust core formed by compressing magnetic powder, or the like is used.
A plurality of groove-like slots 11 and teeth 12 are formed in the circumferential direction of the stator core 10, and the slot accommodating portion 21 of the coil assembly 2 is accommodated.
The stator core 10 may be a so-called split core obtained by splitting a plurality of teeth 12 into pieces, and the split core may be inserted into the coil assembly 2 formed in a substantially annular shape, or in a substantially band shape. After attaching the coiled wire 20 bundled in a strip shape to the formed core, it may be plastically deformed in a substantially annular shape.

  The rotating magnetic field generated by the stator by the distributed winding is close to a sine wave and has excellent rotational speed characteristics and output performance. On the other hand, as shown in FIG. 1B, the coil ends 22U are formed from both sides of the end face 13 of the stator core 10. Therefore, it is desired to reduce the copper loss by reducing the amount of coil wire used by reducing the height H of the coil ends 22U and 22D that do not contribute to the formation of the magnetic field as much as possible. Yes.

The coil assembly 2 as a stator winding is a three-phase winding in which a coil wire 20 is connected in series to form a stator winding, and U, V, and W phases are Y-connected. Stator windings of each phase are arranged with one set of coil wires 20 accommodated in two slots 11 adjacent in the direction, and stator windings of different phases are arranged in three sets of slots 11 adjacent in the circumferential direction. Lines are arranged.
In this embodiment, as shown in FIG. 1C, six coil wire rods 20A, 20B, 20C, 20D, 20E, and 20F are knitted into a bundle, and a pair of coils adjacent in the circumferential direction. Wires 20A and 20B form a U phase, coil wires 20C and 20D form a V phase, and coil wires 20E and 20F form a W phase.
In addition, in order to clarify the positional relationship in which each coil wire is arranged, for convenience, the first coil wire 20A, the second coil wire 20B that forms the U phase, and the third coil wire that forms the V phase. About 20C, 4th coil wire 20D, 5th coil wire 20E which forms W phase, and 6th coil wire 20F, the code | symbol of A to F is attached | subjected, but any coil wire 20A-20F is distinguished. There is no difference in materials, shapes, etc.

In the manufacturing method of the coil assembly 2 of the present invention to be described later, among the six coil wire rods 20A, 20B, 20C, 20D, 20E, and 20F, three coil wire rods 20A, 20B, 20C, and 20D in advance. 20E, and the knitting together by three to 20F, after the three beams coil wire _{20 ABC, 20 DEF,} 1 pieces of coil wire by weaving three bundles two coil wire _{20 ABC, 20 DEF} 6 By using the main bundle 20 _ABCDEF , it is possible to reduce the number of work steps, and it is difficult for local coil ends 22U and 22D to bulge or bend due to plastic deformation of the coil wire 20 during the braiding process, The coil ends 22U and 22D can be knitted more densely.
Further, 2 to 8 coil wire 6 bundles 20 _ABCDEEF are combined to finally form a strip-like 12 to 48 coil wire bundles, which are rounded into a substantially annular shape as shown in FIG. A coil assembly 2 is formed.

As shown in FIG. 3A, the coil wire 20 is composed of a copper conductor 200 having a substantially rectangular cross section, and an insulating coating composed of an inner layer 201 and an outer layer 202 covering the outer peripheral surface and insulating the conductor 200. Has been.
The outer layer 202 covers the outer peripheral surface of the inner layer 201. The thickness of the insulating coating including the inner layer 201 and the outer layer 202 is set between 100 to 200 μm, and insulation between the coil wire materials 20 is sufficiently secured, so insulating paper or the like is sandwiched between the coil wire materials 20. Thus, it is not necessary to insulate the coil wire rods 20 from each other.
The outer layer 202 is formed of an insulating material such as nylon, epoxy resin, or polyferylene sulfide, and the inner layer 201 is formed of an insulating material such as a thermoplastic resin having a glass transition temperature higher than that of the outer layer 202 or polyamideimide.

As shown in FIG. 3 (B), the coil wire 20 is exposed in the vertical direction from the slot accommodating portion 21 that is linearly parallel to the axial direction and accommodated in the slot 11 and the end face 13 of the stator core 10. Thus, the upper turn portion 22U and the lower turn portion 22D that form the coil end are alternately and repeatedly formed in a substantially wave shape that is bent periodically.
Further, step portions 23 that are bent stepwise are formed on the upper turn portion 22U and the lower turn portion 22D so as to have a surface substantially parallel to the end surface 13 of the stator core 10 and a surface substantially orthogonal thereto. In the substantially central portion of the step portion 23 that becomes the peak of the upper turn portion 22U and the substantially central portion of the step portion 23 that becomes the valley of the lower turn portion 22D, respectively, without being twisted, in the radial direction. A crank portion 24 that is substantially parallel to the stator core end face 13 and bends in a crank shape by the substantially width of the coil wire rod 20, and the step portion 23 does not interfere when the adjacent coil wire rods 20 are overlapped with each other. It is possible to turn.

In the present embodiment, the crank portion 24 is formed to bend alternately in the center direction and the outer diameter direction.
In this embodiment, in order for the slot accommodating part 21 accommodated in a pair of adjacent slots 11 to form one phase and to constitute a three-phase stator winding, adjacent in the circumferential direction. A set of six slots 11 faces one pole of the rotor.
For this reason, the coil accommodating part 21 is accommodated across the slot 11 which differs every six pieces with respect to the circumferential direction, and the step part formed in each turn part 22U and 22D in order to avoid interference between coil wire rods 20 23 are provided in seven stages of (3 × 2 + 1).

As shown in FIG. 3C, the entire length of the coil wire 20 is approximately 3 m.
Further, in the stator core 10, the distance between the adjacent slots 11 becomes longer toward the outer diameter side. Accordingly, the turn-back pitches P1, P2,. It is formed so as to gradually increase from the side to become the end of winding of the coil.
In addition, at both ends of the coil wire 20, lead portions 25 are formed for connection to output lines or neutral points.

With reference to FIG. 4A-FIG. 7, the manufacturing method of the coil assembly for rotary electric machines in embodiment of this invention is demonstrated.
First, as described above, it is used for a stator 1 of a rotating electrical machine, and is periodically folded with a predetermined amplitude and a predetermined folding pitch (P ₁ , P ₂ ,... P _n ) alternately up and down with respect to the axial direction. A plurality of coil wire rods 20A, 20B, 20C, 20D, 20E, and 20F, each provided with a plurality of turn portions 22U and 22D and having a substantially waveform, are prepared.

In the coil wire arranging step, the three coil wires 20A, 20B, and 20C are shifted by a predetermined distance in the longitudinal direction, and are arranged so as to overlap as shown in FIGS. 4A and 4B.
In this case, specifically, it is desirable to dispose the coil wire by shifting it by a quarter of the folding pitch (P ₁ , P ₂ ,... P _n ).
In the following description, the coil wires arranged in such a stack are referred to as a first coil wire 20A, a second coil wire 20B, and a third coil wire 20C in order from the bottom for convenience.
By arranging in this way, in the coil assembly forming process in which a plurality of coil wire rods 20A, 20B, and 20C are knitted to form a coil assembly solid, the coil wire rods 20A, 20B, and 20C are arranged vertically in the axial direction. When moving, as shown in FIG. 4C, the first coil wire 20A is provided at, for example, a substantially central portion of the turn portion 22U, and is adjacent to a bent portion 24 that is bent in a crank shape in the radial direction of the stator 1. The second coil wire 20B can be used as a guide when the second coil wire 20B is relatively moved by abutting the slot accommodating portions 21 of the second coil wire 20B.

Further, this relationship is the same not only between the first coil wire 20A and the second coil wire 20B but also between the second coil wire 20B and the third coil wire 20C, and the coil wire 20A. , 20B and 20C can be guided to each other when moving up and down.
Furthermore, FIG. 4B shows a form in which the bending directions of the crank portions 24A, 24B, and 24C provided in the coil wire rods 20A, 20B, and 20C are alternately bent in the inner diameter direction and the outer diameter direction. In the present invention, the bending direction of the crank portion 24 is not particularly limited, and the inner diameter direction or the outer diameter direction is determined according to the known configuration according to the switching of each phase formed by the stator winding. It can be selected as appropriate.

In the manufacture of the coil assembly 2 according to the present embodiment, as shown in FIG. 5A, the first coil wire 20A, the second coil wire 20B, and the third coil are arranged so as to be shifted by a predetermined interval. The wire assemblies 20C are stacked, and a coil assembly (3 bundles) is formed so as to be symmetrical with respect to both longitudinal sides of the coil wires 20A, 20B, and 20C, with the approximate center position of the first coil wire 20A being knitted as a starting point. Advance the process.
Next, as shown in FIG. 5 (B), and the second coil wire 20B and the third coil wire 20C is moved toward the amplitude direction upper side, to the position of the upper turn portions 22U _A of the first coil wire 20A , by pulling up the lower turn portions 22D _C of the lower turn portions 22D _B and the third coil wire 20C of the second coil wire 20B, first, located in a part surrounded in this view Nakamaru, adjacent to the weaving start point the lower turn portions 22D _B of the second coil wire 20B which, as shown in the figure by arrows, causing jumping so as to straddle the upper turn portions 22U _a first of the coil wire 20A.

Next, as shown in FIG. 5C, the second coil wire 20B is moved downward in the amplitude direction, and is superposed on the first coil wire 20A.
Further, located in a part surrounded in this view Nakamaru, the lower turn portions 22D _C of the third coil wire 20C adjacent braiding origin, as shown in the arrows, the upper side of the first coil wire 20 the turn portion 22U _a, causing jumping to straddle the top turn of the second coil wire 20 22U _B.
Thereafter, as shown in FIG. 5 (D), the third coil wire 20C is moved downward in the amplitude direction and overlapped with the first coil wire 20A and the second coil wire 20C.
In the first weaving step, a part of the first coil wire 20A, the second coil wire 20B, and the third coil wire 20C, which are simply overlapped, is obtained through the steps of FIGS. A braided portion knitted into a braid can be formed.

Then, as shown in FIG. 5 (E), a first coil wire 20A and the second coil wire 20B is moved toward the amplitude direction upper side, a position of the upper turn portions 22U _C of the third coil wire 20C until the lower turn portions 22D a first coil wire _20A, and, by raising the lower turn portions 22D _B of the second coil wire 20B, adjacent to the woven portion by the first braiding step, The lower turn portion 22DB of the second coil wire rod 20B that is not knitted located in the circled portion in the figure, and the upper turn portion 20UC of the third coil wire rod 20C as shown by the arrow in the drawing. Jump over as if straddling.
Thereafter, as shown in FIG. 5 (F), the second coil wire 20A is moved downward in the amplitude direction and overlapped with the third coil wire 20C.
Next, as shown in FIG. 5 (F), the lower side of the first coil wire 20A that is not knitted adjacent to the portion knitted by the first knitting process and is located in the portion surrounded by a circle in the figure. the turn portion 20D _a, as shown in the arrows, monkey jumping to straddle the upper turn portions 22U _B of the second coil wire 20B, an upper turn portion 22U _C of the third coil wire 20C.
After that, as shown in FIG. 5G, the first coil wire 20A is moved downward in the amplitude direction, and overlapped with the second coil wire 20B and the third coil wire 20C.
In the second knitting step, the knitting portion is formed through the steps of FIGS.
Further, a predetermined position of the first coil wire 20A that has not been knitted is set as a new knitting start point, and the first knitting process of FIGS. 5 (B) to (D) and FIGS. 5 (E) to (F). By repeating the second weaving step, the bundle of three coil wires 20 _ABC can be formed.

6 (A) to 6 (E) show a process of finishing the weaving to the ends of the three coil wires 20A, B, and C through the same process, and the first weaving similar to the above. The process and the second knitting process are repeated.
In this way, the three coil wire rods 20A, 20B, and 20C can be knitted simultaneously through the coil assembly (three-bundle) forming step.
In this way, the one in which the three coil wires 20A, B, and C are knitted is shifted by a quarter pitch, so that this is shown in FIG. 7B, a coil assembly (three bundles) 20 _{ABC in} which the same weaving pattern is periodically repeated and adjacent coil wires are bundled without interfering with each other is obtained. It is done.

Similarly, as shown in FIG. 7C, two sets of coil assemblies (three bundles) 20 _ABC and a coil assembly (three bundles) 20 _DEF are prepared.
In the coil assembly (six bundles) forming step, two coil assemblies (three bundles) 20 _ABC and 20 _DEF prepared in advance are knitted so that six coil wires as shown in FIG. A bundle 20 _ABCDEF can be formed.
As a method for weaving the two sets of coil assemblies (three bundles) 20 _ABC and 20 _DEF , a conventional method of weaving one set at a time as disclosed in Patent Document 1 can be appropriately employed.

The six coil wires 20A, 20B, 20C, 20D, 20E, and 20F form a pair of phases, and the coil assembly (six bundles) 20 _ABCDEF is wound in an annular shape while being wound in the stator core 10 The stator 1 is completed by mounting and providing terminals and the like for connection to the outside.
In addition, by preparing a plurality of coil assemblies (bundles 6) _ABCDEF and connecting them in series, the number of coil wires 20 mounted in the stator core 10 can be increased up to 48.
In the above-described embodiment, the coil assembly (three bundles) 20 _ABC is distributed symmetrically from the center C / L of the coil wire rod 20 and is knitted to perform the braiding operation, thereby speeding up the operation and reducing the size of the apparatus. As described above, in the state where the predetermined two of the three are pulled up, the three parts are pulled down to the forward dimension position while jumping over the turn portion at the predetermined position. The coil wire may be knitted in order from one end of the coil wire 20 as long as it is not contrary to the spirit of the present invention in which the coil wire is knitted simultaneously.

The effect of the present invention will be described with reference to FIGS. 8A, 8B, and 8C.
In the coil assembly forming process in the embodiment of the present invention, as shown in FIG. 8A, in the production line 1, three coil wire rods 20 are knitted simultaneously to produce coil assemblies (three bundles) 20 _ABC and 20 _DEF. In the production line 2, the coil assembly (three bundles) 20 _ABC and the coil assembly (three bundles) 20 _DEF can be knitted to create the coil assembly (six bundles) 20 _ABCDEF . A production line with excellent productivity can be configured.
On the other hand, in the conventional production line shown as the comparative example 1 in FIG. 8B, since the coil wire material is knitted one by one, different production lines 1 to 5 are necessary for each.
Further, as shown in FIG. 8C as Comparative Example 2, even in the conventional method, the coil assemblies (3 bundles) 20 _ABC and 20 _DEF are regarded as a set of assemblies (3 bundles). Although the number of manufacturing steps can be reduced, even in this case, since at least three manufacturing lines are required, it can be seen that the manufacturing method of the present invention is extremely efficient.

DESCRIPTION OF SYMBOLS 1 Stator 10 Stator core 11 Slot 12 Teeth 13 Core end surface 2 Coil assembly 20 Coil wire 20A, 20D 1st coil wire 20B, 20E 2nd coil wire 20C, 20F 3rd coil wire 20 _ABC , 20 _DEF Coil assembly (3 bundles)
20 _ABCDEF coil assembly (6 bundles)
200 conductor 201 in the insulator layer 202 outer insulating layer 21, 21A, 21B, 21C slot-accommodated portions 22 turn part 22U upper turn portions _{22U A,} 22U B, 22U _C first, second, top turn of the third coil wire 22D Lower turn portion 22D _A , 22D _B , 22D _C Upper turn portion 23 of first, second and third coil wires 23 Step portion 24 Bending portion

JP2012-110105A

Claims (4)

Used for a stator of a rotating electrical machine, a plurality of coil wire rods formed in a substantially waveform are braided together by providing a plurality of turn portions that are periodically folded back and forth alternately with a predetermined amplitude and a predetermined folding pitch with respect to the axial direction. A method for manufacturing a coil assembly,
A coil wire arrangement step in which three coil wires are arranged by being shifted by a predetermined distance in the longitudinal direction;
Among the three coil wires, a predetermined position of the first coil wire is used as a starting point, the second coil wire and the third coil wire are moved upward in the amplitude direction, and the first coil wire is moved. Of the second coil wire adjacent to the weaving origin in a state where the lower turn portion of the second coil wire and the lower turn portion of the third coil wire are pulled up to the position of the upper turn portion of the second coil wire. Jump over the lower turn portion so as to straddle the upper turn portion of the first coil wire, and then move the second coil wire downward in the amplitude direction,
Next, the lower turn portion of the third coil wire adjacent to the knitting start point is jumped over the upper turn portion of the first coil wire and the upper turn portion of the second coil wire,
Thereafter, a first weaving step of forming a braided portion by moving the third coil wire toward the lower side in the amplitude direction,
The first coil wire and the second coil wire are moved upward in the amplitude direction, and the lower turn portion of the first coil wire is moved to the position of the upper turn portion of the third coil wire, and In a state where the lower turn portion of the first coil wire is pulled up, the lower turn portion of the second coil wire not adjacent to the portion knitted by the first knitting step and not knitted is disposed on the first turn. 3. Jump over the upper turn part of the coil wire of 3 above,
Thereafter, the second coil wire is moved downward in the amplitude direction,
Next, the lower turn portion of the first coil wire which is adjacent to the portion knitted by the first knitting step and is not knitted is used as the upper turn portion of the second coil wire and the third coil. Jump over the upper turn part of the wire,
Thereafter, a second weaving step of forming a braided portion by moving the first coil wire toward the lower side in the amplitude direction,
A coil assembly that forms a bundle of three coil wires by repeating the first braiding step and the second braiding step using a predetermined position of the first coil wire not braided as a new starting point. (3 bundles) The manufacturing method of the coil assembly characterized by comprising a formation process.   The coil assembly (three bundles) forming step is performed so that the knitting starting point is the center of the upper turn portion located substantially at the center of the first coil wire, and the left and right sides of the coil wire are symmetrical. The manufacturing method of the coil assembly of Claim 1 to advance.   The predetermined distance is set to a quarter of the folding pitch of the coil wire, and a bent portion that is bent in a crank shape in the radial direction of the stator is provided at a substantially central portion of the upper turn portion and the lower turn portion of the coil wire. The coil assembly according to claim 1 or 2, wherein the coil assembly is used as a guide when the coil wire rod is relatively moved by contacting a slot accommodating portion of another coil wire rod adjacent to the bent portion of the coil wire rod. Solid manufacturing method.   The three coil wire bundles obtained by the above coil assembly (three bundle) forming process are regarded as one set of coil assemblies, and two sets of coil assemblies are knitted to form a coil assembly of six coil wire bundles. The manufacturing method of the coil assembly in any one of Claim 1 thru | or 3 which comprises the coil assembly (6 bundles) formation process to form.

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