JP2017011972A - Winding manufacturing method and winding manufacturing apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a winding group in a small space while reducing a wire joining operation.SOLUTION: A wounding manufacturing method is a method for manufacturing a wounding group of a cylindrical wave coil form. The wounding manufacturing method includes: a molding step of molding a spiral initial striped body r, by arranging a wire 1 in a spiral shape and press-working the wire 1, which includes a main line part P1 extended to a longitudinal direction of the wire 1 and a first sub-line part P2a and a second sub-line part P2b each extended to the longitudinal direction at a position to be off-set in an opposite direction to the main line part P1, and alternately arranges the first sub-line part P1a and second sub-line part P2b while sandwiching the main line part P1; a forming processing step of deforming the initial striped body r into a rectangle wave form by bending the main line part P1 to the first and second sub-line parts P2a and P2b while leading out the initial striped body r from a peripheral edge; and a taking-up step of taking-up the initial striped body r after the forming processing step.SELECTED DRAWING: Figure 22

Description

  The present invention relates to a winding manufacturing method and a winding manufacturing apparatus for a rotating electrical machine (motor, generator, or motor / generator) used in a vehicle or the like.

  As a stator of a radial gap type rotating electrical machine, an annular stator core having a plurality of slots arranged in the circumferential direction, and a winding group (coil) including a copper wire wound around the stator core by wave winding (distributed winding) For example, Patent Document 1 discloses a method of manufacturing a winding group used in a three-phase motor that is one of this type of rotating electrical machines.

  In this manufacturing method, a corrugated plate having a shape equivalent to a shape obtained by cutting a winding group for one phase at one location in the circumferential direction is punched from a metal plate by press working, and the corrugated plate is further pressed by press working. A plurality of strands having a waveform are formed by dividing in the width direction. Then, these strands are integrally bonded and deformed into a circular shape, and the circumferential ends of adjacent strands (one winding) are joined together by welding or the like, whereby a winding group for one phase (Coil) is formed.

JP 2011-188721 A

  However, in the method of Patent Document 1, it is necessary to join adjacent wires for each turn, so that it takes time and labor to manufacture the winding group. In this case, it is also conceivable to omit the joining work by punching a wire having a corrugated shape for one phase from a metal plate by winding and forming the winding group by winding it several times. However, in this case, there is a detrimental effect that a wide (long) processing space is required for pressing the corrugated wire for one phase.

  The present invention has been made in view of the above circumstances, and provides a technique capable of manufacturing a winding group (coil) in a relatively small space while reducing the joining work of the strands by welding or the like. For the purpose.

  In order to solve the above-described problems, the present invention provides a cylindrical winding group that is assembled to a stator core having a plurality of slots arranged in the circumferential direction at regular intervals and opened inward, and one side of the stator core. A first winding portion that passes over the end face of the first and a second transition portion that passes over the other end face are alternately arranged in the circumferential direction via the in-slot passage portion passing through the slot. A method of manufacturing a group of wires, in which the strands are arranged in a spiral shape and the strands are pressed with a die so as to be parallel to the main line portion extending in the longitudinal direction of the strands and the spiral center line. A first sub-line portion and a second sub-line portion extending in the longitudinal direction at positions offset in opposite directions with respect to the main line portion, and the first sub-line portion and the second sub-line portion Lines are alternately arranged in the circumferential direction across the main line A molding process for forming a spiral initial linear body, and the initial linear body is bent with respect to the first and second sub-line sections while pulling out the initial linear body from its outer peripheral end. And a forming process for deforming the body into a rectangular wave shape.

  According to this winding manufacturing method, after the strands are arranged in a spiral shape and a spiral initial linear body is formed by press working, the initial linear body is formed into a rectangular wave shape while being pulled out from the outer peripheral end. As a result, there is no process for processing the initial linear body (elementary wire) in a fully developed state, and therefore it is possible to manufacture the winding group in a relatively small space.

  In this case, further, the initial linear body after the forming step is wound into a cylindrical shape, so that the main line portion, the first sub line portion, and the second sub line portion respectively pass through the slot. It is preferable to have a winding process for forming the winding group in which the winding portion, the first transition portion, and the second transition portion are formed.

  According to this winding manufacturing method, it is possible to manufacture a final wave-winding winding group from a single strand without joining the strands.

  In the winding manufacturing method, in the forming step, the main line portions located on both sides of the first sub-line portion are arranged so that the main line portion extends in a direction orthogonal to the longitudinal direction of the initial linear body. It is preferable to bend the set of main line portions simultaneously as a set.

  According to this winding manufacturing method, the initial linear body can be efficiently transformed into a rectangular wave shape.

  In this case, specifically, the first sub-line portion and the main line portion located on both sides of the first sub-line portion as a set, and the first end portion that is the end portion on the first sub-line portion side of each main line portion. Among the main line parts, the second end part, which is the end part on the second sub-line part side, and the first end parts in the orthogonal direction in a state of keeping the distance therebetween. It is preferable that the main line portion is bent with respect to the first and second sub-line portions by moving the second end portions in a direction approaching each other along the longitudinal direction. is there.

  According to these winding manufacturing methods, it becomes possible to bend each main line part on both sides simultaneously with a symmetrical operation with the first sub-line part as the center, so that workability is improved.

  In this case, it is preferable that grip portions extending in the orthogonal direction are formed at both ends of the main line portion in the molding step, and the grip portion is gripped in the forming step.

  According to this winding manufacturing method, it is possible to make the main line portion after bending more straight along the orthogonal direction.

  Further, in the above-described winding manufacturing method, in the molding step, it is preferable to sequentially press in a certain range from one end of the strands arranged in a spiral toward the other end. It is.

  According to this winding manufacturing method, loosening or pulling of the wire during press working is reduced. Therefore, it is effective for maintaining the cross-sectional shape (cross-sectional area) of the initial linear body obtained by pressing, and for preventing damage to the insulating film formed on the strands.

  Further, in the above-described winding manufacturing method, when the winding group is a twisted part of the winding included in the winding group, the forming step corresponds to the part. It is preferable to press the element wire that has been twisted in advance.

  According to this winding manufacturing method, it is possible to satisfactorily manufacture a winding group partially including a twist as described above.

  On the other hand, the winding manufacturing apparatus of the present invention is an apparatus used in any of the above-described forming processes, and includes a first mold having a spiral forming groove into which the element wire 1 is inserted and the forming groove. A mold having a second mold to be arranged, and a drive device that opens and closes the mold by relatively moving the first mold and the second mold.

  According to this winding manufacturing apparatus, it is possible to satisfactorily manufacture the initial linear body as described above by inserting a strand into the molding groove and pressing the strand with the mold. Become.

  In this case, one of the first mold and the second mold is a movable mold and includes a plurality of divided molds arranged in the longitudinal direction of the molding groove, and the driving device includes the plurality of divided molds. Among them, it is preferable that the mold is sequentially closed from the end on the one side by moving in order from the one near the end on the one side of the molding groove.

  According to this winding manufacturing apparatus, it becomes possible to reduce the looseness and tension of the wire during press working. Therefore, it is possible to prevent the deformation of the initial linear body and the damage to the insulating film due to the loosening or the tension.

  In this winding manufacturing apparatus, the mold is such that the first mold is a fixed mold, the second mold is a movable mold, and the first mold is detachable from the base mold. A plurality of types of exchange molds for forming the first and second sub-linear portions, and a predetermined exchange mold selected from the plurality of types of exchange molds is fixed to the base mold. Each of the split molds is a pair of unit molds that can be arranged in the longitudinal direction of the molding groove and whose interval can be changed, and has a shape corresponding to the interchangeable mold of the first mold. It is suitable.

  According to this winding manufacturing apparatus, it is possible to manufacture a plurality of types of initial linear bodies having different length dimensions of the main line portion, the first sub-line portion, and the second sub-line portion using a common manufacturing apparatus. Become.

  Another winding manufacturing apparatus of the present invention is an apparatus used in the forming process and the winding process described above, and a feeding table that holds the initial linear body in a drawable manner, and the initial linear body. The main wire portion is bent with respect to the first and second sub-wire portions while the main wire portion is pulled out from the outer peripheral end thereof, and a winding body for winding the initial linear body subjected to the forming processing. And a take-off table.

  According to this winding manufacturing apparatus, it is possible to efficiently perform each of the forming process and the winding process.

  As described above, according to the winding manufacturing method and the winding manufacturing apparatus of the present invention, a winding group (coil) is manufactured in a relatively small space while reducing the joining work of the strands by welding or the like. It becomes possible.

It is a perspective schematic diagram showing a stator of a rotating electrical machine. It is a longitudinal section schematic diagram showing a stator. It is a plane section schematic diagram showing a stator. (A) is sectional drawing of a coil | winding (elementary wire), (b) is a principal part enlarged view of FIG. FIG. 3 is a developed longitudinal cross-sectional schematic diagram showing a winding path of a winding group, where (a) shows a winding path of a first U-phase winding group, and (b) shows a winding of a second U-phase winding group. Indicates the route. FIG. 2 is a developed plan schematic view (top view) showing a winding path of a first U-phase winding group, (a) showing a winding path of a forward winding group, and (b) showing a reverse winding group. The winding path of is shown. FIG. 3 is a developed plan schematic view (top view) showing a winding path of a second U-phase winding group, (a) showing a winding path of a forward winding group, and (b) showing a reverse winding group. The winding path of is shown. (A) is a perspective schematic diagram explaining the wiring state of the 1st U-phase winding group (positive winding group) derived | led-out from the slot, (b) extracts the coil | winding with a torsion from (a). FIG. FIG. 7 is a schematic cross-sectional view showing a wiring state of a winding group derived from a slot, where (a) is a line IXa-IXa in FIG. 6 (a), and (b) is a line IXb-IXb in FIG. 6 (a). It is a cross-sectional schematic diagram along each line. (A) is a perspective schematic diagram explaining the wiring state of the 1st U-phase winding group (positive winding group) inserted in a slot, (b) is a figure which shows the coil | winding by which twist is returned. It is the isometric view schematic diagram extracted from. It is a cross-sectional schematic diagram which shows the wiring state of the winding group on the axial direction end surface of a stator core, (a) is a XIa-XIa line of Fig.6 (a), (b) is XIb of Fig.6 (a). -XIb line, (c) is a schematic cross-sectional view taken along line XIc-XIc in FIG. 6 (a), and (d) is a cross-sectional schematic view taken along line XId-XId in FIG. 6 (a). (A)-(c) is explanatory drawing explaining the manufacturing method of a stator. (A)-(c) is explanatory drawing explaining the other example of the manufacturing method of a stator. It is a side view which shows a press working machine (a part of winding manufacturing apparatus). It is a top view which shows the lower mold | type of a press machine. It is sectional drawing (XVI-XVI sectional view taken on the line of FIG. 14) which shows the upper mold | type of a press machine. It is sectional drawing (XVII-XVII sectional view taken on the line of FIG. 16) which shows the upper mold | type and lower mold | type of a press machine. It is sectional drawing which shows the upper mold | type and lower mold | type of a press processing machine. It is an expanded view of the initial linear body obtained by press work. It is a principal part enlarged view of the initial linear body shown in FIG. It is a top view which shows a forming machine (a part of winding manufacturing apparatus). (A), (b) is a side view which shows the processing state of the initial linear body by a wire processing machine (forming machine). (A), (b) is a side view which shows the processing state of the initial linear body by a wire processing machine (forming machine). It is a side view which shows the processing state of the initial linear body by a wire processing machine (forming machine). FIG. 4 is a development view schematically showing a winding group (a positive winding group of a first U-phase winding group).

  Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

  Before describing the stator manufacturing method and the stator manufacturing apparatus of the present invention, first, a stator for a rotating electrical machine manufactured using the manufacturing method and the manufacturing apparatus will be described.

  1 to 3 schematically show a stator S of a rotating electrical machine, FIG. 1 is a perspective view, and FIGS. 2 and 3 are sectional views showing the stator S, respectively.

  A stator S shown in the figure is a stator used in a three-phase AC motor (an example of a rotating electric machine) mounted on a hybrid vehicle. Specifically, a three-phase AC motor is constituted by the stator S, a rotor disposed inside the stator S, a casing that accommodates the stator S and the rotor, and the like.

  The stator S includes an annular stator core 10 and a first coil member 14A and a second coil member 14B each including a plurality of winding groups wound around a slot 12 thereof. In the following description, the direction around the central axis of the stator core 10 is referred to as a circumferential direction, and the radial direction of the stator core 10 is simply referred to as a radial direction.

  As shown in FIG. 3, the stator core 10 includes a plurality of slots 12 that open inward and extend radially at a plurality of positions arranged at equal intervals in the circumferential direction.

  The stator core 10 includes 48 slots 12 in this example. As will be described in detail later, each of the U-phase, V-phase, and W-phase winding groups is wound around the stator 10 so as to pass through a specific plurality of slots 12 among the 48 slots 12. . In other words, the stator core 10 includes two adjacent slots 12 into which U-phase winding groups are respectively inserted, two adjacent slots 12 into which V-phase winding groups are respectively inserted, and W Eight sets of slot groups are provided in the circumferential direction of the stator core 10, with two adjacent slots 12 into which phase winding groups are inserted as one set. That is, the rotating electrical machine to which the stator S is applied is an 8-pole rotating electrical machine having 48 slots.

  In FIG. 3, the slots 12 into which the U-phase winding groups are respectively inserted are denoted by reference numerals U1, U2, U3, U4,... U15, U16, and the slots 12 into which the V-phase winding groups are respectively inserted. Are indicated by reference numerals V1, V2, V3, V4,..., V15, V16, and slots 12 into which W-phase winding groups are respectively inserted are indicated by reference signs W1, W2, W3, W4,. In the following description, the symbols U1, U2, U3, U4,... U15, U16 shown in FIG. Similarly, the symbols V1, V2, V3, V4,... V15, V16 in the figure are used as the symbols of the slots into which the V-phase winding groups are respectively inserted, and the slots into which the W-phase winding groups are respectively inserted. W1 · W2, W3 · W4... W15 · W16 are used.

  The stator core 10 is configured by stacking and integrating a plurality of plates made of a magnetic material (steel plate) having a shape as shown in FIG. 3, for example.

  The first coil member 14 </ b> A and the second coil member 14 </ b> B each include a plurality of winding groups wound around the stator core 10. The basic configuration of the first coil member 14A and the second coil member 14B is the same except that the second coil member 14B is provided inside the first coil member 14A. Therefore, in the following description, the first coil member 14A will be described in detail, and the configuration of the second coil member 14B will be referred to as necessary.

  The first coil member 14A includes a pair of U-phase winding groups 20Ua and 20Ub (first U-phase windings) wound around the stator core 10 so as to pass through the slots U1, U2, U3, U4,. Wire group 20Ua and second U-phase winding group 20Ub (see FIG. 4B)) and two wound around stator core 10 so as to pass through slots V1, V2, V3, V4,. Pass through a set of V-phase winding groups 20Va, 20Vb (referred to as first V-phase winding group 20Va and second V-phase winding group 20Vb) and slots W1, W2, W3, W4, ... W15, W16. And a set of two W-phase winding groups 20Wa and 20Wb (referred to as a first W-phase winding group 20Wa and a second W-phase winding group 20Wb) wound around the stator core 10. In FIG. 1, the first coil member 14 </ b> A and the second coil member 14 </ b> B are shown very schematically by collectively grouping the winding groups wound along the same path.

  The U-phase winding groups 20Ua and 20Ub, the V-phase winding groups 20Va and 20Vb, and the W-phase winding groups 20Wa and 20Wb have the same basic configuration except that the passing slots 12 are different from each other. Therefore, in the following description, the configuration of the U-phase winding groups 20Ua and 20Ub is described in detail, and the configuration of the V-phase winding groups 20Va and 20Vb and the W-phase winding groups 20Wa and 20Wb is referred to as necessary. I will do it. In the following description, upper (upper side) and lower (lower side) refer to the state of the stator S shown in FIG. 1, and inner (inner side) and outer (outer side) refer to the radial direction of the stator core 10. And

  The first U-phase winding group 20Ua is composed of a plurality of windings formed by strands 5 having a pentagonal cross section. Specifically, as shown in FIG. 4A, the strand 1 connects the bottom 2a, a pair of side 2b, 2b extending in parallel from both sides, and the ends of these sides 2b, 2b. A cross-sectional home base type having a pair of oblique sides 2c and 2c. In addition, the part which a pair of hypotenuse 2c connects in the cross section of the strand 1 is called a cusp part. The element wire 1 is provided with an insulating film, and the pointed portion is slightly used to suppress damage to the film due to stress concentration at the time of bending or damage (cracking) of the winding wire (element wire 1). It has a roundness.

  As shown in FIG. 4B, the first U-phase winding group 20Ua is composed of a total of six windings formed by the cross-section home base type strands 1 as described above. Specifically, as shown in the figure, the first U-phase winding group 20Ua includes a positive winding group 22a including three windings r1 to r3 and a reverse winding including three windings r1 ′ to r3 ′. Group 22b. The forward winding group 22a and the reverse winding group 22b are such that the current flowing directions are opposite to each other in the circumferential direction at the coil end portion, and the current flowing directions are the same in the slot 12. As will be described in detail later, the winding insertion direction and the lead-out direction with respect to the slot 12 are opposite to each other.

  Similarly, as shown in FIG. 4B, the second U-phase winding group 20Ub is composed of a total of six windings formed by the home-base type pentagonal wire 1 having a cross section. A forward winding group 24a including three windings r4 to r6 and a reverse winding group 24b including three windings r4 ′ to r6 ′ are included.

  Each of the U-phase winding groups 20Ua and 20Ub is formed by being wound around the stator core 10 by wave winding (a kind of distributed winding) as shown in FIGS. That is, the winding structure of each U-phase winding group 20Ua, 20Ub is a wave winding.

  More specifically, the positions of the slots U1 and U2 will be described as a reference. First, the positive winding group 22a of the first U-phase winding group 20Ua includes the stator core 10 as shown in FIGS. 5 (a) and 6 (a). It is inserted into the slot U1 from the lower side and led out to the upper side, inserted into the slot U4 from the upper side of the stator core 10 and led out to the lower side, and inserted into the slot U5 from the lower side of the stator core 10 and led out to the upper side. Specifically, it is wound around the stator core 10 by wave winding via the slots U1, U4, U5, U8, U9, U12, U13, U16.

  As shown in FIG. 5A and FIG. 6B, the reverse winding group 22b of the first U-phase winding group 20Ua is inserted into the slot U1 from the upper side of the stator core 10 and led out to the lower side. The stator core 10 is wound around the stator core 10 so that it is inserted into the slot U4 from the lower side and led out to the upper side, inserted into the slot U5 from the upper side of the stator core 10 and led out to the lower side. That is, the reverse winding group 22b has the same slots U1, U4, U5, U8, and the same as the positive winding group 22a so that the insertion direction and the leading direction of the winding with respect to the slot 12 are opposite to those of the positive winding group 22a. It is wound around the stator core 10 by wave winding via U9, U12, U13, U16.

  As shown in FIG. 4B, the windings r1 to r3 of the positive winding group 22a and the windings r1 'to r3' of the reverse winding group 22b are arranged in the radial direction of the stator core 10 (in FIG. 4B). In the state of being arranged in a line in the left and right direction, specifically, the windings r1 to r3 of the positive winding group 22a are continuously arranged in a line on one side in the radial direction and adjacent to the positive winding group 22a. Thus, the windings r1 'to r3' of the reverse winding group 22b are inserted into the slots U1 and U4 to U16 in a state where they are continuously arranged in a line. More specifically, the windings in which the pointed portions of the adjacent windings face opposite to each other in the circumferential direction and the hypotenuses 2c of the adjacent windings are in contact with each other and the direction of the pointed portion is common. Of adjacent ones of the windings r1 and r3 of the positive winding group 22a and the windings r2 'of the reverse winding group 22b of the neighboring windings 2b. The windings r1 to r3 are in contact with each other, and the adjacent sides 2b of the winding r2 of the positive winding group 22a and the windings r1 'and r3' of the reverse winding group 22b are in contact with each other. , R1 ′ to r3 ′ are inserted in the slots U1 and U4 to U16.

  As shown in FIGS. 6A and 6B, in the forward winding group 22a and the reverse winding group 22b, the positional relationship between the inside and the outside in the radial direction of the stator core 10 is alternated for each of the slots U1 and U4 to U16. Is wound around the stator core 10 so as to be replaced.

  On the other hand, as shown in FIGS. 5B and 7A, the positive winding group 24a of the second U-phase winding group 20Ub is inserted into the slot U2 from the lower side of the stator core 10 and led out to the upper side. The slots U2, U3, U6, U7, U9 are inserted into the slot U3 from the upper side of the stator core 10 and led out to the lower side, inserted into the slot U6 from the lower side of the stator core 10 and led out to the upper side. It is wound around the stator core 10 by wave winding via U10, U11, U14, U15.

  As shown in FIG. 5B and FIG. 7B, the reverse winding group 24b of the second U-phase winding group 20Ub is inserted into the slot U2 from the upper side of the stator core 10 and led out to the lower side. It is wound around the stator core 10 so that it is inserted into the slot U3 from the lower side and led out to the upper side, inserted into the slot U6 from the upper side of the stator core 10 and led out to the lower side. That is, the reverse winding group 24b has the same slots U2, U3, U6, U7 as the positive winding group 24a so that the insertion direction and the leading direction of the winding with respect to the slot 12 are opposite to those of the positive winding group 24a. It is wound around the stator core 10 by wave winding via U9, U10, U11, U14, U15.

  The windings r4 to r6 of the positive winding group 24a and the windings r4 'to r6' of the reverse winding group 24b are similar to the winding groups 22a and 22b of the first U-phase winding group 20Ua described above, as shown in FIG. As shown in (b), the stator cores 10 are inserted into the slots U2, U3 to U15 in a state of being arranged in a line in the radial direction. As for the second U-phase winding group 20Ub, as shown in FIGS. 7 (a) and 7 (b), the forward winding group 24a and the reverse winding group 24b have the stator core 10 in each of the slots U2, U3 to U15. Is wound around the stator core 10 so that the positional relationship between the inside and the outside in the radial direction is alternately switched.

  Note that the first U-phase winding group 20Ua and the second U-phase winding group 20Ub are formed as pointed windings r1 and r4 positioned on the radially outermost side of the stator core 10, as shown in FIGS. 3 and 4B. In this example, the slots U1, U2,... Are arranged so that the pointed portions of the windings r1, r4 face each other on the same side in the circumferential direction (the lower side in FIG. 4B). ... is inserted into U15 and U16.

  The positive winding group 22a of the first U-phase winding group 20Ua and the positive winding group 24a of the second U-phase winding group 20Ub are axial end faces on the axial end face (upper and lower end faces) of the stator core 10. The windings r1 to r3 and r4 to r6 are arranged along the axial direction of the stator core 10 in a state where the bases 2a are parallel and the oblique sides 2c or the bases 2a are in contact with each other.

  Specifically, as schematically shown in FIG. 8A, the inner two windings r2 of the positive winding group 22a of the first U-phase winding group 20Ua led out from the slot U1 to the upper side of the stator core 10. , R3 are bent at a right angle so as to be substantially horizontal (substantially parallel to the axial end surface of the stator core 10), and the remaining winding r1 is further bent 180 ° inward while being bent at a right angle (FIG. 8). (See (b)), the bottoms 2a of the windings r3 are overlapped with each other so as to contact each other. On the other hand, of the positive winding group 24a of the second U-phase winding group 20Ub led out from the slot U2 to the upper side of the stator core 10, the inner two windings r5 are bent as they are at substantially right angles, and the remaining winding r4. Are overlapped so that the bases 2a of the windings r5 are in contact with each other on the upper side of the winding r5, and the hypotenuses 2c are stacked on the lower side of the winding r1. . As a result, as shown in FIG. 9B, the winding r1 of the positive winding group 22a of the first U-phase winding group 20Ua in a state in which the hypotenuses 2c are in contact with each other or in a state in which the bases 2a are in contact with each other. The windings r4 to r6 of the positive winding group 24a of the second U-phase winding group 20Ub are overlaid on the lower side of .about.r3. 9A is a schematic cross-sectional view of the winding group along the line IXa-IXa in FIG. 6A, and FIG. 9B is the line IXb-IXb in FIG. It is the same cross-sectional schematic diagram along.

  As shown in FIGS. 6 (a) and 7 (a), the positive winding group 22a of the first U-phase winding group 20Ua and the positive winding group 24a of the second U-phase winding group 20Ub are stacked as described above. As it goes to the next slot U3, U4, it is arranged along the upper end surface of the stator core 10 so as to be displaced radially inward of the stator core 10. Then, as schematically shown in FIG. 10A, first, the positive winding group 24a of the second U-phase winding group 20Ub located on the lower side is inserted into the slot U3 from the upper side of the stator core 10. In this case, the lower windings r5 and r6 are bent at a substantially right angle, and the remaining windings r4 are bent at a substantially right angle and arranged outside the other windings r5 and r6. Thus, the positive winding group 24a is inserted into the slot U3 in a state where the windings r4 to r6 are aligned in the radial direction of the stator core 10.

  On the other hand, in the positive winding group 22a of the first U-phase winding group 20Ua, the upper two windings r2 and r3 are bent at a right angle as they are, and the remaining winding r1 is bent at a right angle and 180 ° outward. In a twisted state (see FIG. 10B), they are arranged outside the other windings r2 and r3. Thus, the positive winding group 22a is inserted into the slot U4 in a state where the windings r1 to r3 are arranged in a line in the radial direction of the stator core 10. Note that the winding r1 is twisted 180 ° outward as described above because the winding r1 is led out of the slot U1 and then twisted 180 ° inward to overlap another winding r3. (FIGS. 8A and 8B) to eliminate this twist.

  Here, the arrangement of the positive winding groups 22a and 24a on the upper side of the stator core 10 has been specifically described. However, on the lower side of the stator core 10, the vertical relationship of the positive winding groups 22a and 24a is reversed, that is, FIG. The arrangement is vertically symmetrical with the arrangement of (b). The other arrangements of the positive winding groups 22 a and 24 a are basically common to both the upper and lower sides of the stator core 10.

  Here, although the positive winding groups 22a and 24a have been described, the arrangement of the reverse winding groups 22b and 24b on the upper and lower sides of the stator core 10 is basically the same as that of the positive winding groups 22a and 24a. That is, the arrangement is equivalent to the arrangement in which the windings r1 to r3 and the windings r4 to r6 in FIGS. 9A and 9B are replaced with windings r1 ′ to r3 ′ and windings r4 ′ to r6 ′.

  In this way, the first U-phase winding group 20Ua and the second U-phase winding group 20Ub are wound around the stator core 10. The first U-phase winding group 20Ua and the second U-phase winding group 20Ub are sequentially inserted into a pair of adjacent slots U1, U2, U3, U4,... U15, U16, as described above (FIG. 5). The first U-phase winding group 20Ua and the second U-phase winding group 20Ub are different in the circumferential direction of each pair of slots U1, U2, U3, U4,. Is inserted into the slot 12. That is, the winding group derived from the odd-numbered slot 12 is inserted into the next even-numbered slot 12, while the winding group derived from the even-numbered slot 12 is inserted into the next odd-numbered slot 12. Inserted into. As a result, as described above, the first U-phase winding group 20Ua is inserted into the slots U1, U4, U5, U8, U9, U12, U13, U16, and the second U-phase winding group 20Ub is inserted into the slots U2, U3, It is inserted in U6, U7, U9, U10, U11, U14, U15. In this way, the first U-phase winding group 20Ua and the second U-phase winding group 20Ub are wound around the stator core 10, so that the positive winding group 22a and the positive winding group 24a do not cross each other, and The first U-phase winding group 20Ua and the second U-phase winding group 20Ub are wound around the stator core 10 by wave winding without the reverse winding group 22b and the reverse winding group 24b intersecting each other.

  The configuration of the U-phase winding groups 20Ua and 20Ub has been described in detail above. However, the V-phase winding groups 20Va and 20Vb and the W-phase winding groups 20Wa and 20Wb are basically the same except that the positions of the passing slots 12 are different. Specifically, the configuration is the same as that of the U-phase winding groups 20Ua and 20Ub.

  Note that the U-phase winding groups 20Ua and 20Ub, the V-phase winding groups 20Va and 20Vb, and the W-phase winding groups 20Wa and 20Wb are adjacent to each other in the radial direction of the stator core 10 on the upper and lower end surfaces of the stator core 10. They are led out from the slot 12 and displaced from the lead-out position to the next slot 12, respectively, and are displaced inward or outward in the radial direction of the stator core 10 so that the lead-out position differs from the lead-out position in the radial direction. It is inserted into the slot 12.

  This point will be specifically described with reference to FIGS. 9B and 11A to 11D. 9B is a schematic cross-sectional view of the winding group along the line IXb-IXb in FIG. 6A as described above, that is, a schematic cross-sectional view of the winding group at a position between the slot U2 and the slot V1. 11A to 11D are cross-sectional schematic views of winding groups along the XIa-XIa line, the XIb-XIb line, the XIc-XIc line, and the XId-XId line in FIG. 6A, respectively. FIG. 4 is a schematic cross-sectional view of a winding group between slots V1 to U3.

  As shown in these drawings, at the position between the slot U2 and the slot V1, as shown in FIG. 9B, the positive winding group 22a and the second U-phase winding group 20Ub of the first U-phase winding group 20Ua are provided. The positive winding group 24a is vertically stacked. Then, the reverse winding group 22b of the first W-phase winding group 20Wa and the reverse winding group 24b of the second W-phase winding group 20Wb are similarly stacked on the inside of the U-phase winding groups 20Ua and 20Ub. Further, the reverse winding group 22b of the first V-phase winding group 20Va and the reverse winding group 24b of the second U-phase winding group 20Vb are similarly stacked on the inner side.

  The reverse winding group 22b of the second V-phase winding group 20Va located at the innermost position at the position of the slot V1 is inserted into the slot V1, while the positive winding of the second V-phase winding group 20Va from the slot V1. By deriving the group 22a, at the position between the slot V1 and the slot V2, as shown in FIG. 11A, the positive winding group 22a of the first V-phase winding group 20Va becomes the U-phase winding group 20Ua. , 20 Ub.

  Next, the reverse winding group 24b of the second V-phase winding group 20Vb located at the innermost position at the position of the slot V2 is inserted into the slot V2, while the positive winding of the second V-phase winding group 20Vb from the slot V2 is inserted. When the winding group 24a is derived, the positive winding group 24a of the second V-phase winding group 20Vb becomes U-phase winding at the position between the slot V2 and the slot W1 as shown in FIG. 11B. On the outside of the groups 20Ua and 20Ub, the second V-phase winding group 20Va is overlaid on the lower side of the positive winding group 22a.

  Then, the reverse winding group 22b of the innermost second W-phase winding group 20Wa is inserted into the slot W1 at the position of the slot W1, while the positive winding of the second W-phase winding group 20Wa is inserted from the slot W1. When the winding group 22a is derived, at the position between the slot W1 and the slot W2, as shown in FIG. 11C, the positive winding group 22a of the second W-phase winding group 20Wa becomes the V-phase winding. Superposed on the outside of the groups 20Va, 20Vb.

  Then, the reverse winding group 24b of the second W-phase winding group 20Wb located at the innermost position at the position of the slot W2 is inserted into the slot W2, while the positive winding of the second W-phase winding group 20Wb from the slot W2 is inserted. Since the winding group 24a is derived, the positive winding group 24a of the second W-phase winding group 20Wb becomes a V-phase winding at a position between the slot W2 and the slot U3 as shown in FIG. On the outside of the groups 20Va and 20Vb, they are superimposed on the lower side of the positive winding group 22a of the second W-phase winding group 20Wa.

  In this way, the U-phase winding groups 20Ua and 20Ub, the V-phase winding groups 20Va and 20Vb, and the W-phase winding groups 20Wa and 20Wb are arranged adjacent to each other in the radial direction of the stator core 10, and are respectively formed from the slots 12. The winding groups 20Ua, 20Ub, 20Va, 20Vb, 20Wa, and 20Wb are inserted into the slot 12 while being displaced radially inward of the stator core 10 from the lead-out position toward the next slot 12. Are guided in the next slot 12 while maintaining a compact arrangement without crossing each other.

  The configuration of the first coil member 14A has been described above, but the configuration of the second coil member 14B is also equivalent to the first coil member 14A. 3 and 4B, the second U-phase winding group 20Ua of the second coil member 14B has a diameter of the stator core 10 with respect to the first U-phase winding group 20Ua of the first coil member 14A. The second U-phase winding group 20Ub of the second coil member 14B is inserted into the same slot 12 as the first U-phase winding group 20Ua so as to be aligned in a line in the direction, and the second U-phase winding of the first coil member 14A They are arranged in the same slot 12 as the second U-phase winding group 20Ub so as to be aligned in a row in the radial direction with respect to the group 20Ub. The same applies to the V-phase winding groups 20Va and 20Vb and the W-phase winding groups 20Wa and 20Wb of the second coil member 14B.

  According to the stator S as described above, the windings r1 to r3, r1 'to r3'r4 to r6, and r4' to r6 'of the winding groups 20Ua, 20Ub, 20Va, 20Vb, 20Wa, and 20Wb are pentagonal cross sections. Formed by a base type wire 1, windings r1 to r3, r1 'to r3' (windings r4 to r6, r4 'to r6') are inserted into the slot 12 with the hypotenuses 2c in contact with each other Has been. According to such a configuration, as shown in FIG. 4B, adjacent windings are inserted into the slot 12 in a state where they overlap each other in the radial direction of the stator core 10, so that the cross-sectional area is larger. The windings (thick windings) can be closely arranged in the slot 12 in an aligned state. Therefore, it is possible to effectively increase the linear space factor of the stator S (the ratio of the cross-sectional area of the winding to the cross-sectional area of the slot).

  The stator S described above can be manufactured according to a method as shown in FIG. 12, for example. That is, the winding assembly 30 having the same shape as the coil member 14A wound around the stator core 10 (winding groups 20Ua, 20Ub, 20Va, 20Vb, 20Wa, 20Wb) is formed independently (winding assembly formation). Step) In a state where the entire winding assembly 30 is compressed and deformed in the radial direction, the winding assembly 30 is inserted into the stator core 10 as shown in FIGS. 1A and 1B (winding assembly inserting step). Thereafter, the winding assembly 30 inserted inside the stator core 10 is expanded in diameter, and each winding group 20Ua, 20Ub, 20Va, 20Vb, 20Wa, 20Wb is inserted into a predetermined slot 12 from the inside of the stator core 10. Thus, the winding assembly 30 is mounted on the stator core 10 (winding assembly mounting step). And the stator S provided with two coil members 14A and 14B as shown in FIG. 2 is manufactured by repeating the said process.

  According to such a method, the stator S is manufactured more efficiently than when the winding groups 20Ua, 20Ub, 20Va, 20Vb, 20Wa, and 20Wb are formed while winding the wire 1 around the stator core 10. It becomes possible. In this case, in the winding insertion step, as shown in FIGS. 13A and 13B, by reducing only one axial end of the winding assembly 30 in the radial direction, The entire winding assembly 30 may be compressed and deformed into a substantially truncated cone shape, and the winding assembly 30 may be inserted into the stator core 10 from the reduced diameter side. According to such a method, the diameter of the winding group can be easily increased in the winding mounting process, so that the stator can be manufactured more efficiently.

  12 and 13, the stator S including the two coil members 14A and 14B is manufactured by repeating the above process. For example, in the winding forming process, the two coil members 14A and 14B are included in advance. Such a winding assembly 30 may be formed and inserted into the stator core 10.

  In addition, the winding assembly 30 (coil member 14A) is composed of the U-phase, V-phase, and W-phase winding groups 20Ua, 20Ub, 20Va, 20Vb, 20Wa, and 20Wb. 22a, 22b, 24a, 24b are individually formed, and these winding groups 22a, 22b, 24a, 24b are manufactured by being joined in a predetermined order.

  Hereinafter, a manufacturing method (winding manufacturing method) of these winding groups 22a, 22a, 24a, and 24b constituting the winding assembly 30 and a winding manufacturing apparatus 40 used in the manufacturing method will be described. In the following description, a case will be described in which the positive winding group 22a (the winding group composed of the windings r1 to r3) constituting the first U-phase winding group 20Ua is manufactured.

  A winding manufacturing apparatus 40 that manufactures the positive winding group 22a schematically includes a press machine 41 shown in FIG. 14 and a forming machine 42 shown in FIG.

  As shown in FIGS. 19 and 20, the press machine 41 is offset above the main line portion P <b> 1 and the main line portion P <b> 1 extending in the longitudinal direction of the element wire 1 by pressing the element wire 1. A first subline portion P2a extending in the longitudinal direction at a position, and a second subline portion P2b extending in the longitudinal direction at a position offset below the main line portion P1, and the first subline portion P2a, A spiral initial linear body r in which the second sub-line portion P2b is alternately arranged in the circumferential direction with the main line portion P1 interposed therebetween is formed. 19 and 20, the initial linear body r is shown in an unfolded state.

  Here, the main line portion P1 is a portion corresponding to the in-slot passage portion 17 (see FIG. 5A) passing through the slot 12 of the stator core 10 among the windings r1 to r3 of the positive winding group 22a. The first subline portion P2a is a portion corresponding to the crossover portion 18a (referred to as the first crossover portion 18a / see FIG. 5A) passing through the upper end surface of the stator core 10, and the second subline portion The portion P2b is a portion corresponding to the transition portion 18b (referred to as the second transition portion 18b / see FIG. 5A) that passes on the lower end surface of the stator core 10. The first transition part 18a and the second transition part 18b are collectively referred to as a transition part 18.

  As shown in FIGS. 14 to 18, the press machine 41 includes a lower mold 44 (corresponding to the first mold of the present invention) having a spiral shaped groove 50 and an upper portion arranged along the shaped groove 50. A mold 43 composed of a mold 45 (corresponding to the second mold of the present invention), a driving device for opening and closing the mold 43, and an element wire 1 (initial linear body r) formed by the mold 43 A lift device 57 for taking out the press, and a press control device for controlling the drive device and the lift device 57.

  The lower mold 44 is provided with an insertion portion 44 a for inserting the wire 1 into the molding groove 50 from the outer side of the spiral of the molding groove 50, that is, from the outer peripheral side, and is inserted into the molding groove 50. A clamp mechanism 48 for holding the end of the strand 1 is provided. The clamp mechanism 48 is provided at a position adjacent to the insertion portion 44a.

  As shown in FIG. 17, in the forming groove 50 of the lower mold 44, a horizontal portion 51 for forming the main line portion P1 extending horizontally in the longitudinal direction of the strand 1 and the longitudinal direction while slightly inflating upward. A convex portion 52a for forming the first subline portion P2a that extends and a concave portion 52b for forming the second subline portion P2b that bulges slightly downward and extends in the longitudinal direction are in a predetermined arrangement, that is, The convex portions 52a and the concave portions 52b are repeatedly provided so as to be alternately arranged in the circumferential direction with the horizontal portion 51 interposed therebetween.

  The upper mold 45 is composed of a plurality of divided molds arranged along the molding groove 50 of the lower mold 44. Specifically, a plurality of convex molds 54 respectively provided at positions corresponding to the concave portions 52b of the lower mold 44 and having a shape corresponding to the concave portions 52b, and positions corresponding to the convex portions 52a of the lower mold 44. Each of the plurality of concave molds 55 is provided and has a shape corresponding to the convex section 52a. Each convex mold 54 is constituted by a pair of unit molds 54a and 54b arranged in the longitudinal direction of the molding groove 50, and each concave mold 55 is similarly constituted by a pair of unit molds 55a and 55b arranged in the longitudinal direction. Has been.

  The upper mold 45 is a movable mold. The molds 54 and 55 constituting the upper mold 45 are connected to the driving device (not shown) via a rod 56 for each unit mold. The drive device is configured to open and close the mold 43 by moving the upper mold 45 up and down using an actuator such as a hydraulic cylinder as a drive source.

  As shown in FIG. 15, the lift device 57 includes a plurality of lift pins 58 (not shown in FIG. 17) that are arranged so as to be able to protrude and retract on the inner bottom portion of the forming groove 50, and hydraulic cylinders that lift and lower the lift pins 58. And an external actuator. The lift pins 58 are arranged at predetermined intervals along the forming groove 50, and the actuator raises and lowers the lift pins 58 integrally.

  Processing of the strand 1 (initial linear body r) by the press machine 41 is performed as follows. First, the wire 1 is inserted into the molding groove 50 from the insertion portion 44a of the lower mold 44 in a state where the mold 43 is opened. This insertion is performed manually by an operator or automatically by a feeding device.

  As shown in FIGS. 8 and 10, since the winding r1 constituting the positive winding group 22a is twisted by 180 ° at the entrance and exit of the slot 12, the part corresponding to the winding r1 is not described. The strand 1 is inserted into the forming groove 50 in a state where the first and second sub-wire portions P2a and P2b are twisted 180 ° in advance. Such a twisting operation of the wire 1 is performed in advance by a forming apparatus or the like (not shown).

  When the strand 1 is inserted into the forming groove 50, the end portion on the outer peripheral side of the strand 1 is clamped by the clamp mechanism 48, whereby the setting of the strand 1 to the lower mold 44 is completed. In this state, the strands 1 are spirally arranged along the forming groove 50, and a predetermined gap is formed between the center side end portion (tip portion) and the end portion of the forming groove 50. .

  When the strand 1 is set on the lower die 44, the die 43 is closed by driving the upper die 45 by the driving device, whereby the strand 1 is pressed. At this time, among the convex mold 54 and the concave mold 55 constituting the upper mold 45, the convex mold is sequentially shifted from the one close to the outer peripheral end of the molding groove 50, that is, the one close to the insertion portion 44a. 54 and the concave mold 55 are driven. Thereby, the strand 1 will be press-processed in order from the one end side (insertion part 44a side).

  By pressing the strand 1 in this way, the spiral-shaped initial linear body r in which the first sub-line portion P2a and the second sub-line portion P2b are alternately arranged in the circumferential direction across the main line portion P1. (See FIGS. 19 and 20). In forming the initial linear body r, as described above, the first and second sub-line portions P2a and P2b are vertically offset with respect to the main line portion P1, so that both ends of the main line portion P1 are formed. As shown in FIG. 20, a vertical portion a (corresponding to a gripping portion of the present invention) extending in the vertical direction is formed.

  When the initial linear body r is formed by the press machine 41, the mold 43 is opened by driving the upper mold 45 by the driving device, and the lift device 57 is operated to raise the lift pins 58. The initial linear body r is lifted from the forming groove 50. Thereby, the initial linear body r is removed from the press machine 41. The removal of the initial linear body r from the press machine 41 may be performed manually by an operator or automatically performed by a take-out device.

  As will be described later, the initial linear body r formed in a spiral shape is once pulled out from the end on the outer peripheral side and wound while being subjected to forming processing, thereby forming the positive winding group 22a. Therefore, with respect to the mold 43, the molds corresponding to the winding r3, the winding r2, and the winding r1 are arranged in order from the outer peripheral end along the spiral of the forming groove 50. That is, among the windings r <b> 1 to r <b> 3 constituting the positive winding group 22 a, the winding located on the inner peripheral side of the stator core 10 is disposed at a position closer to the end portion on the outer peripheral side of the forming groove 50.

  Next, the forming machine 42 will be described.

  The forming machine 42 bends the main line portion P1 with respect to the first and second sub-line portions P2a and p2b while pulling out the spiral initial line-shaped body r from the outer peripheral end thereof. The shape r is deformed into a rectangular wave shape and further wound into a cylindrical shape to form the positive winding group 22a. FIG. 25 schematically shows a state in which the positive winding group 22a formed in this way is developed. In FIG. 25, for the sake of convenience, the connecting portions 18 (18a, 18b) are formed with equal lengths. It is shown. U1 to U16 in the figure indicate the positions of the slots 12 into which the in-slot passage portions 17 are inserted.

  As shown in FIG. 21, the forming machine 42 includes a base 60, a feeding table 62 and a take-up table 64 supported on the upper surface thereof, a table driving device that drives these tables 62, 64, and these tables 62. , 64, a pair of feed rollers 68 disposed on both sides of the processing machine main body 66, and a forming control device for controlling the table driving device and the processing machine main body 66. Yes.

  The feeding table 62 holds the initial linear body r. This feeding table 62 is a turntable in which a cylindrical columnar holding portion 62b having a smaller diameter is integrally provided on the upper surface of a disk-shaped table main body 62a, and the initial linear body r is attached to the outer periphery of the holding portion 62b. It is configured to be supported by the table body 62a in a state of being disposed on the surface.

  The winding table 64 is for winding the initial linear body r after being processed by the processing machine main body 66. The take-up table 64 is also a turntable integrally provided with a cylindrical take-up portion 64b having a smaller diameter on the upper surface of a disk-like table main body 64a, and an initial linear body after being processed by the processing machine main body 66. r is wound on the outer peripheral surface of the winding portion 64b.

  As shown in FIG. 22A, the processing machine main body 66 includes a base portion 70 and a ceiling portion 74 that form a space through which the initial linear body r passes, and a pair of lower arms 72 disposed on the base portion 70. And a pair of upper arms 76 arranged on the ceiling portion 74.

  Each lower arm 72 is arranged in a standing state on the base portion 70. Each of the lower arms 72 extends in the left-right direction (for example, a position shown in FIG. 22B) and a left-right direction (for example, a position shown in FIG. 22A) spaced from each other. In FIG. 22, it is provided so as to be movable in conjunction with the left / right direction / direction parallel to the feeding direction of the initial linear body r), and the operating position close to the initial linear body r and the retreat retracted backward from this position. It is configured to be integrally movable in the front-rear direction (in FIG. 22, the direction orthogonal to the paper surface / the direction orthogonal to the feeding direction of the initial linear body r).

  Each lower arm 72 is driven in each direction by, for example, a screw feed mechanism using a servo motor as a drive source, and the interval between the lower arms 72 when approaching and the interval between the lower arms 72 when separated are the servos. It can be adjusted by driving the motor. Each lower arm 72 is provided with an air (air cylinder) driven chuck 73 for gripping the initial linear body r at the tip (upper end) thereof.

  Each upper arm 76 is provided so as to hang from the ceiling 74. Each upper arm 76 extends from a lowered position (position shown in FIG. 22 (a)) close to the base portion 70 to an elevated position (position shown in FIG. 22 (b)) close to the ceiling portion 74 from this position. And can be moved integrally in the front-rear direction over an operating position close to the initial linear body r and a retracted position retracted backward from this position. Further, the upper arms 76 are provided such that their intervals (intervals in the left-right direction) can be changed. Each upper arm 76 is driven in each direction by, for example, a screw feed mechanism using a servo motor as a drive source, and the interval between the upper arms 76 can be adjusted by driving the servo motor. Each upper arm 76 is provided with an air (air cylinder) driven chuck 77 for gripping the initial linear body r at the tip (lower end) thereof.

  Each pair of feed rollers 68 is configured to be switchable between a state of a drive rotor that applies a conveying force to the initial linear body r and a state of a driven roller that simply guides the initial linear body r. For example, the operation state can be switched by the above.

  The forming process of the initial linear body r (positive winding group 22a) by the forming machine 42 is performed as follows.

  First, the initial linear body r removed from the press machine 41 is set on the feeding table 62. Specifically, the initial linear body r is placed on the table main body 62a in a state where it is disposed on the outer peripheral surface of the holding portion 62b. In this state, the tip of the initial linear body r, that is, the outer peripheral end is pulled out and inserted into the processing machine main body 66 via the feed roller pair 68. At this time, the main line portion P1 at the tip of the initial linear body r is inserted into the processing machine main body 66 in a state of being bent perpendicularly to the second sub-line portion P2b, for example (see FIG. 22A). ). When the initial linear body r is set on the forming machine 42, the arms 72 and 76 are set at the initial positions. Specifically, each lower arm 72 is disposed at a separated position and at a retracted position, and each upper arm 76 is disposed at a lowered position and at a retracted position.

  When the setting of the initial linear body r to the forming machine 42 is completed, the forming process of the initial linear body r is started. First, the initial linear body r is sent out by driving the feed roller pair 68, and the first sub-line portion P2a is arranged at a position corresponding to both the upper arms 76 as shown in FIG. At this time, the upper arms 76 correspond to both ends of the first subline portion P2a, in other words, the vertical portions a (first subline portions) of the main line portion P1 located on both sides of the first subline portion P2a. The interval is adjusted in advance so as to correspond to the vertical part a) on the side close to P2a. On the other hand, the distance between the lower arms 72 is adjusted in advance so as to correspond to the vertical portion a on the side close to the second sub-line portion P2a in the main line portion P1.

  When the first sub-line portion P2a is disposed at a position corresponding to the upper arms 76, the arms 72 and 76 move from the retracted position to the operating position, and the initial linear body r is gripped by the chucks 73 and 77. The Specifically, the vertical portion a is gripped by the chucks 73 and 77 (see FIG. 22a).

  Thereafter, each upper arm 76 moves from the lowered position to the raised position, and in synchronization with this, each lower arm 72 moves from the separated position to the approach position. Thus, when the arms 72 and 76 move, as shown in FIG. 22 (b), the second sub-line portions P2b on both sides of the first sub-line portion P2a are drawn inwardly, and thereby, The main line portions P1 located on both sides of the first sub-line portion P2a are bent at both ends so as to extend straight in the vertical direction. At this time, the feed roller pair 68 is switched to the driven roller state, whereby the initial linear body r is allowed to be displaced as the arms 72 and 76 move.

  When the main line portion P1 on both sides of the first sub-line portion P2a is bent in this way, the chucks 73 and 77 are opened and the arms 72 and 76 are opened as shown in FIGS. Are reset to the initial positions, the feed roller pair 68 is switched from the driven roller state to the drive roller state, and the feed roller pair 68 is driven to feed the initial linear body r by a fixed amount. That is, the initial linear body r is sent out so that the next first sub-line portion P <b> 2 a is disposed at a position corresponding to both the upper arms 76.

  As described above, when the arms 73 and 76 are operated (see FIG. 22), the main line portion P1 on both sides of the first sub-line portion P2a is bent so as to extend straight in the vertical direction. Thus, after that, while the initial linear body r is sent out by a certain amount, a set of the first sub-line portion P2a and the main line portion P1 located on both sides of the first sub-line portion P2a (the region indicated by symbol E in FIG. 19) As shown, each main line portion P1 is bent.

  On the other hand, in synchronism with the feeding operation of the initial linear body r accompanying the forming process, the winding table 64 is rotationally driven by a rotation angle corresponding to the feeding amount. That is, the initial linear body r is sequentially wound around the winding table 64 while being deformed into a rectangular wave shape as shown in FIG. Finally, the initial linear body r is wound in triplicate so that the main line portion P1, the first sub-line portion P2a, and the second sub-line portion P2b respectively pass through the in-slot passage portion 17 and the first crossover portion. A positive winding group 22a in which 18a and the second crossing portion 18b are formed is formed.

  The configuration of the winding manufacturing apparatus 40 has been described above. The manufacturing method (winding manufacturing method) of the positive winding group 22a using the winding manufacturing apparatus 40 is summarized as follows.

  That is, in the winding manufacturing method, the strands 1 are arranged in a spiral shape, and the strands 1 are pressed by the mold 43, whereby the main line portion P1 extending in the longitudinal direction of the strands 1 and the main line portion A first sub-line portion P2a and a second sub-line portion, each of which includes a first sub-line portion P2a and a second sub-line portion P2b extending in the longitudinal direction at positions offset in the opposite vertical direction with respect to P1; A step (molding step) of forming a spiral initial linear body r in which P2b is alternately arranged in the circumferential direction with the main line portion P1 interposed therebetween, and the main line portion while pulling out the initial linear body r from the outer peripheral end By bending P1 with respect to the first and second sub-line portions P2a and p2b, the step of forming the initial linear body r into a rectangular wave shape (forming process), and the initial linear shape deformed into a rectangular wave shape By winding the body r into a cylindrical shape A step of forming a positive winding group 22a in which the in-slot passage portion 17, the first crossover portion 18a, and the second crossover portion 18b are formed by the main line portion P1, the first subline portion P2a, and the second subline portion P2b, respectively. (Winding step).

  Here, the method of manufacturing the forward winding group 22a of the first U-phase winding group 20Ua has been described, but the same applies to the winding groups 24a and 24b of the reverse winding group 22b and the second U-phase winding group 20Ub. It can manufacture with the manufacturing method of. The same applies to the winding groups 22a, 22b, 24a, and 24b of the V-phase winding groups 20Va and 20Vb and the W-phase winding groups 20Wa and 20Wb. In that case, the four winding groups 22a, 22b, 24a, and 24b belonging to the same phase are different from each other in the unfolded shape (the dimensions of the sub-line portions P2a and P2b), and thus each winding group 22a, 22b, and 24a. , 24b must be pressed using different molds 43.

  However, with respect to the forming process, the initial linear body r can be processed using the common forming machine 42 by adjusting the interval between the lower arms 72 and the interval between the upper arms 76 of the processing machine body 66. It becomes possible.

  Further, the winding groups 22a, 22b, 24a, 24b of the U-phase winding groups 20Ua, 20Ub and the winding groups 22a, 22b, 24a, 24b of the V-phase winding groups 20Va, 20Vb respectively corresponding thereto are the same. Similarly, the winding groups 22a, 22b, 24a, 24b of the U-phase winding groups 20Ua, 20Ub and the corresponding winding groups 22a, 22b, 24a of the W-phase winding groups 20Wa, 20Wb, respectively. 24b have the same shape. Therefore, the winding groups 22a, 22b, 24a and 24b of the V-phase winding group 20Va and 20Vb and the W-phase winding group 20Wa and 20Wb are respectively combined with the winding groups 22a, 22b and 24a of the U-phase winding group 20Va and 20Vb. It can be manufactured using the above-described winding manufacturing apparatus 40 for manufacturing 24b.

  According to the manufacturing method of the winding group 22a (22b, 24a, 24b) as described above, the positive winding group 22a including the three windings r1 to r3 can be manufactured without joining work such as welding. Is possible. Therefore, compared with the conventional manufacturing method of this kind of winding group (manufacturing method described in patent document 1) which needs to join wires for every turn, the time required for manufacturing the winding group 22a Therefore, the winding group 22a can be efficiently manufactured. Moreover, according to this manufacturing method, after the strands 1 are arranged in a spiral shape and a spiral initial linear body r is formed by pressing, the initial linear body r is drawn out from the outer peripheral end, and is rectangular. Since the winding group 22a is manufactured by winding while processing into a wave shape, the winding group 22a can be manufactured in a relatively small space.

  Therefore, according to said manufacturing method, there exists an advantage that the coil group 22a can be manufactured in a comparatively little space, without accompanying the joining operation | work of strands by welding etc. FIG.

  Further, according to the manufacturing method described above, when the wire 1 is processed by the press machine 41, the mold 43 is sequentially closed from the outer peripheral end of the forming groove 50, as described above, so Since the strands 1 arranged in a shape are sequentially pressed in a certain range from the outer peripheral end portion to the inner peripheral end portion, loosening and pulling of the strands 1 during pressing are reduced. be able to. Therefore, there is an advantage that deformation of the initial linear body r due to the loosening or pulling, damage to the insulating coating of the strand 1 and the like can be effectively prevented.

  Further, according to the above manufacturing method, when the initial linear body r is processed by the forming machine 42 (processing machine body 66), the main line portions P1 located on both sides of the first sub-line portion P2a are taken as a set. Since the set of main line portions P1 is bent at the same time, the initial linear body r can be efficiently transformed into a rectangular wave shape. In particular, in the manufacturing method, the end on the first sub-line part P2a side of each main line part P1 is gripped by the upper arm 76, and the end of the second sub-line part P2b in each main line part P1 is held. In this state, the main arm P1 is bent by bringing the lower arms 72 closer to each other while the upper arms 76 are lifted in a state of keeping the distance therebetween. As described above, according to the method of bending each main line portion P1 with a symmetrical arm operation around the one sub-line portion P2a, the main line portion P1 can be efficiently bent without complicated arm operation. There is also.

  In addition, since the vertical portions a extending in the vertical direction are formed at both ends of the main line portion P1 at the time of pressing the strand 1, the vertical portions a are gripped by the lower arms 72 and 76, respectively. According to the above manufacturing method, there is also an advantage that the main line portion P1 processed by the forming machine 42 can be formed straight in the vertical direction.

  By the way, the winding group 22a (22b, 24a, 24b) manufacturing method and the winding manufacturing apparatus 40 described above are examples of preferred embodiments of the winding group manufacturing method and the winding group manufacturing apparatus according to the present invention. However, specific methods and configurations thereof can be appropriately changed without departing from the gist of the present invention.

  For example, as described above, the four winding groups 22a, 22b, 24a, and 24b belonging to the same phase are different from each other in the unfolded shape (the dimensions of the sub-line portions P2a and P2b). When manufacturing 22b, 24a, and 24b, it is necessary to press the strand 1 using the mutually different metal mold | dies 43, In that case, you may apply the following structures. In other words, the lower die 44 is a base die and an exchangeable die that can be attached to and detached from the base die (exchanging die of the convex portion 52a and the concave portion 52b), and a plurality of types corresponding to the winding groups 22a, 22b, 24a, and 24b. And a predetermined exchange mold selected from the plurality of types of exchange molds can be fixed to the base mold. Further, the upper mold 45 is configured such that the interval between the unit molds 54a and 54b of the convex molds 54 can be adjusted according to the counterpart, that is, the exchange mold. The concave mold 55 is configured similarly. According to such a configuration, the upper die 45 can be made common when manufacturing the winding groups 22a, 22b, 24a, and 24b. Therefore, it is possible to reduce the manufacturing cost of the press machine 41 and, consequently, the manufacturing cost of the winding manufacturing apparatus 40.

  Although not mentioned in the above embodiment, the four winding groups 22a, 22b, 24a, 24b belonging to the same phase of the same coil member 14A (or coil member 14B) constituting the stator S are respectively The shapes of the developed state (the dimensions of the sub-line portions P2a and P2b) are different from each other, but in the case of a cylindrical shape, the positive winding group 22a and the second winding group of the first winding group belonging to the same phase The reverse winding group 24b has substantially the same shape, and the reverse winding group 22b of the first winding group and the positive winding group 24a of the second winding group that belong to the same phase have substantially the same shape. Therefore, among the four winding groups 22a, 22b, 24a, and 24b belonging to the same phase of the same coil member 14A (or coil member 14B), the positive winding group 22a and the second winding group of the first winding group. The reverse winding group 24b is composed of a common winding group, and similarly, the reverse winding group 22b of the first winding group and the positive winding group 24a of the second winding group are composed of a common winding group. You may make it do.

DESCRIPTION OF SYMBOLS 1 Strand 10 Stator core 12 Slot 14A 1st coil member 14B 2nd coil member 17 Passing part in a slot 18a 1st transition part 18b 2nd transition part 20Ua 1st U-phase winding group 20Ub 2nd U-phase winding group 20Va 1st V phase Winding group 20 Vb Second V-phase winding group 20 Wa First W-phase winding group 20 Wb Second W-phase winding group 22 a, 24 a Positive winding group 22 b, 24 b Reverse winding group 40 Winding group manufacturing apparatus 41 Press machine 42 Forming machine 43 Mold 44 Lower mold (1st mold)
45 Upper mold (2nd mold)
50 Forming groove 62 Feeding table 64 Winding table 66 Machine body r Initial linear body r1 to r3, r1 'to r3' Winding r4 to r6, r4 'to r6' Winding P1 Main line part P2a First sub line part P2b Second sub-line part

Claims (11)

A first winding section and the other side, which are cylindrical winding groups that are assembled to a stator core that has a plurality of slots that are open inward, and that are arranged at regular intervals in the circumferential direction, and that pass over the end face on one side of the stator core A second bridging portion that passes over the end face of each of the windings is alternately arranged in a circumferential direction through an in-slot passage portion that passes through the slot,
By arranging the strands in a spiral shape and pressing the strands with a die, a main line portion extending in the longitudinal direction of the strands and a direction parallel to the center line of the spiral and with respect to the main line portion Each of the first subline portion and the second subline portion extending in the longitudinal direction at positions offset in opposite directions, and the first subline portion and the second subline portion sandwich the main line portion. A molding process for molding spiral initial linear bodies arranged alternately in the circumferential direction;
Forming a step of deforming the initial linear body into a rectangular wave shape by bending the main line portion with respect to the first and second sub-line portions while pulling out the initial linear body from an outer peripheral end thereof. A method of manufacturing a winding. In the winding manufacturing method according to claim 1,
By winding the initial linear body after the forming process into a cylindrical shape, the main line portion, the first sub-line portion, and the second sub-line portion respectively pass through the in-slot passing portion and the first crossing portion. And a winding manufacturing method further comprising a winding step of forming the winding group in which the second transition portion is formed. In the winding manufacturing method according to claim 1 or 2,
In the forming process, the main line portions located on both sides of the first sub-line portion are set as one set so that the main line portion extends in a direction orthogonal to the longitudinal direction of the initial linear body. Winding manufacturing method characterized by bending part simultaneously. In the winding manufacturing method according to claim 3,
A set of the first sub-line part and the main line part located on both sides of the first sub-line part, and gripping a first end which is an end part on the first sub-line part side among the main line parts, and each main line Gripping the second end portion, which is the end portion on the second sub-line portion side, and moving each first end portion integrally in the orthogonal direction while maintaining their spacing, A winding manufacturing method, wherein the main line portion is bent with respect to the first and second sub-line portions by moving the second end portion in a direction approaching each other along the longitudinal direction. In the winding manufacturing method according to claim 4,
In the molding step, a gripping portion extending in the orthogonal direction is formed at both ends of the main line portion, and the gripping portion is gripped in the forming process step. In the winding manufacturing method according to any one of claims 1 to 5,
In the molding step, the winding manufacturing method is characterized in that press working is sequentially performed in a certain range from one end of the strands arranged in a spiral shape to the other end. In the winding manufacturing method according to any one of claims 1 to 6,
The winding group is obtained by twisting a part of the winding included in the winding group,
In the forming step, the wire manufacturing method is characterized in that the wire in which a portion corresponding to the part is twisted is pressed. An apparatus used in the molding process according to any one of claims 1 to 7,
A mold having a first mold having a spiral shaped groove into which the element wire is inserted and a second mold disposed along the molding groove, and the first mold and the second mold are relatively A winding manufacturing apparatus comprising: a driving device that opens and closes the mold by moving the metal mold to a position. In the winding manufacturing apparatus according to claim 8,
One of the first mold and the second mold is a movable mold and is composed of a plurality of divided molds arranged in the longitudinal direction of the molding groove,
The drive device sequentially closes the mold from the end on the one side by moving the plurality of divided molds sequentially from the one near the end on the one side of the forming groove. A winding production apparatus. In the winding manufacturing apparatus according to claim 9,
In the mold, the first mold is a fixed mold, and the second mold is a movable mold.
The first mold includes a base mold and a plurality of types of interchangeable molds for forming the first and second sub-linear portions, the interchangeable mold being detachable from the base mold. A predetermined exchange mold selected from the exchange molds is fixed to the base mold,
Each of the divided molds is a pair of unit molds that can be arranged in the longitudinal direction of the molding groove and can change the interval, and each has a shape corresponding to the replacement mold of the first mold. Winding production equipment. An apparatus used for the forming process and the winding process according to any one of claims 2 to 7,
A feed-out table that holds the initial linear body so that it can be pulled out, and a forming process for bending the main line portion with respect to the first and second sub-line portions while pulling out the initial linear body from its outer peripheral end. A winding manufacturing apparatus comprising: a processing machine main body; and a winding table for winding the initial linear body subjected to the forming process.

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