JP6309816B2 - Coil winding / setting method, coil winding / setting device, and stator manufacturing method - Google Patents

Description

  The present invention relates to a coil winding and setting method, a coil winding and setting device, and a stator manufacturing method in which a conductive wire is wound to form a coil, and the coil is set on a coil holder in a state of being spirally overlapped as a whole. Regarding the method.

  As a method for mounting the coil on the stator core, a direct winding method in which the coil is directly wound around the inner teeth of the stator core, and the wound coil is held in a coil insertion jig and inserted into the stator core slot by a coil insertion device. The coil insertion method is adopted.

  However, since the conventional coil insertion method can only form coils that are concentrically wound with respect to each magnetic pole, a motor using such a stator core has torque unevenness due to the phenomenon that the magnetomotive force density in the circumferential direction becomes non-uniform. Occur. This torque unevenness causes motor vibration and noise, and also reduces efficiency.

  In order to solve such a problem, there is known a stator (hereinafter referred to as “spiral winding stator”) in which coils are spirally overlapped when viewed from the end face of the stator core. This stator has excellent characteristics that the coil end is short, the height thereof is relatively uniform and compact, the torque unevenness when the motor is made is small, and the vibration and noise of the motor can be reduced. doing.

  And in order to make such a spiral winding stator, the following patent document 1 has proposed the method of setting a coil to the coil holder in the state which overlapped spirally as a whole. In this method, a coil is set on a coil holder while sequentially superimposing in a coil setting direction, which is a predetermined one direction, with a starting stator coil to be set first as a reference, and a setting position on one side of the starting stator coil On the other hand, the end side stator coil that is set to the same position or the position beyond the other side is set such that the stator coil is inserted into the start side stator coil.

  Patent Document 2 below discloses a coil holder having a plurality of guide rods arranged in an annular shape in order to mount a plurality of coils in a spiral shape on a stator core using a coil insertion device. The U-phase, V-phase, and W-phase coils are sequentially dropped at a predetermined interval from a predetermined position of the gap between the guide rods, and one side of the coil is placed under the adjacent coil to a predetermined gap. In the coil setting method, the coil is set so that the other side of the coil overlaps with the coil adjacent to the opposite side of the coil and enters the predetermined gap, and the coil is overlapped as a whole. When starting to drop a coil from the position of the first coil and the other side of several coils that follow it, when dropping the last coil and one side of several coils before it If the other side of the previous coil is dropped into an irregular gap and the other side of the previous coil cannot be pulled out when dropped into the leg gap, it should be dropped into an irregular gap that does not interfere with them. A coil setting method is characterized in that after the last coil is dropped, the other side of the first coil and several subsequent coils that have been dropped into an irregular gap are extracted and dropped into the regular gap. It is disclosed.

JP 2007-336720 A JP 2012-239323 A

  The method described in Patent Document 1 is characterized in that the end-side stator coil is set so as to be embedded in the start-side stator coil, but when such an operation is actually performed, the start-side stator coil It is difficult to automate the operation by inserting the end-side stator coil and then inserting one side of the start-side stator coil while the one side is lifted. Also, if one side of the start side stator coil is lifted, the coil that overlaps the other side of the start side stator coil will also be lifted, which may require additional steps to fully set the coil. there were.

  On the other hand, in the method described in Patent Document 2, after the last coil has been dropped, the other side of the first coil and several subsequent coils that have been dropped into an irregular gap are extracted and Although it is necessary to drop the coil into the gap, it is necessary to lift the coil that has been dropped once, so it is necessary to pull it out with a very strong force. It was.

  Accordingly, an object of the present invention is to provide a coil winding and setting method in which a coil can be set in a spirally overlapping state as a whole on a blade of an inserter tool in a more rational and reasonable manner. Another object of the present invention is to provide a coil winding / setting device and a method for manufacturing a stator.

To achieve the above object, according to one aspect of the present invention, one side of a coil is adjacent to a predetermined gap of the blade of an inserter tool having a plurality of blades arranged in an annular shape corresponding to the inner teeth of the stator core. Drop the coil so that it enters the predetermined gap under the coil and the other side of the coil overlaps the adjacent coil on the opposite side and enters the predetermined gap, and the coil is spirally overlapped as a whole. In coil winding and setting method to set,
A transfer rod having a larger number of guide bars than the blades of the inserter tool, and arranged in an annular shape so that the guide bars can be partially aligned with the blades by aligning with the inserter tool. Using tools,
The drop start coil and the end coil do not overlap the predetermined gap of the guide rod of the transfer tool, one side of the coil enters the predetermined gap under the adjacent coil, and the other side of the coil is opposite to the above. It overlaps on the coil adjacent to the side and enters a predetermined gap, except between the start coil and the end coil, the coil is dropped into a spirally overlapped state,
The transfer tool is inverted and placed on the inserter tool, and the transfer tool guide bar and the inserter tool blade are aligned with each other while the transfer tool is moved relative to the inserter tool. In this state, the coil is sequentially dropped from the start coil side into the predetermined gap of the blade, and one end portion of the end coil is overlapped with one side portion of the start coil, and the state is overlapped spirally as a whole The present invention provides a coil winding and setting method characterized in that a coil is set in a coil.

  According to the above invention, the coil can be dropped onto the transfer tool by aligning the coil wound around the winding frame with the predetermined gap of the guide rod and dropping it as it is, and the workability is improved. Coil disturbance is less likely to occur. In addition, when transferring from the transfer tool to the inserter tool, one side of the end coil is overlapped with one side of the start coil, so that the entire coil can be spiraled only by dropping the coil. The coil can be set in an overlapping state. This eliminates the need for operations such as inserting the end-side stator coil with the one side of the start-side stator coil lifted, or extracting the coil once dropped and dropping it into the regular gap. In this manner, the coil can be set on the blade of the inserter tool so as to overlap in a spiral manner as a whole.

  In the coil winding and setting method of the present invention, the number of guide rods of the transfer tool is such that the side portions of the start coil and the end coil that overlap with each other when dropped into the inserter tool do not overlap. It is preferable that it is set so as to enter an adjacent gap.

  According to this, the number of gaps of the transfer tool can be reduced as much as possible, and a region where the guide bar of the transfer tool and the blade of the inserter tool are aligned can be made wider when aligning.

  In the coil winding / setting method of the present invention, when the coil is dropped into a predetermined gap of the guide rod of the transfer tool, one side of the coil under the adjacent coil is set to the coil adjacent to the opposite side. Preferably, the coil is slanted by pushing it down more greatly with respect to the other side of the coil that overlies.

  According to this, it can suppress that a coil accumulates and can shorten the required length of the guide rod of a transfer tool.

According to another aspect of the present invention, one side of a coil is below an adjacent coil in a predetermined gap of the blade of an inserter tool having a plurality of blades arranged in an annular shape corresponding to the inner teeth of the stator core. Coil winding to set the coil in a state where it overlaps spirally as a whole by entering the predetermined gap and dropping the coil so that the other side of the coil overlaps the coil adjacent to the opposite side and enters the predetermined gap In the set device,
A winding device that forms a coil by winding a conductive wire around a winding frame;
A transfer rod having a larger number of guide bars than the blades of the inserter tool, and arranged in an annular shape so that the guide bars can be partially aligned with the blades by aligning with the inserter tool. Tools and
A dropping device that moves the winding frame so as to align with a predetermined gap of the guide rod of the transfer tool, and drops the coil wound around the winding frame into the predetermined gap of the guide rod;
The inserter tool;
Placing the transfer tool on the inserter tool in an inverted state, moving the transfer tool relative to the inserter tool, and aligning the guide bar to partially align with the blade; A coil transfer device for sequentially dropping the coil held by the transfer tool into the inserter tool at a portion where the guide bar and the blade are aligned,
The coil wound by the winding device is arranged so that the dropping start coil and the ending coil do not overlap with a predetermined gap of the guide rod of the transfer tool by the dropping device so that one side of the coil is adjacent to the coil. Under the predetermined gap, the other side of the coil overlaps with the coil adjacent to the opposite side, enters the predetermined gap, and overlaps spirally except between the start coil and the end coil Drop the coil into
In the state where the transfer tool is reversed and installed on the inserter tool by the coil transfer device, the transfer tool is moved relative to the inserter tool and aligned, and the transfer tool guide rod And the blade of the inserter tool are aligned with each other, the coil is sequentially dropped from the start coil side into a predetermined gap of the blade, and one end portion of the end coil is overlapped with one side portion of the start coil. The present invention provides a coil winding and setting device characterized in that the coil is set so as to be spirally overlapped as a whole.

  According to the above-described invention, as described above, the coil can be set in a spirally overlapped state as a whole on the blade of the inserter tool by a more rational method without difficulty by only dropping the coil. it can.

  In the coil winding and setting device of the present invention, the number of guide rods of the transfer tool is such that the side portions of the start coil and the end coil that overlap with each other when dropped into the inserter tool do not overlap. It is preferable that it is set so as to enter an adjacent gap.

  According to this, the number of gaps of the transfer tool can be reduced as much as possible, and a region where the guide bar of the transfer tool and the blade of the inserter tool are aligned can be made wider when aligning.

  In the coil winding and setting device according to the present invention, the dropping device may be configured such that when the coil wound around the winding frame is dropped into a predetermined gap of the guide rod, The coil is preferably configured to be inclined by pushing down one side more greatly downward with respect to the other side of the coil overlapping the coil adjacent to the opposite side.

  According to this, it can suppress that a coil accumulates and can shorten the required length of the guide rod of a transfer tool.

  In the coil winding and setting device of the present invention, the transfer tool has a shutter that holds the coil dropped into the predetermined gap of the guide rod so as not to drop when the transfer tool is reversed. The coil can be partially opened, and the coil can be dropped from the reel to the transfer tool and the coil can be dropped from the transfer tool to the inserter tool through the opening. preferable.

  According to this, the coil is dropped from the reel to the transfer tool by the dropping device through the opening of the shutter, and after dropping all the coils, the shutter is closed and the transfer tool is inverted, and the transfer tool is placed on the inserter tool. A tool is installed, and the coil can be sequentially dropped through the opening of the shutter by the coil transfer device.

  According to still another aspect of the present invention, the coil winding and setting method allows a predetermined gap of the blade of the inserter tool to enter a predetermined gap with one side of a coil under an adjacent coil, and the other side of the coil Drop the coil so as to enter the predetermined gap over the adjacent coil on the opposite side, set the coil in a state where it overlaps spirally as a whole, set the inserter tool in the coil insertion device, A stator manufacturing method is provided, wherein a coil is inserted into a slot of a stator core.

  According to the present invention, the coil end is short, the height is relatively uniform and compact, the torque unevenness when the motor is made is small, and the vibration and noise of the motor can be reduced. Can be obtained.

  According to the present invention, it is possible to set the coil in a spirally overlapping state as a whole on the blade of the inserter tool by a more rational method without difficulty by only dropping the coil. And by inserting the coil set in this way into the slot of the stator core by the coil insertion device, the coil end is short, its height is relatively uniform and compact, and when it is used as a motor A stator that can reduce torque unevenness and reduce motor vibration and noise can be obtained.

In one Embodiment of the coil winding and setting method by this invention, it is a model perspective view which shows the state which made the inserter tool hold | maintain a coil. In the coil winding and setting method, it is a schematic plan view showing (a) a state where a coil is held by an inserter tool and (b) a state where a coil is held by a transfer tool. In the same coil winding and setting method, it is a model perspective view which shows the state which made the transfer tool hold | maintain a coil. In the same coil winding and setting method, it is a model perspective view which shows the state which inverted the transfer tool and installed on the inserter tool. It is explanatory drawing which shows the state which aligns the blade of an inserter tool, and the guide rod of a transfer tool partially in the coil winding and setting method. It is a model perspective view which shows the state which starts dropping a coil from a transfer tool to an inserter tool in the coil winding and setting method. It is a model perspective view which shows the state which finishes dropping a coil from a transfer tool to an inserter tool in the coil winding and setting method. It is a perspective view which shows the transfer tool in one Embodiment of the coil winding and setting apparatus of this invention. It is explanatory drawing of the transfer tool in the coil winding and setting apparatus. It is a perspective view which shows the rotation tool in the coil winding and setting apparatus. It is a perspective view which shows the state which installed the transfer tool on the rotation tool in the coil winding and setting apparatus. It is a schematic block diagram which shows the coil winding and dropping device in the coil winding and setting apparatus. It is an enlarged perspective view which shows the state which installs a transfer tool in the coil winding and dropping device, and drops a coil. It is a perspective view which shows the principal part of the coil winding and dropping device. It is explanatory drawing which shows the winding frame in the coil winding and dropping device, (a) is a perspective view which shows the state at the time of winding, (b) A perspective view which shows the state at the time of coil dropping, (c) Coil dropping It is a side view which shows the state of time. It is a perspective view which shows the state which wound the conducting wire around the winding frame in the same coil winding and dropping device, and formed the coil. It is explanatory drawing which shows the state which hold | suppresses the coil wound around the winding frame in the same coil winding and dropping device, and makes it reduce in diameter, (a) is the state which wound the conducting wire around the winding frame, and formed the coil, (b) is the perspective view which shows the state which pressed the coil with the pressing plate, and (c) is the state which reduced the diameter of the winding frame, respectively. It is a perspective view which shows the pressing-down apparatus of the coil in the same coil winding and dropping device. It is explanatory drawing which shows operation | movement of the coil pressing-down apparatus in the same coil winding and dropping device, (a) is the state before a reel moves to a coil holder, (b) is a reel to a coil holder. A state in which the first pressing part and the second pressing part are closed by moving, (c) a state in which the first pressing part and the second pressing part are lowered, and (d) in which the first pressing part is from the second pressing part. FIG. 4 is a perspective view showing a state where the lowering is further greatly lowered. It is a perspective view which shows the state which installs a transfer tool in the coil winding and dropping device, and drops a coil. It is a perspective view which shows the state which dropped the coil into the transfer tool using the coil winding and dropping device. It is a perspective view which shows the state which reversed the transfer tool. In the said coil winding and setting apparatus, it is explanatory drawing which shows the state which installs a transfer tool and an inserter tool in a coil transfer apparatus. It is explanatory drawing which shows the state which installed the transfer tool and the inserter tool in the coil transfer apparatus in the same coil winding and setting apparatus. It is a perspective view which shows the state which drops a coil from the transfer tool to an inserter tool using the same coil transfer apparatus. It is a perspective view which shows the state which the dropping of the coil from a transfer tool to an inserter tool finishes using the same coil transfer apparatus. It is a perspective view which shows the state which dropped the coil into the inserter tool. It is sectional drawing which shows the state which has arrange | positioned the inserter tool to a coil insertion apparatus, and mounted | wore the stator core. FIG. 29 is a cross-sectional view showing a state in which the blade and the stripper are lifted from the state shown in FIG. 28 so that the tip of the blade protrudes from the upper end surface of the stator core. FIG. 30 is a cross-sectional view showing a state where the stripper is raised from the state shown in FIG. 29 and the upper half of the coil is inserted into the slot of the stator core. FIG. 31 is a cross-sectional view showing a state where the stripper is further raised from the state shown in FIG. 30 and the coil is completely inserted into the slot of the stator core. It is a top view of the stator core which attached the coil by the said method.

  Embodiments of the present invention will be described below with reference to the drawings.

  First, an embodiment of a coil winding / setting method according to the present invention will be described with reference to FIGS. 1 to 7 are schematic views for explaining the principle in principle.

  FIG. 1 is a perspective view showing a state where a coil C is finally set on an inserter tool 200 by the coil winding / setting method according to the present invention. The inserter tool 200 has a structure in which a plurality of blades 220 arranged in an annular shape corresponding to the inner teeth of the stator core are held by a holder 212. In the coil winding / setting method of the present invention, when setting the coil by dropping the coil C into the predetermined gap of the blade 220 of the inserter tool 200, one side of the coil C is below the adjacent coil C. Enter the predetermined gap, drop the coil C so that the other side of the coil C overlaps with the coil C adjacent to the opposite side of the coil C and enters the predetermined gap, and set the coil C in a spirally overlapping state as a whole. A method is provided.

  As shown in FIG. 2, in the present invention, in order to realize the setting of the coil C as described above to the inserter tool 200, the transfer tool 100 is used to first drop and set the coil C into the transfer tool 100. Next, a method of inverting the transfer tool 100 and dropping the coil C into the inserter tool 200 is employed.

  4A is a schematic plan view showing a state where the coil C is set on the inserter tool 200, and FIG. 4B is a schematic plan view showing a state where the coil C is set on the transfer tool 100. FIG. The transfer tool 100 has a plurality of guide bars 120 arranged in an annular shape. The number of the guide rods 120 is larger than that of the blades 220 of the inserter tool 200, so that one side of the coil C is below the adjacent coil C and enters the predetermined gap in the predetermined gap of the guide rod 120. When the coil C is sequentially dropped so that the other side of the coil C overlaps with the coil C adjacent to the opposite side and enters the predetermined gap, the start coil Ca and the end coil Cb are not overlapped. ing. In a preferred embodiment, the number of guide bars 120 is set so that the adjacent side portions of the start coil Ca and the end coil Cb enter the gap adjacent to the guide bar 120. In this embodiment, the guide rods 120 are six more than the blades 220 (total 54), so that the number of gaps (54) in the guide rods 120 is the number of gaps (48) in the blades 220. 6 more than This number varies depending on the number of slots in the stator core and the number of slots spanned by the coil C. In any case, the start coil Ca and the end coil Cb do not overlap, and the number of the guide rods 120 is as small as possible. What is necessary is just to set so that it may become. As described above, since the coil necessary for manufacturing the stator is set in the transfer tool 100 having the gap of the guide rod 120 which is larger than the number of gaps of the blade 220 of the inserter tool 200 (corresponding to the number of slots of the stator core), the start coil Ca and end coil Cb can be prevented from overlapping. The spacing between the guide bars 120 is substantially the same as that of the blades 220 so that the guide bars 120 can be aligned with the blades 220 at least partially when the transfer tool 100 is inverted and the coil C is dropped into the inserter tool 200. Interval.

  FIG. 3 is a schematic perspective view showing a state where the coil C is set on the transfer tool 100. A coil C wound by a winding device to be described later enters a predetermined gap from a winding frame of the winding device into a predetermined gap of the guide rod 120 with one side of the coil C under the adjacent coil C. The other side of C is sequentially dropped from the start coil Ca so that it overlaps the coil C adjacent to the opposite side and enters a predetermined gap. Then, one side of the end coil Cb is inserted into the gap immediately before the other side of the start coil Ca is inserted so as not to overlap the other side of the start coil Ca.

  After the coil C is set on the transfer tool 100 in this way, the transfer tool 100 is inverted and supported on the inserter tool 200 as shown in FIG. At this time, the coil C is held by means such as a shutter described later so that the coil C does not fall. Since the number of guide bars 120 of the transfer tool 100 is greater than the number of blades 220 of the inserter tool 200, the guide bars 120 and the blades 220 cannot be perfectly aligned.

  Therefore, by rotating and horizontally moving the transfer tool 100 relative to the inserter tool 200 (see arrows X, Y, and O in FIG. 7), as shown in FIG. In the region, the guide rod 120 and the blade 220 are partially aligned. In FIG. 5, P <b> 1 is the center of the inserter tool 200, and P <b> 2 is the center of the transfer tool 100. Here, when the transfer tool 100 is rotated and horizontally moved relative to the inserter tool 200, the transfer tool 100 may be rotated and horizontally moved relative to the inserter tool 200. This means that the inserter tool 200 may be rotated and horizontally moved.

  Then, as shown in FIG. 6, an opening is provided in a holding means such as a shutter at a portion where the guide rod 120 and the blade 220 are aligned, and the coil C held by the transfer tool 100 is inserted from the start coil Ca side into the inserter. Drop it into the tool 200. Since the portion where the guide rod 120 and the blade 220 are aligned becomes one or a plurality of gaps, the coil C located in the aligned region can be dropped simultaneously. When the coil C held in the gap of the guide rod 120 is dropped into the gap of the blade 220 at the portion where the guide rod 120 and the blade 220 are aligned, the transfer tool 100 is rotated and leveled relative to the inserter tool 200 again. The position is adjusted so that the guide rod 120 and the blade 220 are aligned in the region adjacent to the coil C dropped and moved. Then, the coil C held in the gap between the guide rods 120 is dropped again into the gap between the blades 220, and by repeating such operations, the coil C held in the transfer tool 100 is sequentially inserted from the start coil Ca side into the inserter tool 200. I will drop it into.

  Thus, when the coil C held by the transfer tool 100 is sequentially dropped into the inserter tool 200 from the start coil Ca side, as shown in FIG. 7, the end coil Cb finally comes to a position where it overlaps the start coil Ca. By dropping the end coil Cb, one side of the end coil Cb can be dropped on the other side of the start coil Ca. As a result, as shown in FIG. 1, one side of the coil C is below the adjacent coil C, and the other side of the coil C is superimposed on the coil C adjacent to the opposite side, so as to overlap as a whole. The coil C can be set to the state.

  In this way, in the present invention, the coil C can be set in a state of being spirally overlapped as a whole only by dropping the coil C. As a result, one side of the coil C is lifted and the end coil Cb is inserted under the coil C, or the start coil Ca is dropped into a non-regular gap. Since it is not necessary to pull out the side and drop it into a regular gap, the coil C can be dropped without difficulty, making it easier to automate, making the arrangement of the coil C less likely to be disturbed, and preventing the conductors from being damaged.

  Next, an embodiment of the coil winding / setting apparatus of the present invention for carrying out the above-described coil winding / setting method will be described with reference to FIGS.

  8 and 9 show an example of a transfer tool 100 used in the coil winding / setting device. The transfer tool 100 includes a substantially disc-shaped support plate 110 and a guide rod 120 including an inner guide rod 121 and an outer guide rod 122 that are annularly arranged at predetermined intervals along the periphery of the support plate 110. Yes. The inner guide bar 121 and the outer guide bar 122 are provided in pairs at positions corresponding to the inner and outer sides with respect to the center of the support plate 110. Are arranged at predetermined intervals along the periphery. As described above, the number of guide rods 120 including the pair of inner guide rods 121 and outer guide rods 122 is larger than the number of blades 220 of the inserter tool 200, and thereby a predetermined gap between the guide rods 120. The coil C is placed so that one side of the coil C is under the adjacent coil C and enters the predetermined gap, and the other side of the coil C is superimposed on the coil C adjacent to the opposite side and enters the predetermined gap. When sequentially dropped, the start coil Ca and the end coil Cb are not overlapped. The outer guide rod 122 protrudes slightly longer than the inner guide rod 121. As will be described later, the transfer tool 100 is inverted, and the tip of the inner guide rod 121 is opposed to the tip of the blade 220 of the inserter tool 200. At this time, the outer guide rod 122 overlaps the outer side of the blade 220.

  A support shaft 111 is attached through the center of the support plate 110, and a shutter 130 is attached to an end of the support shaft 111 on the side where the guide rod 120 is erected. The shutter 130 includes a rotating plate 131 and a movable plate 132. The movable plate 132 has a notch 133. When the movable plate 132 rotates, an opening 134 that can be opened and closed is formed. It has become. The movable plate 132 is rotated by a drive mechanism (not shown).

  A push-down plate 140 is attached to the gap between the guide rods 120. The push-down plate 140 includes a base 141 that passes through the support plate 110 through a slit (not shown) provided at the periphery of the support plate 110, and a support plate from the end of the base 141 on the side where the guide rod 120 is erected. 110 and a pressing portion 142 extending in a substantially right-angle direction toward the center of 110. As will be described later, the coil C held in the gap of the guide rod 120 can be dropped into the gap of the blade 220 of the inserter tool 200 by pressing the end of the base portion 141 of the push-down plate 140. It has become.

  FIG. 10 shows a rotation tool 150 on which the transfer tool 100 is installed. The rotating tool 150 includes a substrate 151, a rotating table 152 that is rotatably supported on the substrate 151, and a plurality of columns 153 that are erected from the rotating table 152. FIG. 11 shows a state where the transfer tool 100 is installed on the support column 153 of the rotary tool 150.

  FIG. 12 shows a winding / dropping device 10 for winding a conducting wire to form a coil C and dropping the coil C into the gap between the guide rods 120 of the transfer tool 100. The coil winding / dropping device 10 includes a base 11, and a top plate 16 is supported on the base 11 via a plurality of support columns 15. A transfer tool 100 is installed on the base 11 via a rotary tool 150.

  A winding frame 21 is installed above the transfer tool 100 via a winding frame moving device 20 supported by the top plate 16. In addition, a pressing device 25 that is also supported by the top plate 16 is installed adjacent thereto. The pressing device 25 is for dropping the coil C wound around the winding frame 21 into a predetermined gap of the guide rod 120 of the transfer tool 100.

  Further, a conductive wire supply device 23 is provided on the side of the winding frame 21 through a lifting guide 22 supported so as to hang down from the top plate 16 so as to be lifted and lowered. A conducting wire is supplied to the conducting wire supply device 23 from a conducting wire reel (not shown), and the conducting wire is led out from the nozzle 24.

  As shown in FIG. 13, the reel moving device 20 has a support plate 26 supported on the top plate 16. Referring also to FIG. 14, a slide base 30 is slidably attached to the support plate 26 along a longitudinal direction of the support plate 26 via a guide rail 29 by a drive mechanism (not shown). A lift base 31 that moves up and down is attached to the slide base 30, and the winding frame 21 is rotatably attached via a support shaft 33 that extends through the lift base 31. The reel 21 moves up and down as the lifting base 31 moves up and down. The elevating base 31 is raised and lowered by an elevating air cylinder 34 supported on the elevating base 31, and the reel 21 is rotated by a reel rotating motor 32 supported on the elevator base 31.

  Although not shown in detail, as shown in FIG. 13, a U-phase reel, a V-phase reel, and a W-phase reel are provided as the reel 21, and independent reel movement devices are provided. 20 and is independently movable and rotatable.

  The pressing device 25 is disposed so as to be positioned above the transfer tool 100 via a support plate 27 attached on the top plate 16.

  As shown in FIG. 15A, the winding frame 21 includes a front winding frame 35 and a rear winding frame 36. A guide rod 120 of the transfer tool 100 (not shown) enters the space between the front reel 35 and the rear reel 36. The front reel 35 is attached to the rear reel 36 via the support shaft 40 so as to be tiltable, and is tilted inward as shown in FIG. 21 can be reduced in diameter. An inversion protrusion 37 is attached to the front winding frame 35 through a hole 38 so as to be able to appear and retract. A plurality (two in this embodiment) of holes 38 and inversion protrusions 37 are arranged at predetermined intervals along the longitudinal direction of the front winding frame 35. When the front reel 35 is tilted so as to be close to the rear reel 36 and the reel 21 is reduced in diameter, the reversing projection 37 is formed on the outer surface of the front reel 35 as shown in FIG. So that it does not protrude from the hole 38.

  The winding of the conducting wire 41 to the winding frame 21 is such that the end of the conducting wire 41 fed out from the nozzle 24 of the conducting wire supply device 23 in FIG. Is made by rotating. At this time, by gradually raising the conducting wire supply device 23 along the lifting guide 22, the conducting wire 41 can be spirally wound to form the coil C. In addition, although the conducting wire 41 drawn | fed out from the nozzle 24 may be one, Preferably the para wire which several paralleled was employ | adopted.

  When the winding frame 21 is rotated a predetermined number of times to form one coil C, the lead wire 41 is hooked on the reversing projection 37 and the winding frame 21 is rotated in the reverse direction as shown in FIG. The next coil C is formed. In this way, the plurality of coils C can be sequentially formed upward of the winding frame 21 by alternately changing the winding direction.

  As shown in FIG. 17, the reel 21 is rotatably supported via a support shaft 44. A pressing plate 39 is attached to the support shaft 44 through the guide rod 43 so as to be substantially parallel to the winding frame 21. The guide bar 43 of the holding plate 39 is inserted through a guide block 45 mounted on the support shaft 44, slides along the guide bar 43, and can be brought into contact with and separated from the rear reel 36 of the reel 21. Yes. The holding plate 39 is urged by a tension spring (not shown) so as to be always drawn toward the guide block 45.

  In FIG. 14, when the slide base 30 moves along the guide rail 29 to the base end side of the support plate 26, the guide bar 43 is pressed by the stopper 49 attached to the support plate 26, and is shown in FIG. As described above, the presser plate 39 is pushed out against the tension spring, and the presser plate 39 is separated from the winding frame 21. Therefore, in this state, winding to the winding frame 21 is possible.

  In the state where the slide base 30 is moved along the guide rail 29 toward the front end side of the support plate 26, as shown in FIG. 17B, the guide bar 43 is separated from the stopper 49, and the holding plate is pressed by the tension spring. 39 is pulled toward the guide block 45 and the presser plate 39 is pressed against the winding frame 21 so that the coil C wound around the winding frame 21 does not fall.

  Therefore, as shown in FIG. 17A, the coil C is wound around the winding frame 21 in a state where the presser plate 39 is separated from the winding frame 21, and the coil C is connected to a predetermined gap of the guide rod 120 of the transfer tool 100. (B), the coil C is held by the holding plate 39, and in this state, the front reel is moved closer to the rear reel 36 as shown in FIG. 35 is tilted to reduce the diameter of the reel 21. At this time, as described above, the inversion protrusion 37 is submerged in the inside so as not to protrude from the outer surface of the front winding frame 35. By pressing the coil C with the pressing plate 39, the coil C can be prevented from dropping by its own weight until the coil C is pressed down by the pressing device 25 described later.

  As shown in FIG. 18, the pressing device 25 has an elevating base 47 that is attached via a plurality of guide bars 46 that hang from a support plate 27 supported by the top plate 16 (see FIG. 13). A support bar 48 extends downward from the center of the lower surface of the elevating base 47, and the opening and closing plates 50 and 51 are rotatably attached to the support bar 48. That is, the base 50a of the opening / closing plate 50 and the base 51a of the opening / closing plate 51 are arranged vertically, and the support bar 48 extends so as to pass through them, and the opening / closing plates 50, 51 are opened / closed around the support bar 48. It is possible. The opening / closing operation of the opening / closing plates 50 and 51 is performed by a driving mechanism (not shown). A plurality of pins 52 are erected on the inner surface side of the opening and closing plates 50 and 51. This pin 52 is for pushing down the coil C wound around the outer periphery of the winding frame 21.

  A first pressing portion 53 having a tip extending downward is attached to the outer surface side of the opening / closing plate 50 so as to be slidable in the vertical direction by a driving mechanism such as an air cylinder (not shown). Similarly, on the outer surface side of the opening / closing plate 51, a second pressing portion 54 having a tip extending downward is attached to be slidable in the vertical direction by a driving mechanism such as an air cylinder (not shown). When the first pressing portion 53 and the second pressing portion 54 slide downward, the first pressing portion 53 extends further downward than the second pressing portion 54. Pins 52 for pressing down the coil C are attached to the tips of the first pressing portion 53 and the second pressing portion 54.

  FIG. 19 shows the operation of the pressing device 25. As shown in FIG. 5A, the opening and closing plates 50 and 51 are in an open state and are waiting for the reel 21 to move. As shown in FIG. 5B, when the reel 21 is moved and placed at a predetermined position, the opening and closing plates 50 and 51 are closed. As a result, the pins 52 erected on the inner surface side of the open / close plates 50 and 51 are close to the both side surfaces of the winding frame 21 and above the individual coils C wound on the winding frame 21 (see FIG. 7). It is arranged at the position to engage. In this state, as shown in FIG. 6C, the lifting base 47 is lowered, the uppermost coil C is the second stage, the second coil C is the lowermost stage, and the lowermost coil C is the transfer tool. Move to 100. That is, in this state, the lowermost coil C is inserted into a predetermined gap of the guide rod 120 of the transfer tool 100. Next, as shown in FIG. 4D, the first pressing portion 53 and the second pressing portion 54 slide downward, and the coil C inserted into the transfer tool 100 is further pressed downward. At this time, the first pressing portion 53 slides more downward than the second pressing portion 54, so that one side of the coil C moves more downward than the other side, and the coil C is inserted obliquely. Will be.

  As shown in FIG. 20, when the coil C wound around the winding frame 21 is dropped into a predetermined gap of the guide rod 120 of the transfer tool 100, the movable plate 132 of the shutter 130 rotates to form an opening 134, The coil C is dropped into a predetermined gap of the guide rod 120 through the opening 134. The transfer tool 100 is rotated by a predetermined angle by a turntable 152, and the coil C is sequentially dropped into a predetermined gap of the guide rod 120. As described above, the winding frame 21 is provided with three phases of the U phase, the V phase, and the W phase. The winding frame 21 of each phase sequentially moves above the transfer tool 100, and the U phase, The V-phase and W-phase coils C are dropped in order. Further, even if the turntable 152 is rotated by a predetermined angle, the shutter 130 is not rotated by a support mechanism (not shown) so that the position of the opening 134 does not change.

  FIG. 21 shows a state where all the coils C are dropped into a predetermined gap of the guide rod 120 of the transfer tool 100 in this way. At this time, the movable plate 132 of the shutter 130 rotates to close the opening 134.

  FIG. 22 shows a state where the transfer tool 100 is inverted. The coil C is held by the shutter 130 without falling. A rotary head 112 is attached to the end of the support shaft 111. As described above, the start coil Ca and the end coil Cb are dropped into the gap between the guide bars 120 of the transfer tool 100 without overlapping each other. The gap in which one side of the start coil Ca is inserted and the gap in which the other side of the end coil Cb is inserted are adjacent to each other with a pair of guide rods 120 including the inner guide rod 121 and the outer guide rod 122 interposed therebetween. ing.

  As shown in FIGS. 23 and 24, the coil transfer device 300 includes a substrate 310, a support table 311 installed on the substrate 310, and a horizontal movement device disposed adjacent to the rear side of the support table 311. The movable frame 321 is erected via 320 and the support plate 322 is attached to the upper end of the movable frame 321 in the horizontal direction. The movable frame 321 and the support plate 322 can be horizontally moved in the XY directions by the horizontal movement device 320. A holding groove 323 that receives the support shaft 111 of the transfer tool 100 and engages with the rotary head 112 is formed at the front end edge of the support plate 322. Further, on the support plate 322, a rotation motor 331 that rotates the rotary head 112 and rotates the transfer tool 100 via the support shaft 111 is installed.

  Referring also to FIG. 25, the inserter tool 200 includes a support base 211 installed on the substrate 210, a cylindrical holder 212 supported on the support base 211, and a base end portion held by the holder 212. A wedge guide 230 and a blade 220 disposed inside the wedge guide 230. The blade 220 and the wedge guide 230 are annularly arranged at predetermined intervals corresponding to the internal teeth of the stator core.

  The transfer tool 100 is disposed above the inserter tool 200 by inserting the support shaft 111 into the holding groove 323 and engaging the rotary head 112 with the holding groove 323 in the inverted state. At this time, the inner guide bar 121 of the transfer tool 100 is close to the tip of the blade 220 of the inserter tool 200, and the outer guide bar 122 of the transfer tool 100 is positioned on the outer periphery of the blade 220 of the inserter tool 200. The blade 220 extends so as to overlap the tip of the blade 220 by a predetermined length.

  As described above, since the number of guide bars 120 of the transfer tool 100 is larger than the number of blades 220 of the inserter tool 200, the outer and inner diameters of the inner guide bar 121 and the outer guide bar 122 of the transfer tool 100 are determined by the inserter. The outer diameter and inner diameter of the blade 220 of the tool 200 are larger. However, the transfer tool 100 is horizontally moved in the X and Y directions by the horizontal movement device 320 and the transfer tool 100 is rotated and adjusted by the rotation motor 331 to adjust the position of the transfer tool 100 to the upper end portion of the blade 220 of the inserter tool 200. The lower end portion of the inner guide rod 121 of the tool 100 is aligned, and the outer guide rod 122 is aligned outside the blade 220 to provide a region where the gap between the blade 220 and the gap between the guide rods 120 are aligned. .

  In this embodiment, the position is adjusted by horizontally moving and rotating the transfer tool 100 with respect to the inserter tool 200. However, the position is adjusted by horizontally moving and rotating the inserter tool 200 with respect to the transfer tool 100. May be.

  As shown in FIG. 25, a pressing device 340 is provided on the support plate 322. The push-down device 340 is similar to the first pusher 341 pushed out from below the support plate 322 by the first air cylinder 343 installed on the support plate 322, and the second air cylinder installed on the support plate 322. 344 and a second pusher 342 pushed out from below the support plate 322. The first pusher 341 pushes down the push-down plate 140 halfway to push down the coil C held by the transfer tool 100 to the middle of the guide bar 120, and the second pusher 342 pushes down the push-down plate 140 completely, The coil C held in the gap of the guide rod 120 of the transfer tool 100 is inserted into the gap of the blade 220 of the inserter tool 200. At that time, the movable plate 132 of the aforementioned shutter 130 of the transfer tool 100 is rotated to open the opening 134 (see FIG. 8), and the coil C is dropped through the opening 134.

  Since the coil C held by the transfer tool 100 is spirally overlapped, the coil C is pushed down halfway by the first pusher 341 and completely pushed down by the second pusher 342 as described above. It is preferable to drop into the gap between the 200 blades 220. The number of coils C dropped at a time is determined by the number of gaps in a region where the guide rod 120 of the transfer tool 100 and the blade 220 of the inserter tool 200 are aligned. When the dropping is completed once, the transfer tool 100 is horizontally moved and rotated again to adjust the position so that the coil C pushed down halfway by the first pusher 341 and the guide rod 120 of the transfer tool 100 and the inserter. It arrange | positions so that it may become an area | region where the blade 220 of the tool 200 aligns. By repeating such an operation, the coil C is dropped into a predetermined gap of the blade 220 of the inserter tool 200 so as to sequentially overlap with each other.

  FIG. 26 shows a state in which the coil C is sequentially dropped as described above, and the end coil Cb is finally dropped. At this time, the start coil Ca and the end coil Cb that are in positions that do not overlap each other in the state of being held by the transfer tool 100 are arranged so that the other side of the end coil Cb overlaps one side of the start coil Ca. This is a result of sequentially dropping the coil C while aligning the gap of the guide rod 120 of the transfer tool 100 with the gap of the blade 220 of the inserter tool 200. Therefore, in this state, when the pressing plate 140 is pushed down by the second pusher 342 and the end coil Cb is dropped into the gap of the blade 220 of the inserter tool 200, the other side of the end coil Cb overlaps with one side of the start coil Ca. As shown in FIG. 27, in a state where all the coils C are spirally overlapped, the coil C is dropped and set in the gap between the blades 220 of the inserter tool 200.

  28 to 32 show an operation of inserting the coil C thus spirally overlapped and held in a predetermined gap of the blade 220 of the inserter tool 200 into the 65 slots by the coil insertion device 400. FIG. Note that the structure of the coil insertion device 400 itself is basically the same as that of a conventionally used coil insertion device, and a detailed description thereof will be omitted. Also, the shape of the inserter tool 200 and the like shown in FIGS. 28 to 32 is not exactly aligned with the shape of the inserter tool 200 and the like shown in FIGS. 8 to 27. However, FIGS. It should be understood that this is an explanatory diagram showing the principle.

  As shown in FIG. 28, in the coil insertion device 400, the inserter tool 200 in which the coil C is set in the above-described manner is installed. The inserter tool 200 has a substantially cylindrical holder 212, a plurality of wedge guides 230 disposed in the holder 212, and a plurality of blades 220 disposed on the inside thereof. The wedge guide 230 has its base portion inserted into the inner periphery of the holder 212 and is fixed by bolts. The bases of the blades 220 are fixed to the cylindrical blade holder 75 by bolts, and are disposed inside the blades 220 corresponding to the wedge guides 230.

  A stripper 77 is disposed further inside the blade 220. The stripper 77 has a plurality of push teeth inserted into the gap of the blade 61 on the outer periphery thereof, and serves to insert the coil C hooked on the blade 61 into the slot of the stator core 65. A guide rod 78 for avoiding interference between coil ends is erected at the center of the upper surface of the stripper 77, and a cylindrical adapter 79 is attached to the lower surface of the stripper 77.

  A cylindrical first drive shaft 80 and a second drive shaft 81 inserted into the first drive shaft 80 are inserted into the central opening of the substrate 76. The upper end of the first drive shaft 80 can be connected to the blade holder 75, and the upper end of the second drive shaft 81 can be connected to the cylindrical adapter 79 of the stripper 77. That is, when the first drive shaft 80 is raised, the blade 61 is raised via the blade holder 75, and when the second drive shaft 81 is raised, the stripper 77 is raised via the cylindrical adapter 79.

  Next, a procedure for inserting the coil C set in a predetermined gap of the blade 220 into the stator core 65 using the coil insertion device 400 will be described.

  First, as shown in FIG. 28, the upper end portion of the blade 61 is inserted into the stator core 65, and the stator core 65 is disposed at a position where the tip of the wedge guide 62 contacts the lower end surface of the stay core 65.

  Next, as shown in FIG. 29, the first drive shaft 80 and the second drive shaft 81 are pushed up to raise the blade 220 and the stripper 77 so that the tip of the blade 220 protrudes slightly from the upper end surface of the stator core 65. .

  In this state, as shown in FIG. 30, only the second drive shaft 81 is further pushed up to raise the stripper 77, and the coil C set by being hooked on the blade 220 by the pushing teeth (not shown) of the stripper 77 is set to the stator core. Insert into 65 slots. The coil C is guided by the blade 220 and inserted into a slot corresponding to the gap of the blade 220 in which both sides thereof are inserted.

  Then, as shown in FIG. 31, when the stripper 77 is pushed up until it protrudes from the upper end surface of the stator core 65, the upper end portion of the coil C protrudes from the upper end surface of the stator core 65, gets over the upper end portion of the blade 220 and goes outward. The coil C is fully inserted into the slot of the stator core 65.

  Finally, the first drive shaft 80 and the second drive shaft 81 are lowered, the stripper 77 and the blade 220 are returned to their original positions, and the stator core 65 is removed from the tip of the blade 61, thereby completing the coil insertion operation.

  As shown in FIG. 32, the stator core 65 with a coil manufactured in this way has a shape in which the ends (coil ends) of the coils C protruding from the end face of the stator core 65 are spirally overlapped, and its height is Relatively uniform and compact shape. Therefore, it has excellent characteristics that the torque unevenness when it is used as a motor is small, the vibration and noise of the motor are reduced, and the efficiency of the motor can be improved.

  In the embodiment described above, the coil C is inserted into the stator core slot one by one. However, the two coil side portions are inserted into one slot of the stator core. You can also.

DESCRIPTION OF SYMBOLS 11 Base 12 Turntable 13 Coil holder 14 Guide rod 15 Support column 16 Top plate 20 Reel moving device 21 Reel 22 Lifting guide 23 Conductor supply device 24 Nozzle 25 Depressing device 26 Support plate 27 Support plate 29 Guide rail 30 Slide base 31 Lifting base 32 Winding frame rotation motor 33 Support shaft 34 Lifting air cylinder 35 Front winding frame 36 Rear winding frame 37 Reversing projection 38 Hole 39 Holding plate 40 Support shaft 41 Conductor wire 42 Crossover wire 44 Support shaft 45 Guide block 46 Guide Rod 47 Lifting base 48 Support rod 49 Stopper 50 Opening / closing plate 50a Base 51 Opening / closing plate 51a Base 52 Pin 53 First pressing portion 54 Second pressing portion 55 Groove 65 Stator core 70 Coil insertion device 75 Blade holder 77 Stripper 78 Guide rod 79 Cylindrical Adapter 80 First drive shaft 81 Second drive shaft 100 Transf Tool 110 Support plate 111 Support shaft 112 Rotating head 120 Guide rod 121 Inner guide rod 122 Outer guide rod 130 Shutter 131 Rotating plate 132 Movable plate 133 Notch 134 Opening 140 Depressing plate 141 Base 142 Pressing portion 150 Rotating tool 151 Substrate 152 Rotation Base 153 Post 200 Inserter tool 210 Substrate 211 Support stand 220 Blade 230 Wedge guide 300 Coil transfer device 310 Substrate 311 Support stand 320 Horizontal movement device 321 Movable frame 322 Support plate 323 Holding groove 330 Turning device 340 Pushing device 341 First pusher 342 Second pusher 343 First air cylinder 344 Second air cylinder 400 Coil insertion device C Coil Ca Start coil Cb End coil

Claims (8)

In the inserter tool having a plurality of blades arranged in an annular shape corresponding to the inner teeth of the stator core, one side of the coil falls under the adjacent coil and enters the predetermined gap. In the coil winding and setting method in which the coil is dropped so that the side overlaps with the coil adjacent to the opposite side and enters the predetermined gap, and the coil is set in a spirally overlapping state as a whole,
A transfer rod having a larger number of guide bars than the blades of the inserter tool, and arranged in an annular shape so that the guide bars can be partially aligned with the blades by aligning with the inserter tool. Using tools,
The drop start coil and the end coil do not overlap the predetermined gap of the guide rod of the transfer tool, one side of the coil enters the predetermined gap under the adjacent coil, and the other side of the coil is opposite to the above. It overlaps on the coil adjacent to the side and enters a predetermined gap, except between the start coil and the end coil, the coil is dropped into a spirally overlapped state,
The transfer tool is inverted and placed on the inserter tool, and the transfer tool guide bar and the inserter tool blade are aligned with each other while the transfer tool is moved relative to the inserter tool. In this state, the coil is sequentially dropped from the start coil side into the predetermined gap of the blade, and one end portion of the end coil is overlapped with one side portion of the start coil, and the state is overlapped spirally as a whole A coil winding and setting method, characterized in that a coil is set in a coil.   The number of guide rods of the transfer tool is set so that the side portions of the start coil and the end coil that overlap with each other when dropped into the inserter tool enter the adjacent gap without overlapping. The coil winding / setting method according to Item 1.   When dropping the coil into a predetermined gap of the guide rod of the transfer tool, one side of the coil that is under the adjacent coil is set to the other side of the coil that overlaps the coil that is adjacent to the opposite side. The coil winding / setting method according to claim 1 or 2, wherein the coil is inclined by further pressing downward. In the inserter tool having a plurality of blades arranged in an annular shape corresponding to the inner teeth of the stator core, one side of the coil falls under the adjacent coil and enters the predetermined gap. In the coil winding / setting device in which the coil is dropped so that the side overlaps with the coil adjacent to the opposite side and enters the predetermined gap, and the coil is set in a spirally overlapping state as a whole,
A winding device that forms a coil by winding a conductive wire around a winding frame;
A transfer rod having a larger number of guide bars than the blades of the inserter tool, and arranged in an annular shape so that the guide bars can be partially aligned with the blades by aligning with the inserter tool. Tools and
A dropping device that moves the winding frame so as to align with a predetermined gap of the guide rod of the transfer tool, and drops the coil wound around the winding frame into the predetermined gap of the guide rod;
The inserter tool;
Placing the transfer tool on the inserter tool in an inverted state, moving the transfer tool relative to the inserter tool, and aligning the guide bar to partially align with the blade; A coil transfer device for sequentially dropping the coil held by the transfer tool into the inserter tool at a portion where the guide bar and the blade are aligned,
The coil wound by the winding device is arranged so that the dropping start coil and the ending coil do not overlap with a predetermined gap of the guide rod of the transfer tool by the dropping device so that one side of the coil is adjacent to the coil. Under the predetermined gap, the other side of the coil overlaps with the coil adjacent to the opposite side, enters the predetermined gap, and overlaps spirally except between the start coil and the end coil Drop the coil into
In the state where the transfer tool is reversed and installed on the inserter tool by the coil transfer device, the transfer tool is moved relative to the inserter tool and aligned, and the transfer tool guide rod And the blade of the inserter tool are aligned with each other, the coil is sequentially dropped from the start coil side into a predetermined gap of the blade, and one end portion of the end coil is overlapped with one side portion of the start coil. The coil winding and setting device is characterized in that the coil is set in a state of being overlapped spirally as a whole.   The number of guide rods of the transfer tool is set so that the side portions of the start coil and the end coil that overlap with each other when dropped into the inserter tool enter the adjacent gap without overlapping. Item 4. The coil winding and setting device according to Item 4.   In the dropping device, when the coil wound around the winding frame is dropped into the predetermined gap of the guide rod, one side of the coil under the adjacent coil is adjacent to the opposite side of the coil. The coil winding and setting device according to claim 4 or 5, wherein the coil is inclined by pushing it down more greatly with respect to the other side of the coil that overlaps the coil.   The transfer tool has a shutter that holds the coil that has been dropped into the predetermined gap of the guide rod so as not to fall when the transfer tool is reversed, and the shutter can be partially opened. The coil according to any one of claims 4 to 6, wherein the coil can be dropped from the winding frame to the transfer tool and the coil can be dropped from the transfer tool to the inserter tool through the opening. Winding and setting equipment. The method according to any one of claims 1 to 3, wherein one side of a coil enters a predetermined gap under an adjacent coil in the predetermined gap of the blade of the inserter tool, and the other side of the coil is on the opposite side of the coil. The coil is dropped so that it overlaps with the adjacent coil and enters the predetermined gap, the coil is set in a state of being overlapped spirally as a whole, the inserter tool is set in the coil insertion device, and the coil is placed in the slot of the stator core. A method for manufacturing a stator, wherein