JP2015204647A - Manufacturing method of stator, and coil insertion device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a stator by which a coil end part is small-sized and a coil density within a stator core slot is prevented from being reduced, and a coil insertion device.SOLUTION: A coil insertion device includes rod-like blades 81 as many as teeth 12 of a stator core 1 to which coil bundles 2a-2d are mounted, the blades 81 having a width equal to a circumferential width of inner peripheral side distal ends of the teeth 12 and being disposed annularly in such a manner that the inner circumferential distal ends of the teeth 12 are opposite to the outer peripheral surfaces thereof; blade drive mechanisms 87a and 87b for independently moving the blades 81 in a length direction of the blades 81; a stripper 86 which is disposed along inner side faces of the plurality of blades 81 for moving an inner peripheral side of the stator core 1 axially relatively while being interlocked with all the blades 81 or independently; and sub blades 83a and 83b which are mounted in distal ends of two blades 81 and for which a width of a distal end in a circumferential direction is narrower than the width of the blade 81 and a width of a proximal part at a side to be mounted to the blade 81 in the circumferential direction is equal to the width of the blade 81.

Description

  The present invention relates to a stator manufacturing method and a coil insertion device for inserting a coil wound in advance on a stator core of a rotating electric machine.

  In a stator of a rotating electrical machine having an exciting coil, the coil is generally housed in a slot of a stator core. When winding across multiple magnetic poles (actually, winding around a large length with a margin in another location, and then inserting this into the slot), at the axial end of the stator core The surplus coils are stacked in a high shape and have a useless space.

  The remaining coil portion of the coil end portion does not contribute to the formation of the magnetic field (does not contribute to improvement in performance), and if the stator core has the same size, it is desirable to reduce the volume of this portion. Further, it is required to improve the performance of the rotating electrical machine by increasing the volume of the coil relative to the volume in the slot of the stator core.

  As a conventional method for manufacturing a stator, a plurality of coils having the same peripheral length wound beforehand using a winding frame are mounted between blades of a coil insertion device, and the coil mounted between the blades is stripped. There is known a method of forming a stator by pushing it up and inserting it into a slot of a stator core.

  As one method for reducing the coil end portion of the stator of the rotating electrical machine and shortening the circumferential length of the coil, a step portion is provided on the winding frame of the winding machine when winding the coil, There has been proposed a method of inserting a coil having a circumferential length difference by changing the length stepwise into a stator core. This is because when the ideal path is considered in the coil that forms the coil end portion of the stator, the perimeter differs between the coil that crosses the outer periphery and the coil that crosses the inner periphery. This is because if the outer circumference and the inner circumference have the same length, the coil is left somewhere and an unnecessary space is created (for example, Patent Document 1).

Japanese Patent No. 4345423

  By the way, the blades of the coil insertion device for inserting the coils into the slots between the teeth of the stator core are arranged in accordance with the teeth shape of the stator core, and the interval between adjacent blades is generally a coil. There is only one to several. For this reason, the coil width of the portion accommodated between the blades is substantially the same regardless of whether the coil has a difference in peripheral length or a coil in which the peripheral length of each layer is constant. That is, the portion to be inserted between the blades has the same shape formed by the winding frame from the winding start to the winding end. Actually, in FIG. 9 of Patent Document 1, a step is not shown in the winding frame 111F that is on the blade side, and the magnet wires of the coil are stacked as they are. As a result, when the coil is inserted into the stator core, the coils sequentially inserted into the slot portions of the stator core are pushed out to the opposite end of the stator core in the same shape as the first.

  As shown in FIG. 9 of Patent Document 1, if the coil is such that magnet wires are stacked one by one, it is possible to appropriately form the ends of the coils having different circumferential lengths. When the number of coils stacked increases and the thickness of the coil inserted into the slot (magnet wire stacking direction width) increases, there is a problem that the coils cannot be passed through the gap between the blades at once.

  The present invention has been made in order to solve such a problem. A coil composed of many layers having different circumferential lengths can be inserted into the slot portion at a time, the coil end portion can be reduced in size, and the circumferential length of the coil can be reduced. An object of the present invention is to provide a stator manufacturing method and a coil insertion device that are shortened as a whole and that do not reduce the coil density in the slots of the stator core.

A coil insertion device according to the present invention includes:
It has the same width in the circumferential direction as the inner peripheral side tip of the stator core teeth to which the coil bundle is mounted, and the inner peripheral side tip of each of the stator cores can be opposed to the respective outer peripheral surface. A rod-shaped blade of the same number as the number of teeth arranged in a ring;
A blade drive mechanism for moving each blade in the longitudinal direction of the blade independently or in units of groups;
A cylindrical member disposed along the inner surface of the plurality of blades, the stripper moving relative to the inner peripheral side of the stator core in the axial direction in conjunction with or independently of all the blades. When,
The circumferential width of the tip attached to the tips of the two blades is narrower than the circumferential width of the blade, and the circumferential width of the base on the side to be attached to the blade is the circumference of the blade. A sub-blade that is the same as the width of the direction;
A sub blade attaching / detaching mechanism for attaching / detaching the sub blade to / from the blade.

The method of manufacturing the stator according to the present invention includes:
In a stator manufacturing method in which a coil bundle is mounted in a slot formed between adjacent teeth of a stator core having a ring-shaped yoke and a plurality of teeth projecting radially inward from the yoke,
A coil manufacturing process for manufacturing the coil bundle by winding a magnet wire;
The stator core has the same width as the circumferential width of the inner peripheral tip of the teeth, and the same number of rod-shaped blades as the number of teeth are annular, and the inner peripheral tip of the stator core teeth The outer peripheral surfaces of a plurality of the blades are arranged to face each other,
The blade is independently movable in the longitudinal direction of the blade;
A coil that is disposed along the inner surface of the plurality of blades, and includes a stripper that moves relative to the inner peripheral side of the stator core in the axial direction independently or in conjunction with all the blades. A sub-blade mounting step of lowering the two blades of the insertion device and mounting a sub-blade having a width narrower than the circumferential width of the blade at the tips of the two blades;
Between the blades adjacent to each of the sub-blades, the blades that are hooked through two inter-blade insertion portions of the coil bundle and guided by the blades adjacent to the sub-blades are attached to the blades. An inter-blade coil bundle insertion step of inserting the coil bundle between the matching blades;
After the inter-blade coil bundle insertion step, the coil is pulled by the stripper while being hooked on the blade in the axial direction from the axial end of the stator core toward the inner peripheral side of the stator core. A coil shaping step of pushing the bundle into the slot and forming coil end portions on both end faces of the stator core.

  According to the method for manufacturing a stator and the coil insertion device according to the present invention, it is possible to suppress unnecessary space generated in the coil end portion of the stator, and it is possible to shorten the circumferential length of the coil. Thereby, the performance improvement and size reduction of the rotary electric machine using a stator can be achieved.

It is a top view of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is sectional drawing in the AA of the stator of FIG. It is sectional drawing which divided the stator of FIG. 1 into 2 perpendicular | vertical to the axial direction. FIG. 4 is an enlarged view of a main part of the stator shown in FIG. 3. It is a perspective view of the coil before mounting | wearing with the stator core which concerns on Embodiment 1 of this invention. FIG. 6 is a partial cross-sectional perspective view and a main part enlarged schematic view of the coil of FIG. 5. It is a perspective view which shows the state of the winding start of the coil winding machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the state which removes the coil which concerns on Embodiment 1 of this invention from a winding frame. It is a perspective view which shows the state before mounting | wearing with the coil insertion apparatus which concerns on Embodiment 1 of this invention, and inserting in a stator core. FIG. 10 is a cross-sectional view in which the peripheral portion at the tip of the sub-blade in FIG. 9 is cut vertically along the line DD. It is a cross-sectional schematic diagram of the coil which concerns on Embodiment 1 of this invention. It is a perspective view which shows the state with which the coil which concerns on Embodiment 1 of this invention was mounted | worn with the braid | blade. It is a perspective view of the coil insertion apparatus in a preparation stage. It is a perspective view of the coil insertion apparatus which mounted | wore with the subblade. It is a perspective view of a coil insertion device in a state where a coil is hooked on a blade. It is a perspective view which shows the state by which the coil was pinched | interposed between the blades of a coil insertion apparatus. It is a perspective view of the coil insertion device which retracts the sub blade and prepares for insertion of the coil. It is sectional drawing which shows the state which inserts a coil in a stator core using a coil insertion apparatus. It is a perspective view which shows the state of the winding start of the coil winding machine which concerns on Embodiment 2 of this invention. It is a perspective view which shows the state which removes the coil which concerns on Embodiment 2 of this invention from a winding frame.

Embodiment 1 FIG.
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
In this specification, the terms “circumferential direction”, “radial direction”, and “axial direction” refer to the “circumferential direction”, “radial direction”, and “axial direction” of the stator unless otherwise specified.
FIG. 1 is a plan view of a stator 100 for a rotating electrical machine according to Embodiment 1 of the present invention.
2 is a cross-sectional view taken along line AA of the stator of FIG.
FIG. 3 is a cross-sectional view in which the stator 100 is divided into two perpendicular to the axial direction.
4 is an enlarged view of a main part of the stator 100 shown in FIG.
As shown in FIGS. 1 to 4, the stator 100 includes a stator core 1 having an annular yoke 10 and a plurality of teeth 12 projecting radially inward from the yoke 10, and four types of coils 2 a to 2 d. Consists of. The outer coil 2a and the inner coil 2c are large coils, and are housed in the coil housing slots 11 straddling the five teeth 12, respectively.

  Moreover, the outer coil 2b and the inner coil 2d are small coils, and are accommodated in the slots 11 straddling the three teeth 12, respectively. The slot accommodating portions 21a and 21c of the coil 2a and the coil 2c which are large coils are individually accommodated in the slot 11, and the slot accommodating portions 21b and 21d of the coil 2b and the coil 2d which are small coils are the same slot. 11 is stored separately on the outer peripheral side and the inner peripheral side. The arrangement of the coils shown here is merely an example, and other configurations may be used.

  The portion of the coil 2a in the portion of the two slot accommodating portions 21 that extends in the axial direction from the axial end portion of the stator core 1 and is connected to each other is a coil end portion 24a. Similarly, the portions of the coils 2b, 2c, and 2d in the portions extending from the axial ends of the stator core 1 of the two slot housing portions 21b, 21c, and 21d are connected to the coil end portion 24b, 24c and 24d. In FIG. 1, the coil end part 24b is hidden under the coil end part 24a. Similarly, the coil end portion 24d is hidden under the coil end portion 24c.

  Between the slot 11 of the stator core 1 and the slot accommodating portions 21a to 21d of the coils 2a to 2d, a slot cell 31 and a wedge are provided as an insulating member 3 for maintaining insulation between the stator core 1 and the coils 2a to 2d. 32.

FIG. 5 is a perspective view showing the coil 2 b before being attached to the stator core 1.
Fig.6 (a) is the perspective view which cut | disconnected a part of coil 2b.
FIG. 6B is an enlarged view of the portion marked with a circle B in FIG. 6A, and the arrows indicate the winding order of the coils.

  Hereinafter, the coil 2b will be described as an example, but the same applies to the other coils 2a, 2c, and 2d, and the description thereof will be omitted as appropriate. The coil 2b is formed by winding a single magnet wire 6 in advance in the direction of the arrow as shown in FIG. 6B, and has a width corresponding to the depth of the slot 11 (refers to the width in the stator core radial direction). A plurality of layers are formed in the shape of a coil bundle. The coil 2b is formed in advance using a winding frame described later. In the coil formation stage before being inserted into the stator core 1, the magnet wire 6 has a bundle-like thickness t 1 that is larger than the interval S 1 between the tips of adjacent teeth 12 of the stator core 1. Coil 2b. Specifically, the winding start line of the coil 2b starts from the inner peripheral side, and after the coil array 23 having a predetermined number of turns is formed, the next coil array 23 is formed on the previous coil array 23. A plurality of coil layers 24 that are in close contact with each other are formed. The width t2 of the coil array 23 is equal to the radial depth S2 of the slot 11. And the slot accommodating part 21b of this coil 2b is a part accommodated in the slot 11 of the stator core 1. FIG.

FIG. 7 is a perspective view showing a winding start state of the coil winding machine 7 used for manufacturing the coil 2b (referring to a coil manufacturing process).
FIG. 8 is a perspective view showing a state in which the coil 2b after winding is removed from the winding frames 7a and 7b.
As shown in FIG. 7, the coil winding machine 7 winds a flyer 5 that can turn around a rotating shaft 52 and a magnet wire 6 that is supplied from a nozzle 51 provided in the flyer 5 (magnet wire winding). This refers to the winding frames 7a and 7b forming the coil 2b. The winding lengths of the winding frames 7a and 7b can be changed. When the coil 2b that has completed the winding of the magnet wire 6 is taken out, the interval between the winding frames 7a and 7b is set in the X direction in FIG. Equipped with a reel reduction function for close proximity.

  In addition, upper and lower lids 71a and 71b and lower lids 72a and 72b are provided on the upper and lower surfaces of the winding frames 7a and 7b. These are formed by winding the magnet wire 6 a plurality of times to form a coil array 23 having a width corresponding to the depth of the slot 11 (width in the radial direction), and superimposing this to form the coil layer 24. Winding guide.

  The lower lids 72a and 72b have a lower lid reduction function for reducing the width in the Y direction shown in FIG. 8 when the coil 2b is taken out. As shown in FIG. 8, the space between the two divided reels 7a and 7b is reduced by the reel reduction function, and the width of the lower lids 72a and 72b is reduced by the lower lid reduction function from the inner diameter of the coil 2b. The coil wound around the winding frames 7a and 7b from the coil winding machine 7 by reducing the width (outer diameter) of the coil (referring to a guide reduction process) and pushing it out from above the winding frames 7a and 7b with a pusher (not shown). 2b is separated.

FIG. 9 is a perspective view showing a state before the coil 2 b is mounted on the coil insertion device 8 and inserted into the stator core 1.
The coil insertion device 8 is an instrument used for inserting the coils 2 a to 2 d into the slot 11 of the stator core 1. The coil insertion device 8 includes a plurality of rod-shaped blades 81 for hooking and attaching bundle-like coils 2a to 2d before being attached to the stator core 1, and a wedge 32 simultaneously with insertion of the coils 2a to 2d into the slots 11. Wedge pusher (not visible in FIG. 9), a wedge guide 85 for guiding the wedge pusher from the outer peripheral side, and a vertical movement along the inner side of the blade 81, and the coils 2a to 2d. A cylindrical stripper (not visible in FIG. 9) for inserting 2d into the slot 11 of the stator core 1 while being pushed up is provided.

Further, as auxiliary equipment for mounting the bundled coils 2a to 2d between the blades 81 of the coil insertion device 8, two sub blades 83a and 83b are used for one of the coils 2a to 2d.
In the sub blades 83 a and 83 b, the lateral width (width in the circumferential direction) of the base portion on the side attached to the blade 81 is substantially equal to the lateral width of the blade 81.

  FIG. 10 is a cross-sectional view in which the tip peripheral portion of the sub-blade 83a in FIG. 9 is cut vertically along the line DD. One surface (pointing to the surface in the circumferential direction) of the upper portion of the sub blade 83a has an inclined surface 83a1 that is greatly shaved. In addition, the inclined surface 83a1 is connected to a flat side surface 83a3 through a curved surface 83a2 having a smooth and axial cross section at a lower portion thereof and a quadratic curve. The same applies to the sub blade 83b. Thus, the lateral width (circumferential width) of the tips of the sub blades 83a and 83b is narrower than the lateral width of the base.

  FIG. 11A is a schematic cross-sectional view of the coil 2b. In order to simplify the description, the number of turns of one layer of the magnet wire 6 forming the coil 2b is set to 3, and the stack is also shown as 3 layers. As a matter of course, the circumference of the magnet wire 6 per circumference of the coil 2b gradually increases from the inside to the outside of the coil 2b.

FIG.11 (b) is a figure which shows the state with which the coil 2b shown to Fig.11 (a) was mounted | worn with the blade 81 in the state collapsed.
FIG. 12 is a perspective view showing a state where the coil 2 b is mounted on the blade 81. In FIG. 12, only the blade 81 and the coil 2b are shown, and other members are omitted.

  The inter-blade insertion portion 22b of the coil 2b shown in FIG. 5 is a portion inserted between adjacent blades 81 of the coil insertion device 8 as shown in FIG. When the coil 2b is placed between the blades 81 of the coil insertion device 8, the bundle of the coils 2b needs to be flattened so that the thickness in the stacking direction of the inter-blade insertion portion 22b is equal to or less than the interval between adjacent blades 81. is there. FIG. 12 shows a state in which the inter-blade insertion portion 22b of the coil 2b is extended (refers to a collapsed state).

Hereinafter, a specific method for attaching the coil 2b to the stator core 1 using the coil insertion device 8 will be described.
FIG. 13 is a perspective view of the coil insertion device 8 in a preparation stage. The number of blades 81 of the coil insertion device 8 is the same as the number of teeth 12 (number of slots 11) of the stator core 1 to which the coils 2a to 2d are to be mounted, and a plurality of blades 81 are arranged in a ring shape.

  In FIG. 13, the blade 81 is used in a state where it is lowered every other blade, but the height of each blade 81 in the preparation stage is appropriately set according to the size of the coils 2a to 2b to be mounted. Is done. In FIG. 13, blades 81a and 81b are blades 81a and 81b for hooking the coil 2b. The blades 81c and 81d are further moved downward from this state by a blade driving mechanism (not shown) (see FIG. 18B, reference numerals 87a and 87b), and the blade 81c is mounted so that the sub blade 83 is stacked on the tip. , 81d. The blade drive mechanism can move each blade 81 in the longitudinal direction individually or as a group unit.

  In FIG. 14, the blades 81c and 81d are further lowered from the state shown in FIG. It is a perspective view which shows the state mounted | worn (it points out a subblade mounting process). In the subsequent process, one of the blades 81c and 81d that sandwich the coil 2b is replaced with the sub blades 83a and 83b, and in addition to the gap between the original blades 81, the base blades 83a and 83b start from the base. As a result, the mounting space for the coil 2b can be expanded and secured by an amount corresponding to the amount of cutting that has become thinner.

  FIG. 15 is a perspective view showing a state where the coil 2b is hooked on the blades 81a and 81b. The two inter-blade insertion portions 22b of the coil 2b are sandwiched between the inclined surface 83a1 and the blade 81a of the sub blade 83a and between the inclined surface 83b1 and the blade 81b of the sub blade 83b, respectively.

FIG. 16 is a perspective view showing a state where the coil 2b is sandwiched between the blades 81a and 81c and between the blades 81b and 81d.
The two inter-blade insertion portions 22b of the coil 2b are guided from the state of FIG. 14 to the inclined surfaces 83a1 and 83a2, the curved surfaces 83a2 and 83b2 of the sub blades 83a and 83b, and the blades 81a and 81b. 16, it is sandwiched between the blades 81a and 81c and between the blades 81b and 81d (refers to the inter-blade coil bundle insertion step). At this time, the winding state of the coil 2b collapses to a shape that can pass through the interval between the blades 81 and spreads in the vertical direction in the figure, but there is no problem in mounting the coil 2b. This will be described later.

FIG. 17 is a perspective view showing a state where the sub-blades 83a and 83b are retracted and the blades 81c and 81d are raised again to the position shown in FIG.
As shown in FIG. 9, the stator core 1 is attached to the coil insertion device 8 so that the outer peripheral surfaces of all the blades 81 face the inner peripheral end surfaces of the teeth 12 and cover the blades 81. insert.

Next, a method for accommodating the two slot accommodating portions 21b of the coil 2b in the slot 11 of the stator core 1 will be described.
FIG. 18 is a schematic cross-sectional view of the coil insertion device 8 cut along a plane passing through the central axis of the coil insertion device 8.
FIG. 18 (a) shows two coils 2 b in a state of being hooked on the blade 81 at a position facing the center of the coil insertion device 8 among the blades 81 of the coil insertion device 8.

  The stripper 86 is a cylindrical member that can move up and down along the inner surface of the blade 81. The stripper 86 has a function of inserting the coil 2 b while pushing up the coil 2 b into the slot 11 of the stator core 1, the upper part of which is fixed by the fixing portion 89. Further, the stripper 86 can move up and down in conjunction with or independently of all the blades 81. In the state shown in FIG. 18A, the upper end of the blade 81 protrudes upward from the upper surface of the stripper 86, and the coil 2b is hooked by the protruding portion.

FIG. 18 (b) shows the coil 2 b in a state where it is half in the slot 11 of the stator core 1.
Since the coil 2 b is initially hooked on the blade 81 that moves upward in synchronization with the stripper 86, the coil 2 b is gradually inserted into the slot 11 of the stator core 1 by the lift of the stripper 86. At the same time, the wedge 32 is pushed up and inserted between the coil 2 b and the blade 81 from the outer peripheral side of the blade 81. The wedge 32 is guided by the wedge guide 85 and is pushed up by the wedge pusher 82 that rises in synchronization with the stripper 86 (refers to a wedge mounting step).

FIG. 18C is a cross-sectional view showing the coil insertion device 8 and the coil 2 b that is completely attached to the stator core 1.
When the stripper 86 is completely raised, as shown in the figure, a coil end portion 24b is formed at the upper end portion (the side without the crossover) of the coil 2b, and at the lower end portion of the coil 2b in the drawing. The coil end portion 25b is formed, and the slot storage portion 21b is stored in the slot 11 (refers to a coil shaping step). At this time, the blade 81 that was initially raised in synchronism with the stripper 86 is released from the position slightly above the upper end surface of the stator core 1, and the synchronization is released. As shown in FIG. Has stopped. This is to prevent unnecessary tension from being applied to the coil end portion 24b.

  Actually, as shown in FIG. 3, since the coil 2d is inserted into the same slot 11 after the coil 2b, the wedge 32 is mounted when the coil 2d is inserted. Explained.

  Next, even if the one-turn magnet wire 6 having a different circumferential length constituting the coil 2b is scattered when passing between the blade 81 and the sub-blade 83, the coil end portions 24b and 25b can be formed without a gap. Will be explained.

  First, it is assumed that the coil 2b wound as shown in FIG. 11A is scattered and hooked on the blade 81 as shown in FIG. 11B. The first to third winding magnet wire 6 has the shortest circumference, and the fourth to sixth winding magnet wire 6 has an intermediate length, and the seventh to ninth winding magnets. The wire 6 has the longest circumference.

  When the coil 2 b is inserted into the stator core 1 using the coil insertion device 8, first, the first to third of the portions that become the coil end portion 25 b on the opposite side of the portion hooked by the blade 81. The magnet wire 6 reaches the lower end surface of the stator core 1 (points to the end surface on the coil insertion side) and is caught between the two slots 11 and cannot rise further. For this reason, the downward tension in the drawing is applied to the side of the first to third magnet wires 6 that are hooked on the blade 81, and those magnet wires 6 are hooked on the blade 81 in the portion that becomes the coil end portion 24 b. In the state, gather at the bottom. Next, the 4th to 6th magnet wires 6 are hooked on the 1st to 3rd magnet wires 6 on the lower end surface of the stator core 1 and stacked on the 1st to 3rd magnet wires 6. Finally, the seventh to ninth magnet wires 6 are stacked on the uppermost layer of the coil end portions 24b and 25b. In this way, even if the coil 2b wound in advance is separated, in the process of inserting the coil 2b into the stator core 1, the magnet wire 6 is naturally stacked again from the magnet wire 6 having a short circumference to the lower layer, so that the coil end is not gaped. The portions 24b and 25b can be formed.

  Regarding the arrangement of the sub-blades 83, in addition to the above-described positions and directions, for example, among the three blades 81 arranged in series of low-high-low shown in FIG. The sub blades 83 may be mounted on them, and the inclined surfaces 83a1 of the respective sub blades 83 may be arranged so as to face the side opposite to the side surface of the middle blade 81. When the coils 2 a and 2 c larger than the coil 2 b are mounted on the stator core 1, the coils 2 a and 2 c are further hooked across the two blades 81.

  Further, the shape of the sub blade 83 is not limited to the above-described shape, and a space larger than the space between the adjacent blades 81 can be secured between the sub blade 83 and the adjacent blade 81, and the coil 2b. Any shape can be used as long as it can be rolled up and guided.

  In this embodiment, the stator core 1 is fixed and the stripper 86 is moved. However, the stripper 86 is fixed and the stator core 1 is moved in the axial direction around the stator core 1. .

  According to the stator manufacturing method and the coil insertion device according to the first embodiment of the present invention, useless space generated in the coil end portions 24b and 25b of the stator 100 can be suppressed, and the circumferential length of the coil 2b. Can be shortened. Thereby, the performance improvement and size reduction of the rotary electric machine using the stator 100 can be achieved.

Embodiment 2. FIG.
Hereinafter, the stator manufacturing method and the coil insertion device according to the second embodiment of the present invention will be described with reference to the drawings, focusing on the differences from the first embodiment.
FIG. 19 is a perspective view showing a winding start state of the coil winding machine 207 used for manufacturing the coil 2b.
FIG. 20 is a perspective view showing a state where the coil 2b after winding is removed from the winding frames 207a and 207b.
In the coil winding machine 7 according to the first embodiment, the flyer 5 swirls around the winding frames 7a and 7b and winds the magnet wire 6 around the winding frames 7a and 7b. In the coil winding machine 207, the position of the nozzle 251 is fixed. In contrast to the first embodiment, the two winding frames 207a and 207b are fixed by the winding frame fixing portion 207c, and the winding frame fixing portion 207c is connected to the rotating shaft 207d. Further, since the rotating shaft 207d is movable in the Z direction in FIG. 20, the width corresponding to the depth of the slot 11 (the radial width is set as in the first embodiment) while rotating the reels 207a and 207b. The coil layer 24 can be formed while forming the coil array 23 having The removal from the winding frames 207a and 207b after winding the magnet wire 6 is the same as in the first embodiment.

  According to the method for manufacturing a stator and the coil insertion device according to the second embodiment of the present invention, the same effect as in the first embodiment can be obtained.

  It should be noted that the present invention can be freely combined with each other within the scope of the invention, and each embodiment can be appropriately modified or omitted.

100 Stator, 1 Stator core, 2a-2d coil, 3 Insulating member,
31 slot cells, 32 wedges, 5 flyers, 6 magnet wires,
7,207 coil winding machine, 7a, 207a, 7b, 207b reel,
207c reel fixing part, 207d rotating shaft, 8 coil insertion device,
81, 81a-81d blade, 82 wedge pusher,
83, 83a, 83b sub-blade, 83a1, 83b1 inclined surface,
83a2, 83b2 curved surface, 83a3, 83b3 side surface,
84a, 84b Sub-blade detaching arm, 85 wedge guide,
86 Stripper, 87a, 87b Blade drive mechanism, 89 Fixed part,
11 slots, 12 teeth, 21a, 21b slot housing,
22b Insertion part between blades, 24a to 24d, 25b Coil end part,
23 coil array, 24 coil layers, 51,251 nozzle, 52 rotating shaft,
71a, 71b Upper lid, 72a, 72b Lower lid.

Claims (11)

It has the same width in the circumferential direction as the inner peripheral side tip of the stator core teeth to which the coil bundle is mounted, and the inner peripheral side tip of each of the stator cores can be opposed to the respective outer peripheral surface. A rod-shaped blade of the same number as the number of teeth arranged in a ring;
A blade drive mechanism for moving each blade in the longitudinal direction of the blade independently or in units of groups;
A cylindrical member disposed along the inner surface of the plurality of blades, the stripper moving relative to the inner peripheral side of the stator core in the axial direction in conjunction with or independently of all the blades. When,
The circumferential width of the tip attached to the tips of the two blades is narrower than the circumferential width of the blade, and the circumferential width of the base on the side to be attached to the blade is the circumference of the blade. A sub-blade that is the same as the width of the direction;
A coil insertion device comprising: a sub blade attaching / detaching mechanism for attaching / detaching the sub blade to / from the blade. 2. The coil insertion device according to claim 1, wherein a side surface in the circumferential direction on a tip side of the sub blade has an inclined surface that is cut obliquely so that a tip of the sub blade is thinned. 3. The coil insertion device according to claim 2, wherein the lower portion of the inclined surface is connected to a flat side surface through a smooth curved surface having a quadratic cross section in the axial direction. The coil insertion device according to claim 2 or 3, wherein the two sub blades are mounted such that the inclined surfaces face each other. The coil insertion device according to claim 2 or 3, wherein the two sub blades are mounted such that the inclined surfaces face each other. In conjunction with the operation of the stripper, between the coil bundle inserted in a slot formed between adjacent teeth and the stator core, while insulating between the coil bundle and the stator core, The coil insertion device according to any one of claims 1 to 5, further comprising a wedge pusher that pushes in a wedge that closes an opening of the slot, and a wedge guide that guides the wedge. In a stator manufacturing method in which a coil bundle is mounted in a slot formed between adjacent teeth of a stator core having a ring-shaped yoke and a plurality of teeth projecting radially inward from the yoke,
A coil manufacturing process for manufacturing the coil bundle by winding a magnet wire;
The stator core has the same width as the circumferential width of the inner peripheral tip of the teeth, and the same number of rod-shaped blades as the number of teeth are annular, and the inner peripheral tip of the stator core teeth The outer peripheral surfaces of a plurality of the blades are arranged to face each other,
The blade is independently movable in the longitudinal direction of the blade;
A coil that is disposed along the inner surface of the plurality of blades, and includes a stripper that moves relative to the inner peripheral side of the stator core in the axial direction independently or in conjunction with all the blades. A sub-blade mounting step of lowering the two blades of the insertion device and mounting a sub-blade having a width narrower than the circumferential width of the blade at the tips of the two blades;
Between the blades adjacent to each of the sub-blades, the blades that are hooked through two inter-blade insertion portions of the coil bundle and guided by the blades adjacent to the sub-blades are attached to the blades. An inter-blade coil bundle insertion step of inserting the coil bundle between the matching blades;
After the inter-blade coil bundle insertion step, the coil is pulled by the stripper while being hooked on the blade in the axial direction from the axial end of the stator core toward the inner peripheral side of the stator core. And a coil shaping step of forming a coil end portion on both end faces of the stator core by pushing the bundle into the slot. A wedge mounting step of pushing a wedge that closes an opening of the slot while insulating between the coil bundle and the stator core between the coil bundle inserted into the slot and the stator core. A method for manufacturing the stator according to claim 7. In the coil manufacturing process, a magnet wire is wound around a pair of winding frames having winding guides that regulate the width of a coil array forming the coil bundle from both sides to a width corresponding to the depth of the slot. A magnet wire winding process,
The stator manufacturing method according to claim 7, further comprising a guide reduction step of reducing an outer diameter of the winding guide to be smaller than an inner diameter of the coil bundle. The method of manufacturing a stator according to claim 9, wherein the magnet wire winding step winds the magnet wire by rotating a fryer provided with a nozzle for supplying the magnet wire around a set of the winding frames. . 10. The method of manufacturing a stator according to claim 9, wherein in the magnet wire winding step, the magnet wire is wound by rotating a set of the winding frames with respect to a nozzle that supplies the magnet wire.

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