JP3138033B2 - Stator manufacturing method and apparatus for balancing coils - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a stator of a rotating electrical machine, and more particularly, to a method for forming a coil inserted into a stator core before shaping the coil. To a method and apparatus for improving

[0002]

2. Description of the Related Art A stator in a rotating electric machine such as a motor is formed by inserting a coil into a stator core. The coil is inserted by first winding an electric wire around the winding form in a winding apparatus having a winding form having one or more winding steps corresponding to the winding pitch to form a coil. This is performed by transferring the blades to the annularly arranged blades in the insertion device, and then inserting the coils into the grooves of the stator core by a stripper that moves axially inside the plurality of blades to press the coils. The coil thus inserted into the stator core has a loop-shaped coil end projecting from both end surfaces of the stator core. Further, a combination of a plurality of coils is inserted into the stator core in a similar manner. At this time, it is necessary to expand the previously inserted coil end to the outer diameter side so that the next coil can be easily inserted. The stator assembled in this manner is lead-connected, the coil end is shaped into a shape that can be mounted without any hindrance to the rotating electrical machine, and then attached to the body of the rotating electrical machine.

FIG. 13 is a front view showing a state in which a coil is inserted into the stator core 1 by the coil insertion device. FIG. 14 is a plan view of the coil as viewed from the coil insertion side (upper side), and FIG. It is the bottom view seen from the side (lower side). The coil inserted into the stator core 1 forms an insertion-side coil end 2 and a non-insertion-side coil end 3.
Reference numerals 2a and 3a denote coil ends of a coil group having the largest winding pitch, 2c and 3c denote coil ends of a coil group having the smallest winding pitch, and 2b and 3b denote coil ends of a coil group having an intermediate winding pitch. As shown in the drawing, the circumferential length of the coil is largest near the gaps 5 and 6, and becomes smaller toward the outside. Also, the projecting length of the coil end is very large on the insertion side, whereas the coil length on the opposite side is substantially constant and small for each coil group, and is extremely unbalanced.

[0004] To expand the coil end to the outer diameter side,
This is performed using a jig as shown in FIG. This is constituted by an upper die 13 having a round bar 15 having a conical tapered tip, and a lower die 14 having a hole 16 fitted into the round bar 15. By moving the upper die 13 and the lower die 14 in the direction of approach by inserting the upper die 13 and the lower die 14, the coil ends on the upper and lower sides are pressed by the round portions 17 and 18, and the coil ends are expanded to the outer diameter side.

However, as shown in FIG. 13, the coil inserted by the coil insertion device has a very poor balance between the amount of protrusion on the insertion side and the amount of protrusion on the opposite side. Therefore, the shape obtained after the shaping process is as shown in FIG. FIG.
12 is viewed from the side opposite to the insertion side. On the non-insertion side, since the amount of projecting coil is small, the coil end does not expand sufficiently large, and blocks the path of the coil inserted to cover the groove 24 into which the next coil is inserted. Become. As a result, the higher the efficiency of the motor in which many coils are inserted into the grooves of the stator core, the more failures that break the insulating coating of the coil have increased.

In order to solve the above-mentioned problem, it is preferable to perform a shaping process so that the protruding lengths of the coil ends on the insertion side and the non-insertion side are substantially equal.
A shaping jig disclosed in Japanese Patent Publication No. 51 has been proposed. This shaping jig and a shaping method using the same will be described with reference to FIG.

The shaping jig 21 has a round bar shape which fits inside the stator core 1 as a whole, and has a tapered portion 22 at the tip end thereof. A part 23 is formed. When the shaping jig 21 is inserted into the inside of the stator core 1 from above, the step 23 is caught by the inner coil at the lower coil end 3, the hooked coil is pulled out downward, and the shaping jig 21 is further lowered. To release the hooked inner coil from the stepped portion 23, and a jig 21 having a diameter substantially equal to the inner diameter of the stator core 1.
Is used to push the lower coil end 3 outward.

[0008]

In the conventionally proposed shaping jig and shaping method shown in FIG.
Since the main body 1 is configured to penetrate the coil end on the side opposite to the insertion side to perform shaping, the following problem occurs.
That is, if the coil caught on the step portion 23 does not come off, the coil caught on the jig 21 is extended and destroyed as the jig 21 descends. This is because, in the case of a stator having a large number of coils, the coil ends do not have flexibility, so that the coil ends do not sufficiently expand outward until the base of the jig 21 is inserted. In addition, if the coil stuck on the step portion 23 is configured to be easily detached to avoid the above-described problem, a coil that does not catch on the step portion 23 in the inner coil will be generated. Drawer becomes insufficient. In any case, it is very difficult to control the protruding length of the coil end on the non-insertion side.

Although the above problems can be solved to some extent by preparing a large number of shaping jigs according to the type of winding specification, in the case of small-lot production of various types, it is troublesome to replace jigs every time the winding specification is changed. However, it is not practical because a lot of jig management is required.

[0010] In general, a coil inserted into a stator core by a coil insertion device is characterized in that even if the coils have the same winding pitch, a coil piece inserted beforehand (positioned on the tip end side of the blade in the coil insertion device). The coil piece that is inserted has a longer protruding length on the side opposite to the insertion side, and the coil piece inserted later has a smaller protruding length on the side opposite to the insertion side. By correcting the protrusion length to be substantially the same, and by balancing the protrusion lengths on the insertion side and the non-insertion side, it is possible to improve the shaping in the subsequent process. However, since the conventional coil shown in FIG. 16 has a configuration in which only the inner coil is pulled out downward, the outer coil group, that is, the coil group having the smaller winding pitch, has the same coil group as the coil group in the same coil group. Cannot be corrected to the same protrusion length, or the protrusion lengths on the insertion side and the counter-insertion side cannot be balanced. Therefore, in the shaping in which the coil end of the subsequent process is greatly expanded outward, the shaping effect is not sufficient, and the coil end of the outer layer coil inserted first blocks the path of the inner layer coil inserted later. It is insufficient for manufacturing a high-efficiency motor in which many coils are inserted into the grooves of the stator core.

[0011]

According to the method of manufacturing a stator of the present invention, after a coil is inserted into a stator core, a coil pushing jig is inserted from the coil insertion side to the inner diameter of the stator core, and the coil pushing jig is inserted into the coil pushing jig. The coil pressing portion provided pushes all the coils from the insertion side to the non-insertion side without penetrating the coil end on the non-insertion side, so that the coil end protrusion lengths on the insertion side and the non-insertion side are approximately equal. Is moved, and then the coil is shaped . The apparatus for balancing a coil according to the present invention includes a rod-shaped body that fits the inner diameter of the stator core, a coil pushing jig provided at the tip of the rod-shaped body, and a projecting part provided at the center of the coil pushing jig. A coil gap detector,
When the rod-shaped body is inserted from the coil insertion side to the inner diameter of the stator core and moved toward the non-insertion side, the coil pole detection unit separates the poles of the coil, passes through the coil end on the non-insertion side, and The coil pressing portion of the coil pressing jig is configured such that the coil is moved without pushing through the coil end on the non-insertion side to move the coil, and the rod is moved backward at a point where the movement of the coil reaches a predetermined size. is there.

[0012]

After injects the coil to the action stator core, when the push coil equipped with a coil pressing portion jig is inserted from the coil insertion side the stator core, the coil pushing jig hits the non-insertion side coil end, reliably set the coil The amount can be pushed to the insertion side. Therefore, when the coil is applied to the inserted stator coil insertion apparatus, and can be optimized set amount of projection of the coil end of the non-insertion side so that the coil end spreads largely to the outer diameter side in the shaping of the next step, the stator core The coil to be inserted next can be inserted with the least resistance.

[0013]

EXAMPLES apparatus for the present invention balance the coil was carried out (hereinafter, referred to as coil balancing device), after injects the coils on the stator core, the coil pushing jig from the top of the stator core <br/> side The insertion pushes the coil downward as a whole. The coil pressing jig has a shape that can be inserted into the inner diameter of the stator core, and has a tip detecting portion for detecting the gap between the coil ends on the opposite side of the insertion and separating the same, A coil pressing portion is provided for pressing the insertion-side coil end separately without passing through the coil end. If the entire coil pushing jig passes through the gap between the coil ends on the non-insertion side, the protrusion length of the coil end on the non-insertion side will not be controlled and will vary, so it will not be constant and will not be optimal and uniform I can't get the status. Therefore, the coil pressing jig must have a shape that does not expand the coil end to the outer diameter side.

The coil balance device 11 shown in FIG. 1 is composed of a rod 7 adapted to the inside diameter 19 of the stator core 1 and a columnar coil pushing jig 8 provided at the tip of the rod 7. The coil pressing portion of the coil pressing jig 8 is formed of a circular flat surface with a chamfered periphery. From the coil pressing portion, a gap between the poles configured to pass through the gap 6 of the non-insertion side coil end 3 separately. The detection unit 9 is provided in a protruding manner. The shape of the gap detecting section 9 is a round bar or a flat plate. When each pole coil is arranged symmetrically, it protrudes substantially at the center of the coil pressing jig. It protrudes at a position corresponding to the line connecting the gaps. Further, the movement of the stator core 1 in the downward and side directions is restricted by a support jig (not shown), and the stator core 1 is placed so that the axis of the inner diameter 19 coincides with the axis of the rod 7.

Next, the operation of the coil balance device 11 shown in FIG. 1 will be described.
Is lowered, the rod 7 having the coil pressing jig 8 enters the inner diameter 19 of the stator core 1 from the coil insertion side. In this case, the coil end 2 on the coil insertion side is in a state where the gap 5 is expanded, so that there is no hindrance to the entry of the jig. When the rod 7 is further lowered, the gap detecting section 9 reaches the non-insertion side coil end 3 and the gap 6
And pass through the coil end 3. Eventually, the coil pressing portion of the coil pressing jig 8 comes into contact with and pushes the non-insertion side coil end 3, so that the entire coil moves from the insertion side to the non-insertion side. The state at this time is shown in FIG. When the movement of the coil reaches a predetermined size, the lowering of the rod 7 is stopped, and then the rod 7 is moved up and down to complete the operation. In the case of the coil balance device shown in FIG.
The dimensions may be such that the volumes of the two are approximately balanced. That is, FIG.
In the case of (1), when the comparison is made for each coil group, as shown in FIG. 2, the insertion sides 2a, 2b, 2c and the non-insertion sides 3a, 3b, 3
Although the projecting amount of the coil end is not the same for c and c, the average is balanced, so that it is possible to apply the high-efficiency motor to middle or lower.

FIG. 3 shows another embodiment of the present invention.
It is a hemisphere as shown by. When the coil is pressed by the coil pressing jig 8a configured as described above,
Since the pressed and moved coils are arranged along the gentle inclined pressing surface of the jig 8a, the coil end can be formed in a shape as schematically shown in FIG. That is, in the coil end 3 on the opposite side of the insertion, the coil group 3a in the vicinity of the gap 6 protrudes the largest, and then the projection length becomes smaller as the coil groups 3b and 3c become outer in the order of the coil groups. Since the side and the non-insertion side are roughly balanced, it is possible to apply the high-efficiency motor at a medium level. still,
The shape of the coil pressing jig 8a may be an oval semi-elliptical sphere.

FIG. 5 shows still another embodiment of the present invention.
A protrusion 10 for locking the coil is provided at the outer end of the hemispherical coil pressing portion as shown in FIG. The projecting portion 10 is for preventing the coil end 3 on the non-insertion side from coming off due to pressing, and is provided at a position corresponding to the pole center of the coil on the outer peripheral portion of the coil pushing jig 8b. And the coil end 3c of the coil group having the smallest winding pitch can be completely locked. The coil pressing jig 8b can be formed by, for example, further processing the coil pressing jig 8a shown in FIG. In addition, the projection 10 may be formed by erecting a pin or the like. In this case, the tip is inserted so that the insertion-side coil end is not caught when inserted into the inner diameter of the stator core. It must escape to the inner diameter side from the side coil end. According to the coil balance device provided with the coil pressing jig 8b,
Even when a coil end having a large amount of coil is pressed, the coil does not come off the jig, so that the coil can be reliably moved.

FIG. 6 shows still another embodiment of the present invention.
As shown by reference numeral 8c, the coil pressing jig has a shape in which coil pressing portions 12a, 12b, and 12c are the highest at the center portion and are stepwise lowered toward the outside. The coil pressing jig 8c is, for example, further processed from the coil pressing jig 8 shown in FIG. 1 or the coil pressing jig 8a shown in FIG. 3, and has step-like coil pressing portions 12a, 12b, 1.
2c can be formed. The step shape of the coil pressing portion is formed from the center to the pole center of the coil, and each step 12a, 12b, 12c has a substantially linear shape along each coil group 3a, 3b, 3c of the coil end. Formed. The coil pressing portions 12a, 12b, 12c
Are the respective coil groups 3a, 3b,
The step shape is set in advance so that the ratio of the protruding length between the respective coil groups 3c is balanced with the ratio of the protruding length between the respective coil groups 2a, 2b, and 2c of the insertion side coil end 2.
The absolute amount of each protruding length of the non-insertion side coil end 3 and the insertion side coil end 2 is adjusted by operating the bottom dead center of the lowering of the rod-shaped body 7 so that both coil ends are balanced.

When the coil is pressed by the coil pressing jig 8c configured as described above, each of the coil groups 3a, 3b, 3
c, the coil pressing portions 12a, 12b,
12c, each coil group moves to a different height to form a step-like shape, and the protruding lengths of the coil ends on the insertion side and the non-insertion side are considerably balanced, so that the coil ends have a shape as schematically shown in FIG. Can be formed. In this case, unlike the case where the coil pressing jig 8a shown in FIG. 3 is used, the coils having the same winding pitch all have substantially the same coil end protrusion length.
The shaping for expanding 3 to the outer diameter side is further facilitated, and the high-efficiency motor can be applied to medium or higher.

FIG. 7 shows the coil pressing portions 12a, 12b and 12c having different heights in a stepwise manner shown in FIG.
The coil pushing jig 8d provided with the protrusion 10 for locking the coil is shown. The shape and effect of the projection 10 are the same as in the embodiment of FIG.

FIGS. 8 and 9 show still another embodiment of the present invention, in which the coil pressing jigs 8c and 8d shown in FIGS. 6 and 7 are provided between coil pressing portions 12a, 12b and 12c, respectively. , Coil-to-coil detectors 20a and 20b which are inserted separately between coil groups having different winding pitches. The inter-coil detecting portions 20a and 20b are formed in a round bar shape or a flat plate shape, and similarly to the inter-electrode detecting portion 9, each of the coil groups 3a and 3
b and 3c are separated from each other, and the coils can be prevented from escaping from a predetermined coil pressing portion and escaping into an adjacent coil group.
The protrusion lengths of b and 3c can be reliably separated.

The operation of the coil balancing device using the coil pressing jigs 8a to 8f is the same as the operation using the coil pressing jig 8. Further, in the above embodiments, an example of three coil groups for each pole has been described, but the present invention can be similarly applied even when the number of coil groups is different from this.

[0023]

According to the present invention, the step of balancing the projecting lengths of the coil ends on the insertion side and the opposite side of the coil and the shaping step of expanding the coil end to the outer diameter side are not performed at the same time. Prior to this, only the former step of balancing the protrusion length is surely performed. Therefore, since the main body of the coil pressing jig does not penetrate through the coil end on the side opposite to the insertion side, the coil is not excessively pressed and the insulating coating is not broken. The movement of the coil to the coil can be surely performed.

[0024] Further, from the above-mentioned feature, it is possible to correct the projecting length of the coil end not only for a coil having a large winding pitch but also for a coil having a small winding pitch. It is also easy to adjust the length, and as a result, it becomes possible to optimally set the coil balance between the insertion side and the non-insertion side. In the subsequent process, the coil end can be sufficiently widened to the outer diameter side, the insertability of the coil to be inserted into the inner layer is improved, defects are suppressed, and many coils are inserted into the groove of the stator core. The productivity and quality of a high-efficiency motor can be greatly improved.

[Brief description of the drawings]

FIG. 1 is a front view showing an embodiment of a manufacturing method and apparatus according to the present invention.

FIG. 2 is a front view showing a manufacturing method according to the present invention and a coil end shape of a stator obtained by the present invention.

FIG. 3 is a front view of a coil pressing jig showing the embodiment of the present invention.

FIG. 4 is a front view showing a coil end shape of a stator obtained by the present invention.

FIG. 5 is a front view of a coil pressing jig showing the embodiment of the present invention.

FIG. 6 is a front view of a coil pressing jig showing the embodiment of the present invention.

FIG. 7 is a front view of a coil pressing jig showing the embodiment of the present invention.

FIG. 8 is a front view of a coil pressing jig showing the embodiment of the present invention.

FIG. 9 is a front view of a coil pressing jig showing the embodiment of the present invention.

FIG. 10 is a front view illustrating a method of shaping a coil.

FIG. 11 is a front view showing a conventional coil end shape obtained after a coil shaping process.

FIG. 12 is a bottom view of the stator shown in FIG. 11;

FIG. 13 is a front view of the stator showing a state where a coil is inserted by the coil insertion device.

FIG. 14 is a plan view of the stator shown in FIG. 13;

FIG. 15 is a bottom view of the stator shown in FIG. 13;

FIG. 16 is a front view showing an example of a conventional manufacturing method and apparatus.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Stator core 2 Insertion-side coil end 3 Non-insertion-side coil end 7 Rod-shaped body 8, 8a-8f Coil pushing jig 9 Coil gap detecting part 10 Projection part 12a, 12b, 12c Coil pressing part 20a, 20b Coil detecting part 24 groove

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-60-121944 (JP, A) JP-A-55-109159 (JP, A) JP-A-60-167659 (JP, A) JP-A 53-109 78001 (JP, A) Actually open Sho 61-38875 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) H02K 15/04

Claims (7)

(57) [Claims] 1. After inserting a coil into a stator core
A coil from the coil insertion side to the inner diameter of the stator core
The pressing jig is inserted, and the coil pressing portion provided in the coil pressing jig pushes all the coils from the insertion side to the non-insertion side without passing through the coil end on the non-insertion side. And (c) moving the coil so that the coil end protrusion lengths thereof are substantially equal to each other, and then shaping the coil . 2. After the coil is inserted into the stator core
On, pushing the coil inserted through the inner diameter of the stator core ,
In a device that moves from the insertion side to the non-insertion side,
A rod-shaped body that fits the inner diameter of the stator core, a coil pressing jig provided at the tip of the rod-shaped body, and a coil gap detection unit protruding from the center of the coil pressing jig,
When the rod-shaped body is inserted from the coil insertion side to the inner diameter of the stator core and moved toward the non-insertion side, the coil pole detection unit separates the poles of the coil, passes through the coil end on the non-insertion side, and The coil pressing portion of the coil pressing jig pushes the coil without moving through the non-insertion side coil end to move the coil, and retracts the rod at a point where the movement of the coil reaches a predetermined size. A device for balancing a featured coil. 3. The apparatus for balancing a coil according to claim 2, wherein the coil pressing jig includes a coil pressing portion formed of a flat surface having a chamfered periphery. 4. The apparatus for balancing a coil according to claim 2, wherein the coil pressing jig includes a coil pressing portion having a hemispherical or semielliptical spherical surface. 5. An apparatus for balancing a coil according to claim 2, wherein the coil pressing jig includes a coil pressing portion having a stepped height different from that of the central portion. 6. The apparatus for balancing coils according to claim 5, wherein an inter-coil detecting section inserted between coils having different winding pitches is provided between each step of the step-shaped coil pressing section. 7. A coil pushing jig is provided with a projection for locking a coil at an outer end thereof.
An apparatus for balancing a coil according to any one of the preceding claims.