JP4281496B2 - Stator manufacturing method, coil winding apparatus, and stator manufacturing apparatus - Google Patents

Description

The present invention relates to a method of manufacturing a stator coil winding apparatus, relates to the production equipment of the stator, in particular, relates a method of manufacturing a stator according to the inserter system, the coil winding device and the stator manufacturing equipment according to the inserter system.

  Conventionally, various types of stator manufacturing methods using an inserter system or stator manufacturing apparatuses according to an inserter system have been proposed (see, for example, Patent Document 1, Patent Document 2, and Patent Document 3).

JP 05-236711 A JP 07-39119 A Japanese Patent Application Laid-Open No. 07-59306

  In the manufacturing methods disclosed in Patent Literature 1, Patent Literature 2, and Patent Literature 3, a winding having a plurality of blades arranged in an annular shape while winding a winding made of a plurality of strands around a winding frame. The formed winding is transferred to the transfer tool and set in such a manner that the tool is sandwiched between adjacent blades. Next, after the stator core is disposed at the tip of the blade, the formed winding (coil) set on the transfer tool is pushed up and inserted into the slot of the stator core using a stripper.

  By the way, as disclosed in Patent Document 1, Patent Document 2, and Patent Document 3, in the conventional manufacturing method, in one of the coils 51, in a slot inserted and arranged in at least the slot 32 of the stator core 30. Each strand 40 in the insertion portion 53 is formed into a straight line, and a part of one coil 51 is sandwiched between predetermined blades 521 and transferred to the transfer tool 520 (see FIG. 9). Thereafter, the winding 50 is pulled out from the flyer 515 (or the gripper) while tension is applied to the winding 50, and the transfer tool 520 or the winding frame (not shown) is rotated around the axis C2 of the transfer tool 520 to move the transition portion 57 ( Next, the coil 50 is wound around the winding frame to form the next coil 51, and is transferred to the transfer tool 520 while being sandwiched between the other blades 521.

  However, in such a method, as shown in FIG. 9, at least one of the transfer tool 520 and the reel (not shown) is rotated around the axis C <b> 2 of the transfer tool 520 while applying tension to the winding 50. While the crossover portion 57 is formed, the first most distal side slot insertion portion 53b that is once linearly formed (of the slot insertion portion 53, located closest to the tip of the blade 521 and adjacent to the crossover portion 57) In some cases, the inserted portion in the slot) bends with the blade 521 as a fulcrum. In this way, the first most distal side slot insertion portion 53b (indicated by a black circle in FIG. 10) that is inserted first into the slot 32 is bent and comes into contact with the slot inner wall 32b while being in contact with the slot inner wall 32b. Since it is inserted in 32X (outer direction of the radial direction of the stator core 30 passing through the slot 32), it becomes resistance for insertion. In addition, during insertion, they receive a force in the circumferential direction of the stator core 30 and are disposed offset in the circumferential direction (see FIG. 10). In addition, since the wire 40 is inserted into the slot 32 in a bent state, the wire 40 inserted later is prevented from proceeding to the back side 32X. As shown in FIG. In some cases, a dead space DS in which the wire 40 is not disposed on the side 32X is formed. In particular, when a stator having a high space factor (for example, a space factor of 60% or more) is to be manufactured, a part of the strand 40 to be inserted can be inserted into the slot 32 due to the presence of the dead space DS. In some cases, the stator iron core 30 may be protruded from the inner periphery.

The present invention has been made in view of such a current situation, and is a stator manufacturing method capable of suppressing the formation of a dead space in which no wire is arranged on the back side in the slot, and in the first most advanced side slot. coil winding apparatus can be linearly the wires in the insertion portion, and an object thereof is to provide a stator manufacturing equipment of capable of producing the inner stator wire is disposed to the slot .

  The solution is that a part of a coil formed by winding a wire consisting of a plurality of strands in advance is inserted into a slot formed in an internal tooth-shaped stator core having a front surface and a back surface. A stator manufacturing method comprising: a plurality of coil portions that form the winding and are wound by a predetermined number of turns to form a coil; and an insertion portion that includes a transition portion that spans between the coil portions. In the form in which the sandwiched portion of the coil portion is sandwiched between adjacent blades of a transfer tool having a plurality of blades arranged in an annular shape, the molded winding for insertion is formed. A winding molding setting step for setting in the transfer tool, and the set molded winding for insertion is moved along the blade by a stripper, and the coil portion of the molded molding for insertion is moved. The slot insertion portion is inserted and arranged in the slot of the stator core, and the coil end portion other than the slot insertion portion and the transition portion of the coil portion are arranged on the front surface or the back surface of the stator core. A winding insertion step disposed on the winding forming set step, wherein the winding forming and setting step includes, on the portion from the most advanced clamping portion located on the most distal end side of the blade to the transition portion, The slot in which each element wire is linearly formed in a shape including the insertion part in the slot in which each element wire is linearly formed, or in a portion up to the transition part including the most distal side clamping part. This is a method for manufacturing a stator which is set on the transfer tool while forming the inserted pre-formed winding into a shape to be an inner insertion portion.

  In the stator manufacturing method of the present invention, a molded winding for insertion is formed into a shape including an insertion portion in a slot in which each element wire is linearly formed in a portion from the most advanced side clamping portion to the transition portion. While setting the transfer tool. Alternatively, set the transfer tool while forming the pre-molded winding for insertion into the shape where the part including the most advanced side clamping part to the transition part becomes the insertion part in the slot where each element wire is formed linearly To do. That is, in the manufacturing method of the present invention, unlike the prior art, the first most advanced side slot insertion portion (among the slot insertion portions, the slot insertion portion that is adjacent to the crossover portion at the position closest to the tip of the blade). The shape is set in a straight line without bending.

  For this reason, when the formed coil for insertion set in the transfer tool is inserted into the slot of the stator iron core using the stripper, the first most advanced side slot insertion portion inserted first in the slot is It can be smoothly inserted into the back side of the slot (referred to as the outside direction in the radial direction of the stator core passing through the slot, the same applies hereinafter). That is, unlike the prior art, the first most advanced side slot insertion portion that is inserted first into the slot is not inserted into the back of the slot while being in contact with the inner wall of the slot in a bent state, A force is received in the circumferential direction of the stator iron core, and the stator iron core is not displaced in the circumferential direction. Therefore, according to the manufacturing method of the present invention, the strands are stuffed into the slots in order from the back side according to the general insertion order, and a dead space in which no strands are arranged on the back side in the slot is created. Can be suppressed.

  The manufacturing method of the present invention is particularly effective when manufacturing a stator having a high value such that the space factor of the windings relative to the slots is, for example, 60% or more. When manufacturing a stator with a high space factor of 60% or more with respect to the slot, when the winding is inserted into the slot at the time of manufacture, only a slight dead space is created, and the stator is inserted at the end. It becomes difficult to insert the wire, or it becomes difficult to insert the wedge paper, which may cause a defect. On the other hand, according to the manufacturing method of the present invention, as described above, it is possible to suppress the formation of a dead space in which no wire is disposed on the back side in the slot. Even when a high value stator such as% or more is manufactured, it can be manufactured appropriately.

Here, the space factor means the ratio of the strands (including the insulation coating) occupying in the slots. In general, the radius of the wire (including the insulation coating) is r (m), the number of wires in the slot is n, and the slot cross-sectional area (effective slot cross-sectional area excluding an insulator such as slot paper) is A (m ² ). ), The space factor S (%) is obtained as S = (nπr ² / A) × 100.

In addition , a stator in which a part of a coil formed by winding a wire made of a plurality of strands in advance is inserted into a slot formed in an internal tooth-shaped stator core having a front surface and a back surface. A method for manufacturing an insert, comprising: a plurality of coil parts that form the coil by winding a predetermined number of turns to form a coil; and a transition part that extends between the coil parts. The inserted winding is inserted into the transfer tool in a form in which the holding portion of the coil portion is held between adjacent blades among the transfer tools having a plurality of blades arranged in an annular shape while forming the winding. A winding molding setting step for setting the coil, and the set molded winding for insertion is moved along the blade by a stripper, and the coil portion of the molded winding for insertion is slotted. The insertion portion is inserted and arranged in the slot of the stator core, and the coil end portion and the transition portion other than the insertion portion in the slot of the coil portion are on the front surface or the back surface of the stator core. A winding insertion step to be arranged, and in the winding forming and setting step, the strands in the insertion portion in the foremost side slot located closest to the tip side of the blade among the insertion portions in the slot are straight lines. A method of manufacturing a stator that is molded into a shape is preferred .

In the manufacturing method of this stator, the winding-molded setting step, the respective wires in the cutting-edge-side slot insert is molded in a straight line. That is, each of the most distal end side slot insertion portions including the first most distal side slot insertion portion (among the slot insertion portions, the slot insertion portion connected adjacent to the crossing portion at the position closest to the tip of the blade). Both strands are formed in a straight line. For this reason, when the molded pre-insertion winding set on the transfer tool is inserted into the slot of the stator core using a stripper, the most advanced slot insertion portion that is inserted first into the slot is the back of the slot. It is smoothly inserted to the side (when the slot is viewed in the radial direction of the stator core, the outer side in the radial direction of the stator core).

That is, unlike the prior art, the first most distal end slot insertion portion that is inserted first into the slot is inserted into the back of the slot in a bent state while abutting against the inner wall of the slot, and in the circumferential direction of the stator core. It receives force and is not arranged in the circumferential direction. Similarly, among the most advanced side slot insertion portions, the most advanced side slot insertion portion (hereinafter also referred to as the second most advanced side slot insertion portion) different from the first most advanced side slot insertion portion, It is not arranged in the circumferential direction. Therefore, according to the manufacturing method of this, the wire from the back side in this order according to the order of outline insertion packed into the slot, prevent the can dead space wire on the far side is not located out of the slot can do.

The manufacturing method of this is the space factor of the winding for the slots is, for example, in the case of producing the high value of the stator such that 60% or more, is particularly effective. When manufacturing a stator with a high space factor of 60% or more with respect to the slot, when the winding is inserted into the slot at the time of manufacture, only a slight dead space is created, and the stator is inserted at the end. It becomes difficult to insert the wire, or it becomes difficult to insert the wedge paper, which may cause a defect. In contrast, according to the manufacturing method of this, as described above, since the can dead space wire on the far side is not located out of the slot can be prevented, the space factor is 60% Even when a stator having a high value as described above is manufactured, it can be appropriately manufactured.

  Furthermore, in any one of the above-described stator manufacturing methods, in the winding forming and setting step, it is preferable to use a stator manufacturing method in which any of the strands in the slot insertion portion is linearly formed.

In the winding forming and setting step of the present invention, any of the strands in the slot insertion portion is linearly formed without having a bent portion. For this reason, when the molded winding for insertion set on the transfer tool is inserted into the slot of the stator core using a stripper, the insertion portion in the slot is smoothly moved from the tip end side of the blade to the back side of the slot. Inserted into. Therefore, in any slot, it is possible to suppress the formation of dead space in the slot due to the wires being stuffed into the slot in order from the back side according to the approximate insertion order.
Such a manufacturing method of the present invention is particularly effective in the case of manufacturing a stator having a high value such as a space factor of 60% or more. That is, since it is possible to suppress the formation of a dead space in the slot, even when a stator having a high value such as a space factor of 60% or more is manufactured, it can be appropriately manufactured.

Another solution is to form a winding made of a plurality of strands around a winding frame and sandwiched between adjacent blades among transfer tools having a plurality of annularly arranged blades. The formed winding is transferred to the transfer tool, and a molded winding for insertion having a plurality of coil portions wound by a predetermined number of turns to form a coil and a transition portion extending between the coil portions, A coil winding device to be set on a transfer tool, wherein at least one of the coil portions is inserted into a slot of a stator core, and each of the strands in the slot insertion portion is linearly formed, In a form in which a part of the coil portion is sandwiched between the predetermined blades, after being transferred to the transfer tool, the winding is applied while applying tension to the winding. And at least one of the transfer tool and the winding frame is rotated around the axis of the transfer tool to form the transition portion, and then the winding is wound around the winding frame to form the next coil portion. When transferring to the transfer tool in a form that is formed and sandwiched between the other blades, the one in the slot of the one coil portion that is located closest to the tip of the blade is inserted into the most advanced slot. When the insertion portion is provided with a bending prevention mechanism for preventing the bending of each of the strands in the insertion portion in the first cutting edge side that is adjacent to the transition portion of the insertion portion in the cutting edge side slot and is continuous , The bend preventing mechanism is a bend member disposed radially outside the transfer tool with respect to the blade, and the tension is applied to the winding. The winding is pulled out while being applied, and at least one of the transfer tool and the winding frame is rotated around the axis of the transfer tool to form the transition portion, the winding is turned around the bending member. A coil winding apparatus including a bending member that bends the winding at a portion in contact with the bending member while keeping the insertion portion in the first foremost side slot in a straight line .

  In the conventional coil winding device, while tension is applied to the winding, at least one of the transfer tool and the reel is rotated around the axis of the transfer tool to form the crossing portion, and then is linearly formed. The first most advanced side slot insertion portion may be bent using the blade as a fulcrum. As a result, when the first most distal end slot insertion portion that is inserted first into the slot is inserted into the back of the slot while being in contact with the inner wall of the slot in a bent state, smooth insertion is prevented. In addition, the force is applied in the circumferential direction of the stator iron core, and the stator iron core may be disposed in the circumferential direction. As a result, there is a case where a dead space is formed in which no wire is arranged on the back side in the slot.

On the other hand, the coil winding device of the present invention draws the winding while applying tension to the winding, and rotates at least one of the transfer tool and the winding frame around the axis of the transfer tool to form the transition portion. Next, when winding the winding around the winding frame to form the next coil part and transferring it to the transfer tool in the form of being sandwiched between the other blades, the bending of each strand in the first most advanced slot insertion part It is provided with a bend prevention mechanism for preventing this. This bend prevention mechanism includes a bend member disposed on the radially outer side of the transfer tool with respect to the blade. This bending member pulls out the winding while applying tension to the winding, and at least one of the transfer tool and the winding frame is rotated around the axis of the transfer tool to form a crossing portion. The winding is bent at a portion that contacts the bending member while keeping the insertion portion in the first foremost side slot in a straight line.
Thereby, finally, each strand in the insertion part in the 1st most advanced side slot can be made into the shape of a straight line about the shaping | molding winding for insertion set to the transfer tool.

For this reason, when the inserted molded winding set in the transfer tool is inserted into the slot of the stator iron core using a stripper, the insertion part in the slot is sequentially moved from the tip end side of the blade to the back side of the slot. It becomes possible to insert smoothly. Thereby, it can suppress that a dead space is made in the back | inner side in a slot.
The coil winding apparatus of the present invention is particularly effective when manufacturing a stator having a high value such as a space factor of 60% or more. That is, by using the coil winding device of the present invention, it is possible to suppress the formation of a dead space on the back side in the slot, and thus a stator having a high value such as a space factor of 60% or more is manufactured. Even in this case, it can be manufactured appropriately. Moreover, the deformation preventing mechanism including the bending member as described above is extremely simple in structure and inexpensive.

Other solutions, before and SL of the coil winding apparatus, in a state in which the stator iron core is disposed at the distal end position of the blade, the insertion preformed winding set in the transfer tool, the transfer tool And a stripper that is inserted into a slot of the stator core while being pushed out toward the stator core in the axial direction of the stator.

A stator manufacturing apparatus according to the present invention includes a coil winding device having the above-described bending prevention mechanism and a stator winding core while extruding a molded winding for insertion set in the transfer tool toward the stator core in the axial direction of the transfer tool. A stripper for insertion into the slot. By using such a manufacturing apparatus, it is possible to manufacture a stator in which the strands are arranged to the back of the slot without causing a dead space on the back side in the slot.
Note that the stator manufacturing apparatus of the present invention is particularly effective in the case of manufacturing a stator having a high value such as a space factor of 60% or more. That is, by using the coil winding device of the present invention, since the strands can be arranged to the back of the slot without causing a dead space in the back of the slot, the space factor is as high as 60% or more. Even when the stator is manufactured, it can be appropriately manufactured.

In addition , an internal tooth-shaped stator iron core and a winding made of a plurality of strands are used, and this winding is pre-rolled, and a part of the winding is inserted into the slot formed by the internal teeth. A plurality of coils formed between the adjacent coils, and a cross section between the adjacent coils, and a portion of the winding forming the coil inserted into the slot is an in-slot insertion portion, When the portion adjacent to the crossing portion extending from the back side of the slot among the insertion portions in the slot is used as the first distal end slot insertion portion, any of the coils is in the first distal end slot. A stator in which the insertion portion is located on the back side in the slot with respect to the insertion portion in the other slot is preferable .

This stator for each of the coils, of the slots in the insertion portion, the first distal end side in the slot insertion section, slot than the insertion portion other slots continuous adjacent the connecting portions extending from the inner side of the slot It is located at the back side. In this way, the stator in which the first distal end side slot insertion portion is inserted and arranged deeper in the slot than the other slot insertion portions does not cause a dead space, and the strands extend from the back of the slot to the mouth. Can be arranged appropriately.

Further, in the above-described stator, the stator comprising a space factor of the winding relative to the slot as a 60% or more.

In the case of a stator with a high space factor of 60% or more with respect to the slot, when the winding is inserted into the slot during its manufacture, only a small dead space is created, and the last strand to be inserted Insertion becomes difficult, or it becomes difficult to insert wedge paper, which may be defective. For this reason, as in the conventional case, in the stator in which the winding (insertion portion in the slot) is inserted in the slot with the insertion portion in the first distal end side slot bent, there is a dead space on the back side of the slot to be formed. As a result, manufacturing may become difficult.
In contrast, this stator, as described above, the first distal end side slot insertion portion, and is positioned on the back side in the slot than the insertion portion other slots. Therefore, since the strands can be arranged with high density from the back of the slot to the mouth without causing a dead space, a stator having a space factor of 60% or more can be easily obtained. Therefore, this stator, when used in a motor, as compared with the conventional stator, high output, compact, can be lightweight.

A motor including any one of the above stators and a rotor is preferable .

Stator constituting the this motor, for each of the coils, of the slots in the insertion portion, the first slot insertion portion continuous adjacent the connecting portions extending from the inner side of the slots, than the insertion portion other slots Located behind the slot. In the stator in which the first slot insertion portion is inserted and arranged in this way, the strands are arranged at a high density from the back of the slot to the mouth. Therefore, the stator can have a high value such that the space factor of the winding with respect to the slot is, for example, 60% or more.
Therefore, the motor of this, as is traditional, will be able to dead space on the back side of the slot, compared to a motor comprising a winding low space factor stator for the slots, high output, compact, It can be lightweight.

Next, embodiments of the present invention will be described with reference to the drawings.
(Example)

  First, a motor 10 according to the present embodiment will be described with reference to FIG. The motor 10 is a three-phase motor including a rotor 11 and a stator 20. Among these, the rotor 11 is an 8-pole permanent magnet rotor including a cylindrical rotor body 13 centering on the rotation shaft 12 and a magnet 14. The magnets 14 are each inserted and fixed to the rotor body 13 in slits 13S formed in a zigzag manner along the vicinity of the outer peripheral surface, like petals in plan view. On the other hand, the stator 20 is disposed so as to surround the rotor 11.

  This stator 20 is a three-phase eight-pole distributed winding stator. As shown in FIG. 2, the stator 20 includes a stator core 30 having a ring shape in plan view and having 48 teeth (inner teeth) 31 and slots 32. In addition, eight U-phase coils 51, V-phase coils 61, and W-phase coils 71 are provided. In these coils, a U-phase winding 50, a V-phase winding 60, and a W-phase winding 70 are inserted into predetermined slots 32 for each of the U-phase, V-phase, and W-phase, and wound around the teeth 31 by distributed winding. Formed. Each of the U-phase winding 50, the V-phase winding 60, and the W-phase winding 70 has a U-phase terminal 50T, a V-phase terminal 60T, and a W-phase terminal 70T at one end, and the other end is terminated by a common terminal 79. Yes.

In the present embodiment, for such a stator 20, the space factor of the windings (U-phase winding 50, V-phase winding 60, W-phase winding 70) with respect to the slot 32 is about 70%. Here, the space factor refers to the proportion of the wire 40 (including the insulation coating) occupying the slot 32. In this embodiment, the radius of the wire 40 (including the insulation coating) is r (m), the number of wires in the slot 32 is n, and the slot cross-sectional area (effective slot cross-sectional area excluding insulators such as slot paper) The space factor S (%) is calculated as S = (nπr ² / A) × 100, where A is (m ² ).

  1 and 2 show the difference in winding method (clockwise and counterclockwise) of the windings 50, 60, 70 of each phase in the U-phase coil 51, the V-phase coil 61, and the W-phase coil 71. “Dot (•)” and “Cross (×)” are shown on the sides of the coils 51 and the like of each phase. Of the coils 51 and the like of each phase, the side indicated by “dot” is close to the terminals 50T, 60T, and 70T of each phase, and the side indicated by “cross” is close to the common terminal 79. As can be understood, the eight coils 51, 61, 71 of each phase are alternately wound in opposite directions, and adjacent coils have opposite polarities.

  Next, a schematic view of a manufacturing apparatus 100 for manufacturing such a stator 20 is shown in FIG. As shown in FIG. 3, the manufacturing apparatus 100 includes a winding machine 110, a transfer tool 120 disposed below the winding machine 110, and a stripper 130. Among these, the winding machine 110 is a known winding machine, and includes a winding frame 111, a support plate 112 that holds the winding frame 111 and can move in the direction of the axis C <b> 1 (vertical direction in the drawing), and the winding frame. A flyer that is located on the radially outer side of 111 and is inserted with windings (U-phase winding 50, V-phase winding 60, W-phase winding 70) composed of a plurality of (10 in this embodiment) wire 40. 115. The flyer 115 is provided so as to be rotatable around the axis C <b> 1, and is wound around the reel 111 by lowering the reel 111 together with the support plate 112 while turning the flyer 115 around the reel 111 at a high speed. A wire (such as a U-phase winding 50) can be wound spirally.

  Further, the winding machine 110 is fixed to a plurality of coil drop 113 slidably mounted on the support plate 112 in the direction of the axis C1 (vertical direction in the figure), and a lower end portion of the coil drop 113. A pressing plate 114 is provided. For this reason, windings (U-phase winding 50 and the like) having a predetermined number of turns (5 turns in this embodiment) are wound around the winding frame 111, and one coil portion (U-phase coil portion 51b, V-phase coil portion 61b) is wound. , W-phase coil portion 71b), and then moving the coil drop 113 downward, the coil portion wound around the winding frame 111 is pushed downward by the push plate 114, and the transfer tool is disposed below. 120 (see FIG. 6). Note that the flyer 115 is also provided so as to be movable in the direction of the axis C1 (the vertical direction in the figure), and is configured to move downward in synchronization with the coil drop 113.

  In the present embodiment, a winding (U-phase winding 50 or the like) formed by the winding machine 110 and set on the transfer tool 120 is inserted for insertion (molded U-phase winding 50b for insertion, insertion) The molded V-phase winding 60b and the inserted molded W-phase winding 70b) are used. Of the molded winding for insertion (such as the molded U-phase winding 50b for insertion), a coil portion (U-phase coil) is formed by winding the winding (U-phase winding 50, etc.) every 5 turns. Portion 51b, V-phase coil portion 61b, W-phase coil portion 71b), and a portion that crosses between the coil portions (U-phase coil portion 51b, etc.) is a crossover portion (U-phase crossover portion 57, V-phase crossover portion 67, W phase transition part 77).

  Further, a portion sandwiched between adjacent blades 121 of the transfer tool 120 is defined as a sandwiching portion (U-phase sandwiching portion 54, V-phase sandwiching portion 64, W-phase sandwiching portion 74), and this sandwiching portion (U-phase sandwiching portion 54). Etc.) are located at the most distal end side (upper side in FIG. 4) of the blade 121, the most advanced side clamping part (the most advanced side U-phase clamping part 54b, the most advanced side V-phase clamping part 64b, the most advanced side) W-phase clamping portion 74b) (see FIGS. 4 and 7).

Further, portions of the coil part (U-phase coil part 51b, etc.) inserted into the slots 32 of the stator core 30 are inserted into the slot insertion parts (U-phase slot insertion part 53, V-phase slot insertion part 63, W Phase slot insertion portion 73). Further, the portions arranged on the surface 30b of the stator iron core 30 are the surface side coil end portions (surface side U-phase coil end portion 56b, surface side V-phase coil end portion 66b, surface side W-phase coil end portion 76b), back surface The portion disposed on 30c is defined as a back-side coil end (back-side U-phase coil end 56c, back-side V-phase coil end 66c, back-side W-phase coil end 76c) (see FIGS. 4 and 7). ).
In the present embodiment, the clamping part (U-phase clamping part 54 and the like) is included in the slot insertion part (U-phase slot insertion part 53 and the like). In other words, the coil part (U-phase coil part 51b and the like) is sandwiched between the blades 121 in the in-slot insertion part (U-phase slot insertion part 53 and the like).

  Further, among the in-slot insertion portions (the U-phase slot insertion portion 53 and the like), the one located on the most distal side (upper side in the drawing) of the blade 121 of the transfer tool 120 is the most advanced side slot insertion portion (the most advanced side). The U-phase slot insertion portion 53c, the foremost side V-phase slot insertion portion 63c, and the foremost side W-phase slot insertion portion 73c). Furthermore, among the most advanced side slot insertion portions (the most advanced side U-phase slot insertion portion 53c, etc.), the one adjacent to the transition portion (the U-phase transition portion 57, etc.) is connected to the first most advanced side slot. The inner insertion portions (first most advanced U-phase slot insertion portion 53b, first most advanced V-phase slot insertion portion 63b, first most advanced W-phase slot insertion portion 73b) (FIG. 4, FIG. 7).

  The transfer tool 120 includes a base portion 123, a plurality (24 in this embodiment) of blades 121 extending from the base portion 123 in the direction of the axis C <b> 2, and an axial line at a position radially outside the transfer tool 120 relative to the blade 121. And a plurality (eight in this embodiment) of bending members 125 extending in the C2 direction (see FIGS. 3 and 5). Among these, as shown in FIG. 5, the blade 121 includes three movable blades 121c (movable in the direction of the axis C2) and two fixed blades 121b arranged on both sides of the movable blade 121c. A total of eight sets of blades 121 are annularly arranged around the axis C2 so as to correspond to the positions of the teeth 31 constituting the slots 32 into which the coils are to be inserted.

  As shown in FIG. 5, the bending members 125 are annularly arranged at a position radially outward from the blade 121, in which a set of two adjacent bending members 125 is a total of four sets, equally spaced around the axis C <b> 2. Has been placed. More specifically, the bending member 125 is a virtual extension line K obtained by extending a first most distal end side slot insertion portion (such as the first most distal side U phase slot insertion portion 53b) that is formed in a straight line outward in the radial direction. It is arranged at the position that touches. By providing such a bending member 125, as will be described in detail later, the winding (U-phase winding 50 and the like) is pulled out from the flyer 115 while applying tension to the winding (U-phase winding 50 and the like). When forming the transition part (U-phase transition part 57 etc.) by rotating and moving 120 around the axis C <b> 2, the winding (U-phase winding 50 etc.) is turned around this bending member 125, and the first most advanced side The winding (U-phase winding 50 and the like) can be bent at a portion in contact with the bending member 125 while the in-slot insertion portion (the first most advanced side U-phase slot insertion portion 53b and the like) is kept linear. (See FIG. 4). That is, in the present embodiment, the bending member 125 is provided with a bending prevention mechanism that prevents the bending of each strand 40 in the first most distal end side slot insertion portion (the first most distal side U phase slot insertion portion 53b or the like). It is composed.

The bending member 125 is detachably attached to the base portion 123. For this reason, as will be described in detail later, when inserting a molded winding for insertion (such as a molded U-phase winding 50b for insertion) set on the transfer tool 120 into the slot 32 of the stator core 30, a bending member is inserted. By removing 125 from the base portion 123, it is possible to prevent the bending member 125 from interfering with the insertion of the inserted molded winding (such as the inserted molded U-phase winding 50b).
In the present embodiment, the coil winding device 101 is configured by the winding machine 110 and the transfer tool 120.

  The stripper 130 is a known stripper and is provided so as to be movable in the direction of the axis C2 (see FIGS. 3 and 6). As will be described in detail later, by moving the stripper 130 upward, a molded winding for insertion (such as a molded U-phase winding 50b for insertion) set on the transfer tool 120 is inserted into the slot 32 of the stator core 30. Can be inserted in.

Next, a method for manufacturing the stator 20 using such a stator manufacturing apparatus 100 will be described.
First, in the winding forming set process, the winding machine 110 forms a winding (U-phase winding 50 and the like), and the insertion-molded winding (insertion-molded U-phase winding 50b and the like) is transferred to the transfer tool 120. Set to. Specifically, as shown in FIG. 3, while the flyer 115 of the winding machine 110 is swung around the reel 111 at a high speed, the reel 111 is lowered together with the support plate 112, and the winding ( U-phase winding 50 and the like) are wound spirally. At this time, the windings (U-phase winding 50 and the like) wound around the winding frame 111 are sequentially inserted between the adjacent blades 121 of the transfer tool 120 as the winding frame 111 descends. In this way, a winding (U-phase winding 50, etc.) having a predetermined number of turns (5 turns in this embodiment) is wound around the winding frame 111 to form one coil part (U-phase coil part 51b, etc.). To do. Of the formed coil portions (U-phase coil portion 51b, etc.), each wire 40 in the in-slot insertion portion (U-phase slot insertion portion 53, etc.) is formed linearly (see FIG. 4). ).

  Next, when the coil drop 113 is moved downward, the coil portion (U-phase coil portion 51b and the like) wound around the winding frame 111 is pushed downward by the push plate 114, and as shown in FIG. It is transferred to. At this time, the flyer 115 is moved downward together with the coil part (U-phase coil part 51b, etc.), and is disposed substantially on the side of the coil part (U-phase coil part 51b, etc.). In FIG. 4, the coil part (U-phase coil part 51 b or the like) located on the left side corresponds to a transfer of the coil part (U-phase coil part 51 b or the like) shown in FIG. The coil part (U-phase coil part 51b etc.) which has been positioned indicates a coil part (U-phase coil part 51b etc.) which has been transferred to the transfer tool 120 earlier than this.

  Next, as shown in FIG. 4, in order to sandwich a newly formed coil part (U-phase coil part 51b, etc.) between the predetermined blades 121, the transfer tool 120 is rotated around the axis C2 at a predetermined angle (this embodiment). In the example, it is rotated about 45 °). At this time, while applying tension to the winding (U-phase winding 50, etc.), the winding (U-phase winding 50, etc.) is pulled out from the flyer 115 to form a transition part (U-phase transition part 57, etc.).

By the way, in the present embodiment, as described above, the first cutting edge side slot insertion portion (first cutting edge side U-phase slot insertion portion 53b, etc.) formed linearly is extended radially outward. A bending member 125 is disposed at a position in contact with the extension line K (see FIG. 5). For this reason, as described above, when the transfer tool 120 is rotationally moved around the axis C2 to form a transition part (U-phase transition part 57 or the like), the winding (U-phase winding 50 or the like) is used as the bending member 125. Rotate and keep winding the first cutting edge side in-slot insertion portion (the first cutting edge side U-phase slot insertion portion 53b, etc.) in a straight line while contacting the bending member 125 (U-phase winding) 50 etc.) can be bent (see FIG. 4).
In this way, a coil part (U-phase coil part 51b and the like) and a transition part (U-phase transition part 57 and the like) are sequentially formed, and as shown in FIG. Etc.) can be set on the transfer tool 120. Each of the strands 40 can be set in the transfer tool 120. The molded winding for insertion (such as the molded U-phase winding 50b for insertion) formed linearly.

  Next, in the winding insertion process, the inserted molded winding (inserted molded U-phase winding 50 b and the like) set on the transfer tool 120 is inserted into the slot 32 of the stator core 30. Specifically, after setting the insertion-molded winding (insertion-molded U-phase winding 50b, etc.) to the transfer tool 120, the bending member 125 is removed from the base portion 123 as shown in FIG. The stator core 30 is arranged at the tip end position of the blade 121 so that the blade 121 corresponds to the position of the tooth 31 constituting the slot 32 into which the in-slot insertion portion (U-phase slot insertion portion 53 or the like) is to be inserted. Next, the stripper 130 is moved upward to insert the inserted molded winding (inserted molded U-phase winding 50 b or the like) set in the transfer tool 120 into the slot 32 of the stator core 30.

At this time, the in-slot insertion portion (U-phase slot insertion portion 53, etc.) is in the most distal-side slot including the first most distal-side slot insertion portion (the first most distal-side U-phase slot insertion portion 53b). The insertion portion (the most advanced U-phase slot insertion portion 53c or the like) is inserted into the slot first, and the slot is inserted in order from the slot insertion portion (U-phase slot insertion portion 53 or the like) positioned on the tip side of the blade 121. 32 is inserted. In the present embodiment, the movable blade 121c sandwiched between the fixed blades 121b is lifted with the rise of the stripper 130, so that the space between the blade 121 and the in-slot insertion portion (such as the U-phase slot insertion portion 53) is increased. Reduces friction.
As described above, after inserting the molded U-phase winding 50b for insertion, the molded V-phase winding 60b for insertion, and the molded W-phase winding 70b for insertion into the slot 32, respectively, the surface side coil The end portion (front surface side U-phase coil end portion 56b and the like) and the back surface side coil end portion (back surface side U-phase coil end portion 56c and the like) are shaped, and the stator 20 shown in FIG. 7 is completed.

  By the way, in the present embodiment, as described above, the insertion portion in the slot (the insertion portion in the U-phase slot) including the first insertion portion in the most advanced slot (the insertion portion 53b in the first cutting edge side U-phase slot, etc.). 53, etc.) is linearly formed (see FIG. 5). For this reason, when the insertion-molded winding (insertion-molded U-phase winding 50b, etc.) is inserted into the slot 32 of the stator core 30, the slot insertion portion (U-phase slot insertion portion 53, etc.) Inserted smoothly into the back side 32X of the slot 32 in order from the distal end side slot insertion portion (the most advanced side U-phase slot insertion portion 53c and the like).

As a result, as shown in FIG. 8, including the first most advanced side slot insertion portion (first most advanced U phase slot insertion portion 53 b), the most advanced side slot insertion portion (most advanced U phase slot). Each strand 40 in the inner insertion portion 53c or the like) can be positioned on the back side 32X in the slot 32 with respect to other slot insertion portions (U-phase slot insertion portion 53 or the like). Therefore, the wire 40 can be arranged in high density in order from the back side 32X in the slot 32 without creating a dead space in the slot 32. For this reason, all the strands 40 to be inserted can be inserted into the slot 32, and the wedge paper 25 can be inserted into the slot 32 appropriately without difficulty.
As described above, the stator 20 in which the space factor of the windings (such as the U-phase winding 50) with respect to the slot 32 is 60% or more (about 70% in this embodiment) can be reliably manufactured.

While the present invention has been described with reference to the embodiments, it is needless to say that the present invention is not limited to the above-described embodiments and can be appropriately modified and applied without departing from the scope of the invention.
For example, although the bending member 125 is provided in the transfer tool 120 in the embodiment, it may be provided in the winding machine 110. Or you may make it provide the bending prevention apparatus which has the bending member 125 separately. Further, in the embodiment, the bending member 125 is used as a bending prevention mechanism, but any mechanism that can prevent the bending of the first most advanced side slot insertion portion (first most distal side U-phase slot insertion portion 53b) can be used. Any mechanism may be used, for example, a bend prevention device may be provided separately.

In the embodiment, the three-phase, eight-pole distributed winding stator 20 is manufactured. However, the present invention can be applied to any distributed winding stator having any of a plurality of phases and a plurality of poles. Further, the present invention can be applied not only to distributed winding but also to concentrated winding stators.
In the embodiment, the number of turns of one coil part (U-phase coil part 51b, V-phase coil part 61b, W-phase coil part 71b) is set to 5 turns. It can be changed as appropriate according to the situation.

In the embodiment, the transfer tool 120 is rotated around the axis C2, and the formed coil parts (U-phase coil part 51b, etc.) are sequentially transferred to the transfer tool 120. However, the reel 111 is transferred to the transfer tool 120. The tool 120 may be rotated around the axis C2.
In the embodiment, the flyer 115 is swung around the reel 111 to wind the winding (such as the U-phase winding 50) around the reel 111. However, the reel 111 is rotated about the axis C1 as the rotation axis. You may do it.

1 is a schematic diagram of a motor 10 according to an embodiment. It is a schematic diagram of the stator 20 concerning an Example. It is the schematic of the manufacturing apparatus 100 of the stator concerning an Example. It is a perspective view for demonstrating the principal part of the winding shaping | molding set process by the manufacturing apparatus 100 (coil winding apparatus 101) of the stator concerning an Example. FIG. 6 is a schematic diagram when an insertion-molded U-phase winding 50b is set on the transfer tool 120. FIG. 5 is an explanatory view for explaining a winding insertion process for inserting a molded U-phase winding 50b for insertion set in a transfer tool 120 into a slot 32 of a stator core 30. 3 is a front view schematically showing a molded U-phase winding 50b for insertion inserted into a slot 32 of a stator core 30. FIG. FIG. 8 is a cross-sectional view taken along the line AA in FIG. 7 and shows an arrangement of the strands 40 (in-slot insertion portions 53) inserted into the slots 32; It is a perspective view for demonstrating the principal part of the winding shaping | molding set process by the conventional stator manufacturing apparatus 500. FIG. It is sectional drawing which shows the arrangement | sequence of the strand 40 (insertion part 53 in a slot) inserted in the slot 32 using the conventional manufacturing apparatus 500 of a stator.

Explanation of symbols

10 Motor 20 Stator 30 Stator Iron Core 32 Slot 40 Wire 50 U-phase Winding (Winding)
50b Molded U-phase winding for insertion (molded winding for insertion)
51 U-phase coil (coil)
51b U-phase coil part (coil part)
53 U-phase slot insertion part (slot insertion part)
53b First cutting edge side U-phase slot insertion part (first cutting edge side slot insertion part)
53c Insertion part in the most advanced U phase slot (Insertion part in the most advanced slot)
54 U-phase clamping part (clamping part)
54b The most advanced side clamping part (The most advanced side U-phase clamping part)
56b Surface side U-phase coil end part (surface side coil end part)
56c Back side U-phase coil end (back side coil end)
57 U phase crossover (crossover)
100,500 Stator manufacturing apparatus 101 Coil winding apparatus 110 Winding machine 111 Reel 115,515 Flyer 120,520 Transfer tool 121,521 Blade 125 Bending member 130 Stripper

Claims (4)

Manufacture of a stator in which a part of a coil formed by winding a winding made of a plurality of strands in advance is inserted into a slot formed in an internal tooth-shaped stator core having a front surface and a back surface. A method,
The coil is formed, and the coil is formed with a plurality of coil portions wound by a predetermined number of turns to form a coil, and a transition winding portion between the coil portions. Winding forming set that sets the inserted pre-formed winding to the transfer tool in a form in which the sandwiching portion among the portions is sandwiched between adjacent blades among transfer tools having a plurality of annularly arranged blades Process,
The set molded winding for insertion is moved along the blade with a stripper, and the insertion portion in the slot of the coil portion of the molded winding for insertion is inserted into the slot of the stator core. A winding insertion step of arranging the coil end portion other than the in-slot insertion portion and the crossing portion on the front surface or the back surface of the stator iron core, among the coil portions,
The winding molding set process
In the shape including the insertion portion in the slot in which each of the strands is linearly formed in a portion from the most distal side clamping portion located on the most distal end side of the blade among the clamping portions to the transition portion,
Alternatively, the portion up to the transition part including the most advanced side sandwiching part has a shape that becomes the insertion part in the slot in which each of the strands is linearly formed,
A method for manufacturing a stator, which is set on the transfer tool while forming the molded winding for insertion. It is a manufacturing method of the stator according to claim 1 ,
In the winding forming and setting step, a stator manufacturing method in which any of the strands in the slot insertion portion is linearly formed. While winding a winding made of a plurality of strands around a winding frame and forming the winding, the above-described formed winding is held between adjacent blades among transfer tools having a plurality of annularly arranged blades. A coil that is transferred to a transfer tool and sets a molded winding for insertion having a plurality of coil portions wound around a predetermined number of turns to form a coil and a transition portion that spans between the coil portions in the transfer tool. A winding device,
Each of the strands in the slot insertion portion to be inserted and arranged in at least the slot of the stator core of one coil portion is linearly formed, and a part of the one coil portion is sandwiched between predetermined blades. After the transfer to the transfer tool, pull out the winding while applying tension to the winding, and rotate and transfer at least one of the transfer tool and the winding frame around the axis of the transfer tool. Forming the transition part, and then forming the next coil part by winding the winding around the winding frame, and transferring to the transfer tool in the form of being sandwiched between the other blades,
When the most inserted portion in the slot of the one coil portion located closest to the tip of the blade is the insert portion in the most advanced slot, the insert portion in the most advanced slot is adjacent to the crossing portion. A bending preventing mechanism for preventing bending of each of the strands in the first leading edge side slot insertion portion that is continuous ;
The bending prevention mechanism is
A bending member disposed radially outside the transfer tool from the blade,
The winding is pulled out while tension is applied to the winding, and at least one of the transfer tool and the winding frame is rotated around the axis of the transfer tool to form the transition portion, A bending member that turns the bending member to bend the winding at a portion in contact with the bending member while keeping the insertion portion in the first foremost side slot in a straight line. apparatus. A coil winding device according to claim 3 ;
While the stator core is disposed at the tip of the blade, the molded winding for insertion set on the transfer tool is pushed toward the stator core in the axial direction of the transfer tool while the stator core A stripper to be inserted into the slot;
A stator manufacturing apparatus comprising:

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