JP4442172B2 - Coil forming apparatus and method, and method for manufacturing rotating electrical machine - Google Patents

Description

The present invention relates to a coil forming apparatus and method for forming a coil inserted in a slot of an outer core of a rotating electric machine such as a motor or a generator for the convenience of subsequent processes such as insertion of a subsequent coil, and rotation by the method . The present invention relates to a method of manufacturing an electric machine .

  In the manufacturing process of a rotating electrical machine, a plurality of coils each having a conductor wound thereon are prepared in advance, and these are sequentially inserted into slots of an outer core (mostly a stator core). Here, if the coil inserted into the slot is left as it is, it interferes with subsequent processes such as insertion of subsequent coils. For this reason, it is necessary to mold the inserted coil so as not to interfere with the subsequent process. Patent documents 1 and 2 etc. are mentioned as what is proposed conventionally as a forming technique for that.

The coil molding process is basically divided into two processes, intermediate molding and expansion molding. In the intermediate forming process, the coil end part (the part protruding from the end of the core) is pushed outward in the radial direction, and the coil side part (the part located in the slot) is pushed toward the bottom of the slot. It is a process. However, with this alone, the end portion of the coil can be expanded only to the outer diameter portion of the slot. Furthermore, the end portion returns slightly inward due to the springback (restoring force) of the coil. For this reason, it is not possible to completely make a slot space for the subsequent process. Therefore, after the intermediate forming process, an expansion forming process is required in which the end portion of the coil is further expanded outward.
JP 11-27889 A JP-A-5-304748

  However, the conventional technique described above has the following problems. In other words, both the intermediate molding and the expansion molding cannot be performed completely with one apparatus. For example, in the technique of Patent Document 1, it is considered that intermediate molding and expansion molding can be performed by the apparatus described in FIG. However, as described in paragraph [0009] of the same document, the expansion molding in this apparatus is only due to the axial pressing of the upper and lower molds and is insufficient. Therefore, as shown in FIG. 2 of the same document, it has been necessary to perform another expansion molding using another apparatus. Even in the technique of Patent Document 2, expansion molding is insufficient in spite of intermediate molding. As described above, conventionally, separate apparatuses are required for intermediate molding and expansion molding, which is a burden on the number of processes and equipment.

The present invention has been made to solve the above-described problems of the prior art. That is, the object is to provide a coil forming apparatus and method , and a method of manufacturing a rotating electrical machine using the same , in which both the intermediate forming process and the extension forming process can be performed completely with a single apparatus. .

  The coil forming apparatus of the present invention, which has been made for the purpose of solving this problem, is an apparatus for forming a coil inserted into a slot of an outer core, and includes a bullet-like member that enters the inner side of the outer core from one side in an axial direction. , A blade member that is built into the shell-shaped member and enters the outer core slot by protruding in the radial direction, and is provided at a position behind the blade member in the direction of entering the outer core in the shell-shaped member, The first expansion member that pushes the portion of the coil that protrudes from one end of the outer core outward, and the outer core is positioned on the opposite side of the shell-like member and moves in the axial direction of the outer core. The extension member holder and the part of the extension member holder that protrudes from the other end of the outer core of the coil Extruded and has a second extension member.

Coil forming by this coil forming apparatus is performed as follows. That is, the bullet-like member is made to enter inside the outer core in which the coil is inserted. As a result, the blade member faces the outer core coil. Then, the blade member is pushed out from the shell-like member in the radial direction. Then, the blade member enters the slot of the outer core. Thereby, the part which protruded from the end of the outer core of a coil is extruded to the outer-diameter part of a slot. This is the intermediate forming of the coil. Next, let the 1st expansion member and the 2nd expansion member be the state which faces the both ends of an outer core. Thereby, it is set as the state which the 1st expansion member and the 2nd expansion member face the part which protruded from the end of the outer core of a coil. Then, the first expansion member and the second expansion member are pushed out in the radial direction. Thereby, the part which protruded from the end of the outer core of a coil is extruded further outside from the outer diameter part of a slot. This is coil expansion molding. As described above, intermediate molding and expansion molding can be performed by a single coil molding apparatus. This coil molding is performed during the manufacturing process of the rotating electrical machine.

In the coil forming apparatus of the present invention, the bullet-shaped member and the expansion member holder further include an expansion cam that is provided obliquely with respect to the radial direction and rotates about the axis. The first expansion member and the second expansion member It is that not meshing portion is provided meshing with expansion cams. For this reason , when the expansion cam is rotated, the first expansion member and the second expansion member move in the radial direction by the cooperation of the expansion cam and the meshing portion. Thus, that protrudes in the radial direction of the first extension member and the second extension member is realized.

  In the coil forming apparatus of the present invention, the bullet-shaped member has an opening / closing cam that moves the blade member in the radial direction by moving in the axial direction, and the blade member has a cam groove that meshes with the opening / closing cam. It is good to do. In this case, when the opening / closing cam is moved in the axial direction, the blade member moves in the radial direction by the cooperation of the opening / closing cam and the cam groove. As a result, the blade member can be pushed out in the radial direction.

According to the present invention, there is provided a coil forming apparatus and method , and a method for manufacturing a rotating electrical machine using the same , in which both steps of intermediate forming and expansion forming can be carried out completely with one apparatus.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the best mode for embodying the present invention will be described in detail with reference to the accompanying drawings. This embodiment embodies the present invention as a coil forming apparatus that forms a coil inserted into a stator core of a motor.

  The coil forming apparatus according to the present embodiment schematically has the entire configuration shown in FIG. The coil forming apparatus in FIG. 1 includes a bullet-like member 2 on a base 1. A blade member 3 is built in the bullet-like member 2. Further, the bullet-like member 2 is provided with a first expansion member 4 at a position below the blade member 3. Further, the upper plate 6 is supported by the support column 5 with respect to the base 1, and an upper molding portion 7 is provided on the upper plate 6. The upper molding part 7 is provided with a second expansion member 8. The bullet-like member 2 can be moved up and down with respect to the base 1 together with the blade member 3 and the first expansion member 4. Further, the upper molding portion 7 can be moved up and down with respect to the upper plate 6 together with the second expansion member 8. A workpiece 100, that is, a work pallet 101 holding a stator core, is conveyed between the shell-shaped member 2 and the upper molding portion 7 from a direction perpendicular to the paper surface of FIG. It has come to be.

The bullet-like member 2 will be further described with reference to FIG. The bullet member 2 includes the blade member 3 as described above. The blade member 3 is a flat plate- like member and can move in the radial direction with respect to the bullet-like member 2. In FIG. 1 and FIG. 2, the blade member 3 is drawn as if there are only two left and right, but in reality, a large number of blade members 3 are provided around the center of the shell-like member 2. The blade member 3 actually forms a coil at its outer side 31. A recess 32 is formed below the outer side 31. A cam groove 33 is formed on the inner side of the blade member 3.

  A cam shaft 9 is provided along the center of the bullet-like member 2. An umbrella-shaped cam member 91 that meshes with the cam groove 33 of the blade member 3 is attached to the cam shaft 9. The cam shaft 9 and the cam member 91 are integrally moved with respect to the bullet-like member 2 in the vertical direction. The vertical movement of the cam shaft 9 and the cam member 91 is independent of the vertical movement of the bullet-like member 2 relative to the base 1. In addition, a restriction member 92 that restricts the vertical movement of the blade member 3 is provided inside the bullet-like member 2. As a result, the blade member 3 can be pushed outward in the radial direction or returned to its original position. The blade member 3 in FIG. 2 shows the original position. FIG. 3 shows a state in which the blade member 3 protrudes. In this state, the recess 32 is formed in the blade member 3, thereby preventing interference between the blade member 3 and the first expansion member 4. The amount of protrusion of the blade member 3 can be adjusted by adjusting the amount of increase from the position of the camshaft 9 shown in FIG.

  Below the blade member 3, a donut-shaped cam disk 41 and a handle 42 are provided as a push-out mechanism that pushes the first expansion member 4 radially outward. As shown in FIG. 4, a cam groove 43 that is inclined with respect to the radial direction is formed on the upper surface of the cam disk 41 in FIG. On the other hand, the 1st expansion member 4 is attached to the base member 44, and the cam pin 45 is formed in the lower part of the base member. The cam pin 45 is inserted into the cam groove 43 of the cam disk 41. 1 and 2, the first expansion member 4 is depicted as if there are only two left and right, but in reality, as shown in FIG. 4, there are many first expansion members 4 around the center of the shell-like member 2. Is provided. The first expansion member 4 is actually formed into a coil by the recess 46. The cam disk 41 can be rotated around the axis by the handle 42. However, the first expansion member 4 and the base member 44 are movable only in the radial direction and do not rotate with the cam disk 41. Therefore, the cooperation of the inclined cam groove 43 and the cam pin 45 can realize a state in which the first expansion member 4 is pushed out in the radial direction (FIGS. 5 and 6). FIG. 6 illustrates a state in which the blade member 3 is returned to the base state and only the first expansion member 4 is pushed out. The amount of protrusion of the first expansion member 4 can be adjusted by adjusting the amount of rotation of the cam disk 41. Alternatively, the amount of protrusion of the first expansion member 4 can be adjusted by the length of the cam groove 43 in the cam disk 41 and the angle with respect to the radial direction.

  Next, the upper molding part 7 in FIG. 1 will be described. The upper molding portion 7 also has a push-out mechanism that pushes the second expansion member 8 in the radial direction. Since this mechanism is the same mechanism as the mechanism such as the cam disk 41 below the bullet-like member 2, detailed description thereof is omitted. However, it is arranged upside down from that of the shell-like member 2. Further, since the cam disk 41 has a donut shape, the top of the bullet-like member 2 can enter the cam disk 41. This is to prevent interference when the cannonball-shaped member 2 is raised and the upper molding portion 7 is lowered.

  As shown in FIG. 7, actually, three bullet-like members 2 and two upper molding portions 7 are provided. The reason is that the shape and the number required for the blade member 3, the first expansion member 4, and the second expansion member 8 are different for each coil of the first phase to the third phase. Therefore, a dedicated bullet-like member 2 and an upper molding portion 7 are provided for each phase coil. However, after insertion of the third phase coil, which is the final phase, only intermediate formation is performed and expansion formation is not performed. This is because no further coil is inserted thereafter. For this reason, the number of the upper molding parts 7 is two. Further, the third-phase bullet-like member 2 is not provided with the first expansion member 4 and the projecting mechanism thereof. FIG. 7 depicts the situation when the coil forming apparatus of FIG. 1 is viewed from the side, omitting components other than the shell-like member 2 and the upper forming portion 7.

  Subsequently, a coil forming operation by the coil forming apparatus according to the present embodiment will be described. First, the corresponding shell-like member 2 and the upper molding portion 7 are set at the working position. Then, the bullet-like member 2 is lowered and the upper molding part 7 is raised. All of the blade member 3, the first expansion member 4, and the second expansion member 8 are stored inside. In this state, the work 100 held on the work pallet 101 is received at the work position of the coil forming apparatus. The molding operation is started from here. At this time, although the coil is inserted into the workpiece 100, that is, the stator core, as shown in FIG. 8A, the entire coil is substantially vertical. That is, the end portion 102 of the coil is not pushed outward. In particular, the upper end portion 102 is rather slightly inward. For this reason, the insertion of the next phase coil is prevented.

  Therefore, the bullet-like member 2 is raised and entered inside the workpiece 100. Then, the outer side 31 of the blade member 3 faces the workpiece 100. This state is shown in FIG. In this state, the end portion 102 on the coil is pushed slightly outward as compared with the state of FIG. This is because the top of the shell-like member 2 has entered the work 100 from below. From this state, the camshaft 9 in FIG. 2 is raised. Then, the blade member 3 is pushed outward in the radial direction by the action of the cam member 91 and the cam groove 33. Therefore, the blade member 3 is in the state shown in FIG. As a result, the end portion 102 of the coil is expanded to the outer diameter portion of the slot of the workpiece 100. That is, the state shown in FIG. This operation from (a) to (b) in FIG. 8 is intermediate molding. After the intermediate molding, the blade member 3 is returned to its original state.

  Here, the difference in the intermediate forming depending on the coil phase will be described. Therefore, first, the difference in the action of the blade member 3 between the inserted slot and the non-inserted slot will be described. As shown in FIG. 10, in the inserted slot 104, the blade member 3 only slightly enters the slot. This is because the side portion 103 of the coil already exists in the slot and is only pressed toward the bottom of the slot. On the other hand, in the uninserted slot 105, the blade member 3 enters near the bottom of the slot. This is because the end portion 102 of the coil is extended to the outer diameter portion of the slot. Next, the difference for each phase will be described. After insertion of the first-phase coil, as shown in FIG. 11, the four non-inserted slots 105 and the two inserted slots 104 form one period of the slot arrangement. After the insertion of the second phase coil, as shown in FIG. 12, the two non-inserted slots 105 and the four inserted slots 104 form one slot arrangement period. Note that after insertion of the third phase coil, all slots become inserted slots. The arrangement of the blade member 3 in the bullet-like member 2 dedicated to each phase is adapted to this.

  After the insertion of the first-phase or second-phase coil, extension molding is performed following the intermediate molding. Therefore, the bullet-like member 2 is further raised from the position shown in FIG. Further, the upper molding part 7 is lowered. Thus, the upper and lower first expansion members 4 and the second expansion member 8 are brought into contact with the end portion 102 of the coil. This state is shown in FIG. From this state, the cam disk 41 is rotated in the upper and lower directions to the state shown in FIG. Then, by the cooperation of the cam groove 43 and the cam pin 45, the first expansion member 4 and the second expansion member 8 are pushed outward in the radial direction. Therefore, the 1st expansion member 4 will be in the state shown in FIG. The second expansion member 8 is also in the same state. As a result, the end portion 102 of the coil is further expanded outward from the outer diameter portion of the slot of the workpiece 100. That is, the state shown in FIG. This operation from (b) to (c) in FIG. 8 is expansion molding.

  There is a difference depending on the phase of the coil for expansion molding. This is because the expansion molding is performed only for the non-inserted slot described in FIG. 10 for the intermediate molding. Therefore, the number or location of slots to be expanded differs between the insertion of the first phase coil and the insertion of the second phase coil. In addition, after insertion of the third phase coil, there is no longer any slot to be expanded. The arrangement of the first expansion member 4 in the bullet-like member 2 dedicated to the first phase and the second phase corresponds to this. The arrangement of the second expansion member 8 in the upper molding portion 7 dedicated for each phase is the same.

  When intermediate molding and expansion molding are performed as described above, the first expansion member 4 and the second expansion member 8 are stored as they were. The bullet-like member 2 is lowered and the upper molding portion 7 is raised. Then, the work pallet 101 holding the work 100 moves toward the next process. Of course, in this state, the coil end portion 102 does not get in the way in the next step (coil insertion of the next phase, etc.).

  As described above in detail, in the coil forming apparatus according to this embodiment, the bullet-like member 2 is provided below the working position, and the upper forming portion 7 is provided above. Then, a blade member 3 is provided on the bullet-like member 2, and an intermediate molding of the coil is performed by a radially outwardly projecting operation of the blade member 3. Furthermore, a first expansion member 4 and a second expansion member 8 are provided in the shell-shaped member 2 and the upper molding portion 7 respectively, and the coil is formed by the radially outwardly projecting operation of the first expansion member 4 and the second expansion member 8 The expansion molding is performed. As a result, a coil forming apparatus and method that can complete the coil forming by performing both the intermediate forming and the expansion forming with one apparatus are realized. In the coil forming apparatus according to the present embodiment, in particular, the expansion forming is performed not by the axial operation but by the radially outward pushing operation. For this reason, the end portion of the coil after intermediate forming can be sufficiently expanded radially outward. Therefore, it is possible to insert the coil of the next phase and the like without having to redo expansion molding with another device thereafter.

  Note that this embodiment is merely an example, and does not limit the present invention. Therefore, the present invention can naturally be improved and modified in various ways without departing from the gist thereof.

It is a front view which shows the whole structure of the coil forming apparatus which concerns on the best form. It is an internal structure figure of a shell-like member in a coil forming device. It is an internal structure figure of a shell-like member showing the state where a blade member was pushed out. It is a top view which shows the cam disk which projects an expansion member radially. It is a top view of the cam disk which shows the state which extended the expansion member to radial direction. It is an internal structure figure of a shell-like member showing the state where the expansion member was pushed out in the diameter direction. It is a side view which shows the main components of a coil forming apparatus. It is a side view which shows the change of the shape of a coil end by progress of the shaping | molding operation | work of a coil. It is a fragmentary sectional view which shows the condition before performing intermediate shaping | molding. It is a top view which shows the effect | action of the blade member at the time of the intermediate | middle shaping | molding in the inserted slot and the non-inserted slot of a core. It is a top view which shows the condition after insertion of a 1st phase coil. It is a top view which shows the condition after insertion of a 2nd phase coil. It is a fragmentary sectional view which shows the condition before performing expansion molding.

Explanation of symbols

2 Cannonball-shaped member 3 Blade member 4 First expansion member 7 Upper molding part (expansion member holder)
8 Second expansion member 33 Cam groove 43 Cam groove (expansion cam)
45 Cam pin (meshing part)
91 Cam member (opening / closing cam)

Claims (4)

In a coil forming apparatus for forming a coil inserted into an outer core slot,
A bullet-like member entering the inner side of the outer core from one of the axial directions;
A blade member that is built into the shell-shaped member and enters the slot of the outer core by protruding in the radial direction;
A first extension of the shell-like member that is provided at a position rearward of the blade member in the approaching direction to the outer core and pushes the portion protruding from one end of the outer core of the coil outward by pushing out in the radial direction. Members,
An expansion member holder that is located on the opposite side of the shell-shaped member across the outer core and moves in the axial direction of the outer core;
Provided in the extension member holder, by pushed out in the radial direction, it has a second extension member to push the protruding portion from the other end of the outer core of the coil outward,
The bullet-shaped member and the expansion member holder are provided obliquely with respect to the radial direction and have an expansion cam that rotates around the axis,
Wherein the first extension member and the second extension member, the coil forming apparatus characterized that you have the being engaging portion meshed with the extended cam provided. In the coil forming apparatus according to claim 1,
The bullet-shaped member has an opening / closing cam that moves the blade member in the radial direction by movement in the axial direction;
A coil forming apparatus, wherein the blade member is formed with a cam groove that meshes with the opening / closing cam. In a coil forming method for forming a coil inserted into an outer core slot,
A bullet-like member entering the inner side of the outer core from one of the axial directions;
A blade member that is built into the shell-shaped member and enters the slot of the outer core by protruding in the radial direction;
A first extension of the shell-like member that is provided at a position rearward of the blade member in the approaching direction to the outer core and pushes the portion protruding from one end of the outer core of the coil outward by pushing out in the radial direction. Members,
An expansion member holder that is located on the opposite side of the shell-shaped member across the outer core and moves in the axial direction of the outer core;
Provided in the extension member holder, by pushed out in the radial direction, it has a second extension member to push the protruding portion from the other end of the outer core of the coil outward,
The bullet-shaped member and the expansion member holder are provided obliquely with respect to the radial direction and have an expansion cam that rotates around an axis;
Wherein the first extension member and the second expansion member, with the coil-forming device engaging portion meshed with the extended cam that is provided,
The bullet-like member is moved inside the outer core into which the coil is inserted,
The blade member is pushed out from the shell-like member in the radial direction to perform intermediate molding of the coil,
The first expansion member and the second expansion member are brought into a state of facing both ends of the outer core, and the first expansion member and the second expansion member are rotated by rotation of the expansion cams of the bullet-shaped member and the expansion member holder. The coil forming method is characterized in that the coil is expanded in a radial direction. A method for manufacturing a rotating electrical machine, comprising the coil forming method according to claim 3.

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