JP2020195225A - Motor coil winding device and motor coil winding method - Google Patents

Abstract

To efficiently wind a motor coil of a motor with a split core structure in a short time to improve a space factor.SOLUTION: A coil winding device 1 that winds a wire 6 around a split core 2 includes a jig 4 provided with a basket portion 11 for rotatably accommodating and holding the split core 2, a spindle 5 that abuts and rotates the split core 2, and a nozzle 7 that feeds the wire 6. The basket portion 11 includes first and second basket portions 11a and 11b that can be folded in half by a hinge 12, and the spindle 5 is provided in contact with the split cores 2a and 2b housed in the first and second basket portions 11a and 11b folded in an overlapping manner. While the split core 2 is rotated by the spindle 5, the nozzle 7 is moved to wind the 6 wires around the split core 2.SELECTED DRAWING: Figure 1

Description

The present invention relates to a motor coil winding technique, and more particularly to a motor coil winding device / winding method that is effective when applied to a stator coil winding process in a brushless motor having a split core structure.

Conventionally, a brushless motor having a split core structure in which a stator core is split and formed for each tooth has been known in response to a demand for miniaturization and high performance of the motor. FIG. 8 is an explanatory view showing a stator structure of a brushless motor having a split core structure. As shown in FIG. 8, in a motor having a divided core structure, a coil 52 is wound around each of the divided stator cores (hereinafter referred to as divided cores) 51, and the divided cores 51 are assembled in an annular shape after the winding is completed. To form the stator 53. Such a split core structure saves nozzle space and enables winding with a high space factor. Therefore, in recent years, it is often used in in-vehicle motors that require miniaturization and high performance, such as motors for electric oil pumps of automobiles. It has been adopted.

On the other hand, in a motor having a split core structure, power is often supplied to each phase coil by an annular metal plate called a bus bar. In this case, the bus bar is composed of a plurality of plates common to each phase, and each coil 52 is connected to a plate common to the corresponding phase of the coil. At that time, the ends of the coils (the parts at the start and end of winding) 52a and 52b are welded to the bus bar plate, but by connecting the coils of the same phase with a crossover, the number of welded points with the bus bar can be reduced. Is also widely practiced. In particular, in a small motor, if each phase coil is individually wound and individually connected to the bus bar, welding work is difficult and inefficient, so it is like drawing an in-phase coil with a crossover wire. A method of winding the coil integrally with the wire is often used.

Japanese Unexamined Patent Publication No. 2008-187807

However, when the in-phase coil is integrally wound, the split core 51 is fixed side by side to the jig 54 and the nozzle 55 is moved to wind the coil 52 as shown in FIG. 9A in order to process the crossover. The winding is done in the form of wearing. Therefore, in order to wind the coil 52, as shown in FIG. 3B, the nozzle 55 is moved in four directions (X and Y directions) up, down, left and right for each turn, and the teeth thickness direction (Z direction). : See also (a) in the figure), there is a problem that the operating distance of the nozzle 55 is long and the manufacturing time is long. In addition, although the split core structure is one of the features of high space factor, in the winding method using the nozzle 55, it is not possible to wind while pressing the coil, so it is difficult to perform aligned winding, and high space capacity is achieved. There was also the problem that it was difficult to rate.

An object of the present invention is to provide a motor coil winding device / winding method capable of efficiently winding a motor coil in a motor having a split core structure in a short time and improving the space factor.

The coil winding device of the present invention is a coil winding device that winds a wire around the divided core used in a motor having a stator in which a plurality of divided cores are arranged in an annular shape, and rotates the divided core. A jig provided with a cage portion that can be freely accommodated and held, a rotary drive shaft that abuts on the split core accommodated in the cage portion and rotates the split core, and a nozzle that feeds out the wire rod, The jig has a first car part and a second car part as the car part, and the first and second car parts can be folded in an overlapping manner between the first car part and the second car part. The split core is housed in the first and second car portions folded so as to be overlapped with each other, and the rotation drive shaft is housed in the first and second car portions, respectively. It is attached in a state of being in contact with the core, and is characterized in that the wire rod is wound around the divided core by moving the nozzle while rotating both the divided cores around the rotation drive shaft.

In the present invention, two split cores are housed in a jig that can be folded in half, a rotation drive shaft is attached to the jig folded in layers, and the two split cores are rotated by one rotation drive shaft. Perform winding. In the apparatus of the present invention, when winding, the nozzles need only move in the left-right direction, and the nozzle movement distance is shorter and the winding speed is faster than in the conventional apparatus. Therefore, the time required for coil formation can be shortened, and the manufacturing man-hours can be reduced.

In the coil winding device, the jig may be provided with a guide member for guiding the wire rod, and the installation position of the guide member may be changed according to the specifications of the motor. Thereby, by changing the installation position of the guide member, the length of the crossover wire connecting the coils wound around the divided cores in the first and second car portions can be adjusted. In addition, the guide member allows the wire to be wound around the split core while applying tension, and a high space factor of the winding can be achieved.

Further, a core holding member may be rotatably provided in the car portion of the jig, and the divided core may be held by the core holding member by uneven fitting.

Further, the motor may be a brushless motor having an even number of the divided cores. In this case, the motor may be a brushless motor having a configuration of 4 poles and 6 slots or an integral multiple thereof, or 10 poles and 12 slots thereof. A brushless motor having an integral multiple configuration may be used.

On the other hand, the coil winding method of the present invention is a coil winding method in which a wire rod is fed out from a nozzle and wound around the divided core used in a motor having a stator in which a plurality of divided cores are arranged in an annular shape. It has a first car portion and a second car portion for rotatably accommodating and holding the divided core, and the first and second car portions are overlapped between the first car portion and the second car portion. The split core is housed in each of the first car portion and the second car portion with respect to the jig provided with the connecting member that can be folded into the above, and the first and second car portions are centered on the connecting member. The rotation drive shafts are brought into contact with the respective division cores in the first and second cages folded in an overlapping manner, and the two division cores are rotated around the rotation drive shaft. It is characterized in that the wire rod is wound around the divided core while moving the nozzle.

In the present invention, the two split cores are housed in a jig that can be folded in half, and the rotation drive shaft is brought into contact with the split cores in the jig folded in layers, and the two split cores are split by one rotary drive shaft. Rotate the core to wind it. In the method of the present invention, when winding, the nozzle needs to move only in the left-right direction, and the nozzle moving distance is short and the winding speed is high as compared with the conventional device. Therefore, the time required for coil formation can be shortened, and the manufacturing man-hours can be reduced.

In the coil winding method, the jig is provided with a guide member for guiding the wire rod, the installation position of the guide member can be changed according to the specifications of the motor, and the installation position of the guide member is changed. Therefore, the length of the crossover wire connecting the coils wound around the divided cores in the first and second car portions may be adjusted. In this case, the guide member allows the wire to be wound around the split core while applying tension, and a high space factor of the winding can be achieved.

Further, a core holding member may be rotatably provided in the car portion of the jig, and the divided core may be held by the core holding member by uneven fitting.

Further, the motor may be a brushless motor having an even number of the divided cores. In this case, the motor may be a brushless motor having a configuration of 4 poles and 6 slots or an integral multiple thereof, or 10 poles and 12 slots thereof. A brushless motor having an integral multiple configuration may be used.

According to the coil winding device of the present invention, a jig having first and second cages that can be folded in layers and both housed in the first and second cages that are folded in layers, respectively. A rotation drive shaft provided in contact with the division core is provided, and the nozzle is moved to perform winding while rotating the division core around the rotation drive shaft. The movement of the nozzle is sufficient only in the left-right direction, the nozzle movement distance can be shortened as compared with the conventional device, and the winding speed can be increased. Therefore, the time required for coil formation can be shortened, and the manufacturing man-hours can be reduced.

According to the coil winding method of the present invention, the split core is housed in a jig provided with first and second cages that can be folded in layers, and then the split core in the jig is folded in layers. Since the rotation drive shaft is in contact and the split core is rotated to perform winding, the nozzle can be moved only in the left-right direction during winding, and the nozzle movement distance can be shortened compared to the conventional device. , It is possible to increase the winding speed. Therefore, the time required for coil formation can be shortened, and the manufacturing man-hours can be reduced.

It is explanatory drawing which shows the structure of the motor coil winding device which is Embodiment 1 of this invention. It is explanatory drawing which shows the formation process of a coil. It is explanatory drawing which shows the structure of the set of the coil which provided the crossover wire formed by the winding device of FIG. It is explanatory drawing which shows the structure of the motor coil winding device which is Embodiment 2 of this invention, and shows the arrangement of the guide pin in the winding device. This is a description showing a winding configuration of a motor having a 10-pole 12-slot configuration and a motor having a 4-pole 6-slot configuration. It is explanatory drawing which shows the structure of the set of coils with a crossover wire formed by the winding device of FIG. It is explanatory drawing which shows the coil structure when the guide pin is arranged on the lower surface part of the jig. It is explanatory drawing which shows the stator structure of the brushless motor of the split core structure. It is explanatory drawing which shows the conventional coil winding method with respect to the split core.

(Embodiment 1)
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is an explanatory diagram showing a configuration of a motor coil winding device (hereinafter, abbreviated as a winding device) according to an embodiment of the present invention. The winding device 1 of FIG. 1 is a device for winding the coil 3 around the split core 2 of the brushless motor, and the split core 2 is used for the stator core of the motor for an electric oil pump. The winding device 1 includes a jig 4 for accommodating the split core 2, a spindle (rotational drive shaft) 5 for rotating the jig 4, and a nozzle 7 for supplying a wire rod 6 for forming a coil 3. In the winding device 1, the split core 2 is housed in the jig 4, and while the split core 2 is rotated by the spindle 5, the wire rod 6 is wound around the split core 2 by the nozzle 7 to form the coil 3.

The jig 4 includes a rectangular parallelepiped car portion 11 having an open side. Two car portions 11 are provided (11a, 11b). A hinge (connecting member) 12 is provided between the car portions 11a and 11b, and the car portions 11a and 11b are folded so as to be overlapped with the opening side facing outward. A core holding plate (core holding member) 13 is rotatably provided at the center of the bottom surface of each of the car portions 11a and 11b. The core holding plate 13 is provided with a convex portion 14 extending in the diameter direction. The convex portion 14 is provided so as to be unevenly fitted with the groove (recessed portion) 16 formed in the outer flange portion 15 of the split core 2. The split core 2 is rotatably held in the car portion 11 with the groove 16 fitted in the convex portion 14. When the car portions 11a and 11b are folded at the hinge 12 portions, the split cores 2a and 2b in both the car portions 11a and 11b are arranged back to back with the outer collar portions 15 facing each other. At this time, the split cores 2a and 2b are arranged so that their center lines M overlap on the same line.

The spindles 5 abut on the split cores 2a and 2b in the jig 4 from both sides in the axial direction along the center line M. A pressure welding member 17 made of rubber or the like is provided at the tip of the spindle 5. The spindle 5 is pressed against the inner flanges 18 of the divided cores 2a and 2b via the pressure contact member 17, and the divided cores 2a and 2b are sandwiched between the spindles 5 from both sides in the axial direction. The winding device 1 is provided with a rotation mechanism (not shown) for rotating the spindle 5, and the spindle 5 can rotate around the center line M. The winding device 1 is further provided with a reciprocating mechanism (not shown) for moving the spindle 5 in the axial direction, and the spindle 5 is pressed against the split core 2 by the reciprocating mechanism.

A plurality of guide pins (guide members) 21 are erected on the upper surface portion 4a of the jig 4 as coil guides for guiding the wire rod 6. The guide pin 21 is inserted and fixed in the pin hole 22 provided in the upper surface portion 4a, and can be appropriately and selectively arranged according to the motor specifications. The winding device 1 of the first embodiment is set for a motor of 10 poles and 12 slots (hereinafter, poles are referred to as P and slots are referred to as S, for example, 10 poles and 12 slots are described as 10P12S). There is. FIG. 2 is an explanatory diagram showing the arrangement of the guide pins 21 in the winding device 1. As shown in FIG. 2, in the winding device 1, the gate pins 21a to 21d for introducing and deriving the wire rod 6 as the guide pin 21, the tension pins 21e and 21f for applying tension to the wire rod 6 at the time of winding, and the wire rod Lead pins 21g and 21h for guiding 6 are provided.

In such a winding device 1, the coil 3 is formed as follows. FIG. 2 is an explanatory diagram showing a forming process of the coil 3. In addition, in FIG. 2, in order to show the apparatus configuration in an easy-to-understand manner, the dimensional ratio of each part is changed. Here, first, the divided cores 2a and 2b are housed in the jig 4, and the car portions 11a and 11b are folded by the hinges 12 as shown in FIG. 2A. After folding the car portions 11a and 11b, the spindle 5 is pressed into the split cores 2a and 2b along the center line M (FIG. 2B). After holding the split cores 2a and 2b on the jig 4 in the state as shown in FIG. 2B, the wire rod 6 is fed out from the nozzle 7 while rotating the spindle 5, and the wire rod 6 is wound around the split core 2 to form the coil 3. (FIGS. 2 (c) to (f)).

Therefore, as shown in FIG. 2C, the nozzle 7 is first moved in the vertical and horizontal directions in the drawing, the wire rod 6 is passed between the gate pins 21a and 21b, and then hooked on the tension pin 21e to the split core 2a side. Route to. Then, in this state, the nozzle 7 is moved in the left-right direction in the drawing while rotating the spindle 5. The wire rod 6 is supplied from the nozzle 7 along the coil guide 19, whereby the wire rod 6 is wound around the split core 2a and the coil 3 is wound. At this time, since the wire rod 6 is wound around the split core 2a while being hooked on the tension pin 21e, the coil 3 can be wound while pressing the wire rod 6. Therefore, the coils 3 can be wound in an aligned manner, and a high space factor can be achieved.

After forming the coil 3, the nozzle 7 is moved, and as shown in FIG. 2D, the wire rod 6 is stretched along the lead pin 21g and the tension pin 21f and routed to the split core 2b side. Then, the nozzle 7 is moved in the left-right direction in the drawing while rotating the spindle 5 (FIG. 2 (e)). As a result, the coil 3 is wound around the split core 2b. At this time as well, the coil 3 is aligned and wound around the split core 2b, and the nozzle 7 moves only in the left-right direction during winding. The rotation direction of the spindle 5 can be changed between the split cores 2a and 2b according to the winding specifications.

After forming the coil 3 on the split core 2b, the wire rod 6 is hooked on the lead pin 21h as shown in FIG. 2F, and further passed between the gate pins 21c and 21d to end the winding. As a result, as shown in FIG. 4, the coil 3 provided with the crossover 23 is formed in the divided cores 2a and 2b. In this way, in the winding device 1, two workpieces (divided cores 2a and 2b) are rotated by one axis (spindle 5) to perform winding. At that time, the movement of the nozzle required for winding is sufficient only in the left-right direction, and the nozzle movement distance is short and the winding speed is high as compared with the conventional device. Therefore, the time required to form a set of coils connected by the crossover line 23 can be shortened, the manufacturing man-hours can be reduced, and the cost can be reduced. Further, as described above, a high space factor, which is one of the advantages of the split core structure, can be achieved.

(Embodiment 2)
Next, the winding device according to the second embodiment of the present invention will be described. In the second embodiment, the same members and parts as those in the first embodiment are designated by the same reference numerals as those in the first embodiment, and the description thereof will be omitted.

FIG. 4 is an explanatory view showing the configuration of the jig 25 in the winding device according to the second embodiment, and shows the arrangement of the guide pins 21 in the jig 25. The jig 25 is set for a motor having a 4P6S configuration, and the arrangement of the guide pin 21 on the upper surface portion 25a is different from that of the jig 4 of the winding device 1. Here, as shown in FIG. 5, the length of the crossover line 23 is different between the motor having the 10P12S configuration and the motor having the 4P6S configuration. In the winding device according to the present invention, the length and winding direction of the crossover wire 23 can be changed by changing the arrangement of the guide pins 21, and the winding form of the coil 3 can be appropriately adjusted according to the motor configuration.

As shown in FIG. 4, in the jig 25, the guide pin arrangement on the split core 2a side is the same as that of the winding device 1 of the first embodiment, but the guide pin arrangement on the split core 2b side is the same as that of the winding device 1. Is different. That is, in the jig 25, the gate pins 21a to 21d are arranged in parallel on the same side, the lead pin 21i is arranged at the position of the tension pin 21f of the winding device 1, and the tension pin 21j is arranged at the position of the lead pin 21h. Further, a lead pin 21k has been added.

In this case, the coil 3 on the split core 2a side is formed in the same manner as the winding device 1 of the first embodiment. On the other hand, when moving from the split core 2a side to the split core 2b side, unlike the winding device 1, the wire rod 6 is stretched along the lead pin 21i and the tension pin 21j and routed to the split core 2b side. Then, the spindle 5 is rotated in the direction opposite to the split core 2a side, the nozzle 7 is moved in the left-right direction in the drawing, and the coil 3 is wound around the split core 2b. As a result, the coil 3 provided with the crossover 23 as shown in FIG. 6 is formed in the divided cores 2a and 2b. That is, the jig 25 winds the coil 3 provided with the crossover wire 23 (see FIG. 5) corresponding to the motor having the 4P6S configuration.

As described above, in the winding device of the present invention, by changing the arrangement of the guide pins 21, the path of the wire rod 6 connecting the divided cores 2a and 2b can be changed, and the length of the crossover wire 23 can be appropriately adjusted. it can. Therefore, different specifications can be flexibly adapted to the motor by changing the arrangement of the guide pins, the versatility of the device can be improved, and the equipment cost can be reduced.

It goes without saying that the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the gist thereof.
For example, in the above-described embodiment, an example in which the present invention is applied to winding a stator coil in a motor having a 10P12S or 4P6S configuration is shown, but the configuration of the motor to which the present invention can be applied is not limited to these, and the 10P12S It can be widely applied to motors that are integral multiples of 4P6S and motors with a 14P12S configuration, and is particularly effective when the coil of an even-slot motor is wound in a single stroke.

Further, the arrangement of the guide pin 21 is not limited to the mode of the above-described embodiment, and can be appropriately changed according to the specifications of the motor. Further, in FIG. 5, as an example of the winding specifications of the motors having a 10P12S / 4P6S configuration, those with 4 series Y connection and series Δ connection are shown, respectively, but the present invention is also applied to motors with other winding specifications. It is possible. For example, in 10P12S, a motor with 4 series Δ connection, 2 series 2 parallel Y connection, 2 series 2 parallel Δ connection, 4P6S series Y connection, 8P12S 2 series 2 parallel Y connection, 2 series 2 parallel Δ connection motor The winding device of the present invention can also be used for forming a coil such as.

In addition, in the above-described embodiment, the example in which the guide pin 21 is provided on one end surface side (upper surface portions 4a, 25a) of the jigs 4 and 25 is shown, but the guide pin 21 is cured like the lower surface portion 4b. It is also possible to provide the tools 4 and 25 on the other end surface side (see FIG. 1), and for this purpose, the jig 4 is also provided with a pin hole 22 on the lower surface portion 4b (the same applies to the jig 25: shown. Z). By providing the guide pin 21 on the lower surface portion 4b in this way, as shown in FIG. 7, the crossover wire 23 can be arranged on the side opposite to the winding start 3a and the winding end 3b of the coil 3.

When the winding start 3a / winding end 3b and the crossover wire 23 are arranged on the same side as shown in FIGS. 3 and 6, the coil 3 has an integral multiple of the number of turns, while the crossover wire 23 is connected to the coil 3 as shown in FIG. If the coil 3 is arranged on the opposite side of the winding start 3a and winding end 3b, the coil 3 has a step of 0.5 turn. That is, in the winding device / method according to the present invention, the number of turns of the coil 3 can be set in 0.5 turn increments by changing the arrangement of the guide pins 21, which flexibly corresponds to the winding specifications. be able to.

In the above-described embodiment, an example in which the apparatus / method of the present invention is applied to the coil forming process of the split core used in the motor for an automobile oil pump is shown, but the application target is not limited to this. For example, the present invention can be applied to winding a stator coil of another in-vehicle motor of an automobile or a motor for industrial machinery / home appliances.

1 Winding device 2 Divided core 2a, 2b Divided core 3 Coil 3a Winding start 3b Winding end 4 Jig 4a Top surface 4b Bottom surface 5 Spindle 6 Wire rod 7 Nozzle 11 Cage 11a, 11b Cage 12 Hinge (connecting member)
13 Core holding plate 14 Convex part 15 Outer flange part 16 Groove 17 Pressure welding member 18 Inner flange part 19 Coil guide 21 Guide pins 21a to 21d Gate pins 21e, 21f, 21j Tension pins 21g to 21i, 21k Lead pins 22 Pin holes 23 Crossovers 25 Jig 25a Top surface 51 Divided core 52 Coil 52a Coil winding start 52b Coil winding end 53 Stator 54 Jig 55 Nozzle M Center line

Claims (12)

A coil winding device for winding a wire around the divided core used in a motor having a stator in which a plurality of divided cores are arranged in an annular shape.
A jig equipped with a cage that rotatably accommodates and holds the split core,
A rotary drive shaft that comes into contact with the split core housed in the car portion and rotates the split core,
With a nozzle that feeds out the wire,
The jig has a first car part and a second car part as the car part, and the first and second car parts are folded so as to overlap between the first car part and the second car part. A connecting member is provided to enable
The split cores are housed in the first and second car portions, which are folded in layers, respectively.
The rotary drive shaft is attached in a state of being in contact with each of the divided cores in the first and second car portions.
A coil winding device characterized in that the wire rod is wound around the divided core by moving the nozzle while rotating both the divided cores around the rotation drive shaft. In the coil winding device according to claim 1,
The jig includes a guide member for guiding the wire rod.
The guide member is a coil winding device whose installation position can be changed according to the specifications of the motor. In the coil winding device according to claim 1 or 2.
The jig has a core holding member rotatably provided in the car portion.
The coil winding device, wherein the divided core is held by the core holding member by uneven fitting. In the coil winding device according to any one of claims 1 to 3.
The motor is a coil winding device characterized by being a brushless motor having an even number of the divided cores. In the coil winding device according to claim 4,
The coil winding device is characterized in that the motor is a brushless motor having a configuration of 4 poles and 6 slots or an integral multiple thereof. In the coil winding device according to claim 4,
The coil winding device is characterized in that the motor is a brushless motor having a configuration of 10 poles and 12 slots or an integral multiple thereof. A coil winding method in which a wire rod is fed out from a nozzle and wound around the divided core used in a motor having a stator in which a plurality of divided cores are arranged in an annular shape.
It has a first car part and a second car part that rotatably accommodate and hold the divided core, and the first and second car parts are folded so as to overlap between the first car part and the second car part. The split core is housed in each of the first car portion and the second car portion with respect to the jig provided with the enabling connecting member.
The first and second car portions are folded so as to overlap each other around the connecting member.
The rotation drive shaft is brought into contact with each of the divided cores in the first and second car portions folded so as to be overlapped with each other.
A coil winding method characterized in that both split cores are rotated around the rotary drive shaft, and the wire rod is wound around the split core while moving the nozzle. In the coil winding method according to claim 7,
The jig includes a guide member for guiding the wire rod.
The installation position of the guide member can be changed according to the specifications of the motor.
By changing the installation position of the guide member, the length of the crossover wire connecting the coils wound around the divided cores in the first and second car portions is adjusted. How to dress. In the coil winding method according to claim 7 or 8.
The jig has a core holding member rotatably provided in the car portion.
A coil winding method characterized in that the divided core is held by the core holding member by uneven fitting. In the coil winding method according to any one of claims 7 to 9,
A coil winding method, wherein the motor is a brushless motor having an even number of the divided cores. In the coil winding method according to claim 10,
A coil winding method, wherein the motor is a brushless motor having a configuration of 4 poles and 6 slots or an integral multiple thereof. In the coil winding method according to claim 10,
A coil winding method, wherein the motor is a brushless motor having 10 poles and 12 slots or an integral multiple thereof.

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