JP6572549B2 - Stator coil manufacturing apparatus and manufacturing method - Google Patents

Description

  The present invention relates to the manufacture of stator coils such as electric motors.

  As an apparatus for winding a coil around a stator core such as an electric motor, an inserter tool for mounting a wire previously wound in a coil shape on a slot of the stator core is known. The stator core is formed in a hollow cylindrical shape having both ends opened. The stator core has teeth formed at equal angular intervals on the inner periphery, and slots formed between the teeth and having openings on the inner peripheral surface and both end surfaces. The inserter tool is provided with the same number of blades as the teeth fitted to the inner peripheral surface of the teeth, and a cylindrical pusher provided on the outer periphery with a protruding portion that is axially displaced within the gap between the blades. The width of the blades is set in advance so that the gap between the blades is approximately equal to the opening of the slot. The inserter tool drives the pusher in the axial direction to enter the inside of one end of the stator core while the wire wound in a coil shape is wound around one end of each tooth.

  As a result, the protrusion on the outer periphery of the pusher is displaced in the axial direction in the gap between the blades, and the coiled wire rod wound around each blade is pushed by the protrusion and enters the slot. The protrusions are displaced from the opening at one end of the stator to the opening at the other end, so that the wire sequentially enters the inside of each slot. As a result, the coiled wire rod is wound around each tooth as a coil including a linear portion that has entered the slot and a coil end that protrudes axially outward from both ends of the stator. After the wire rod has entered each slot, a wedge that closes the opening of the slot facing the center direction of the steer core is inserted into the slot from the axial direction.

  Patent Document 1 proposes that an inserter tool is provided with a support mechanism for supporting insulating paper sandwiched between layers when a plurality of layers of coils are mounted on the same tooth.

Japanese Utility Model Publication No. 5-95186

  In an inserter tool having a structure in which a coiled wire rod enters a slot by axial displacement of the projection, the projection only pushes the wire in the axial direction. However, since one coil end is wound around the teeth, the wire wound in a coil shape cannot be displaced in the axial direction. Therefore, the wire rod is retreated into the slot to release the axial pressing force. That is, the protrusion moves in the slot in the axial direction while pushing the wire toward the inside of the slot. Under this operating principle, the protrusion cannot exert a radial force on the wire once retracted into the slot.

  In a stator coil manufacturing apparatus using such an inserter tool, when the amount of winding is increased, the wire rod that has been pushed away by the protrusion and retracted into the slot once again protrudes from the slot after passing through the protrusion. Therefore, the wires cannot be densely arranged in the slot, and it is difficult to increase the space factor of the stator coil, that is, the ratio of the coil cross-sectional area to the slot cross-sectional area.

  The present invention has been made to solve the above problems, and an object thereof is to manufacture a stator coil having a high space factor.

In order to achieve the above object, the present invention is applied to a stator coil manufacturing apparatus in which a wire previously wound in a coil shape is attached to a plurality of teeth formed on the inner periphery of a cylindrical stator core. The stator coil manufacturing apparatus has a resin injecting means for injecting resin into the slot from the inner peripheral side of the stator core after temporarily inserting the wire into the slot between the teeth, and a gap corresponding to the slot, During the period from the temporary insertion of the wire into the slot to the injection of the resin into the slot by the resin injection means, the resin is injected and held on the inner periphery of the teeth, and the resin injection into the slot by the resin injection means An inner diameter jig that is removed after the gap is removed from the gap, and the inner diameter jig is rotationally displaced after completion of the injection of the resin into the slot by the resin injection means until the resin is solidified. The inside is configured to close the slot .

  After the wire is temporarily inserted into the slot, the radial force load means applies a radially outward force to the wire temporarily inserted into the slot between the teeth. The radially outward force acts as a force for pushing the wire into the slot. Therefore, the wire rod protruding from the slot toward the center of the steer core is also pushed into the slot. In this state, the resin injection means injects resin into the slot. As the injected resin is solidified, the wire is fixedly held in the slot.

  By injecting resin into the slot while applying a force for pushing the wire into the slot, a stator coil with a higher space factor can be manufactured. Further, since the wire can be securely held in the slot, a wedge that has been conventionally used for closing the opening of the slot is not necessary.

It is a schematic longitudinal cross-sectional view of the stator coil manufacturing apparatus by 1st Embodiment of this invention. Similarly, it is a schematic longitudinal cross-sectional view of the stator coil manufacturing apparatus of the resin injection | pouring stage. It is the cross-sectional view which expanded the stator core principal part, inner-diameter jig | tool, and wire which demonstrate the effect | action of the force to a wire. It is a cross-sectional view of the stator core for explaining the coil mounting process to the stator core from the setting of the inner diameter jig to the injection of resin and the removal of the inner diameter jig. It is the schematic longitudinal cross-sectional view and schematic cross-sectional view of the stator coil manufacturing apparatus by 2nd Embodiment of this invention. It is the schematic longitudinal cross-sectional view and schematic cross-sectional view of the stator coil manufacturing apparatus of the resin injection | pouring stage by 2nd Embodiment of this invention. It is a schematic longitudinal cross-sectional view of the stator coil manufacturing apparatus by 3rd Embodiment of this invention. It is a schematic cross-sectional view of the stator coil manufacturing apparatus explaining the rotation of the inner mold of the stator coil manufacturing apparatus according to the fourth embodiment of the present invention.

  A first embodiment of the present invention will be described with reference to FIGS.

  A stator coil manufacturing apparatus 1 shown in FIG. 1 is an apparatus for attaching a coil to a stator core 2 such as an electric motor.

  Referring to FIG. 4A, a plurality of teeth 3 are previously formed at equal angular intervals on the inner periphery of the cylindrical stator core 2. Between adjacent teeth 3, a slot 4 is formed that opens toward the center direction and the axial direction of the stator core 2. The coil is wound around the teeth 3 by attaching the wire 5 wound in a predetermined shape to each tooth 3 using the slots 4. The coil wound around the teeth 3 passes through the slots 4 on both sides of the teeth 3 in the circumferential direction, and the coil ends 5A bent at 180 degrees as shown in FIG. Projects outward in the direction.

  The coil is attached to the stator core 2 by first inserting the wire 5 wound in advance in a coil shape into each slot 4 using an inserter tool. Since the structure of the inserter tool is known as disclosed in Patent Document 1, the description thereof is omitted.

  As shown in FIG. 4A, the inserter tool includes a blade 6 as an inner diameter jig that fits to the inner peripheral surface of each tooth 3. The blade 6 is disposed with a gap 6 </ b> A corresponding to the slot 4 between the teeth 3.

  FIG. 1 shows a state in which the wire 5 wound in a coil shape is attached to each tooth 3 by the inserter tool. After application of the inserter tool, the force for holding the wire 5 inserted in each slot 4 in the slot 4 does not act. For this reason, the insertion of the wire 5 into each slot 4 by the inserter tool is referred to as temporary insertion here. When the inserter tool temporarily inserts the wire 5 wound in a coil shape into the slots 4 on both sides in the circumferential direction of each tooth 3, the coil is wound around each tooth 3. The wire 5 temporarily inserted into each slot 4 is hardened with the resin 9 injected into each slot 4 from the resin molding device 7, whereby the mounting of the coil to the stator core 2 is completed.

  The resin molding apparatus 7 includes an outer mold 7A-7C that holds the stator core, an inner mold 8 that has a cylindrical wall 8A that fits on the inner periphery of the blade 6, an injection port 7D that is formed in the outer mold 7B, and an injection port And a piston 10 for press-fitting the resin 9 into 7D.

  By the way, the wire 5 temporarily inserted into each slot 4 by the inserter tool in the above process loses the holding force in the slot 4 after application of the inserter tool as described above. Therefore, when the inserter tool inserts a large amount of the wire 5 into the slot 4 at a high density in order to increase the space factor of the coil, after the inserter tool passes, as shown in FIG. 4 protrudes into the gap 6 </ b> A of the blade 6 toward the center of the theta core 2. In this state, the wire cannot be held in the slot 4. Therefore, under the conventional stator coil manufacturing apparatus, the amount of the wire 5 has to be suppressed, and as a result, it is difficult to increase the space factor of the stator coil.

  In order to increase the space factor of the stator coil, the present invention is provided with a radial force loading means for exerting a radially outward force on the wire rod temporarily inserted in the slot 4. In this embodiment, the resin mold apparatus 7 serves as both a radial direction force load means and a resin injection means for injecting resin into the slot.

  Referring to FIG. 2, the resin molding apparatus 7 injects a resin 9 into each slot 4 from one end face of the stator core 2. The injection port of the resin 9 to the stator core 2 is provided in the vicinity of the cylindrical wall 8A of the inner mold 8 in the radial direction. By driving the piston 10 downward in the figure, the resin 9 pressurized to the piston 10 first enters the space between the wire 5 and the cylindrical wall 8A in the gap 6A as shown in FIG. When the piston 10 is further driven downward in FIG. 1, the resin in the gap 6 </ b> A enters the slots 4 from the inner peripheral side of the stator core 2 toward the outer peripheral side. The penetration pressure of the resin 9 into each slot 4 exerts a radially outward force on the wire 5 as indicated by the arrow in FIG. By this action of the force, the wire 5 protruding from the slot 4 into the gap 6 </ b> A moves back into the slot 4.

  The resin 9 injected into the slot 4 in this way is solidified in the slot 4 after the wire 5 is pushed into the slot 4 as shown in FIG. After the resin 9 in the slot 4 is solidified, the blade 6 is removed from the stator core 2 together with the inner mold 8 as shown in FIG.

  According to this stator coil manufacturing apparatus 1, even if the wire 5 is temporarily inserted into the slot 4 by the insert tool and the wire 5 protrudes from the slot 4 into the gap 6A, the protruding wire remains outward in the radial direction exerted by the resin 9. The resin 9 is pushed back into the slot 4 by the force of and the resin 9 solidified in the slot 4 is stably held in the slot 4. Therefore, a large amount of wire 5 can be accommodated in the slot 4, and the space factor of the stator coil can be increased. Moreover, since the wire 5 can be reliably held in the slot 4, a wedge conventionally used for closing the opening of the slot 4 is also unnecessary.

  The blade 6 as an inner jig is fitted and held on the inner periphery of the tooth 3 throughout the period from the temporary insertion of the wire 5 into the slot 4 to the injection of the resin into the slot 4 by the resin molding device 7. Removed after injection is complete.

  The gap 6A formed by the blade 6 keeps the wire 5 protruding from the slot 4 after the inserter tool passes in the gap 6A, and guides the resin 9 injected between the wire 5 and the cylindrical wall 8A to the slot 4. Act as a guide. Therefore, the resin 9 entering the slot 4 directly exerts a radially outward force on the wire 5 protruding from the slot 4 into the gap 6A. As a result, the wire 5 protruding from the slot 4 to the gap 6 </ b> A is reliably pushed back to the slot 4. Further, since the blade 6 is fitted to the inner periphery of the tooth 3, the amount of the resin 9 injected into the slot 4 to protrude from the slot 4 into the gap 6 </ b> A can be reduced. The resin 9 protruding into the gap 6A may be removed by machining as necessary. According to this stator coil manufacturing apparatus 1, the trouble of machining can be greatly reduced even in that case.

  A second embodiment of the present invention will be described with reference to FIGS.

  The stator coil manufacturing apparatus 1 according to this embodiment includes a rotating device for the steer core 2 as radial direction force load means. As a rotating device, the stator coil manufacturing apparatus 1 includes a base 12 that is rotated by means such as an electric motor.

  After temporarily inserting the wire 5 into the slot 4 by an inserter tool or manually, the base 12 is rotated. Centrifugal force acts on the stator core 2 that rotates together with the base 12. This centrifugal force exerts a radially outward force on the wire 5. Therefore, even if the wire 5 temporarily inserted into the slot 4 by the inserter tool protrudes from the slot 4 into the gap 6A after the inserter tool is used, the protruding wire 5 is re-slotted by the radially outward force caused by the centrifugal force. Pushed back to 4.

  As shown in FIG. 6, the resin molding device 7 drives the piston 10 into the gap 6A as shown in FIG. 6 while maintaining the rotation of the base 12 with the wire 5 pushed back into the slot 4. inject. The injected resin 9 penetrates into the slot 4 due to centrifugal force, and in the process, exerts a radially outward force exerted on the wire 5 by the centrifugal force.

  That is, in addition to the radially outward force that the centrifugal force directly exerts on the wire 5, the intrusion pressure of the resin 9 that enters the slot 4 by the centrifugal force acts as a force that pushes the wire that protrudes into the gap 6 </ b> A back into the slot 4. . In this way, the injection of the resin 9 is completed while holding the wire 5 in the slot 4.

  After the injection of the resin 9, the outer mold 7A-7C and the inner mold 8 are removed from the stator core 2 after the injected resin 9 is solidified.

  As described above, this embodiment also makes it possible to hold a large amount of wire 5 in the slot 4 and increase the space factor of the stator coil.

  In this embodiment, since the centrifugal force acts on the resin 9 injected into the gap 6A, the resin 9 hardly remains in the gap 6A after the injection of the resin 9 is completed. Therefore, it is possible to reduce the labor of removing the resin 9 that protrudes into the gap 6A.

  A third embodiment of the present invention will be described with reference to FIG.

  The stator coil manufacturing apparatus 1 according to this embodiment includes a high-pressure fluid passage 11 that passes through the outer mold 7 </ b> C and is guided into the inner mold 8 as a radial direction force load means. Here, high-pressure air is used as the high-pressure fluid. High pressure air is supplied from a compressor connected to the passage 11. A plurality of branch passages 11 </ b> A that branch in the radial direction in the inner mold 8 are connected to the passage 11. Each of the plurality of branch passages 11A includes an opening provided in the cylindrical wall 8A.

  With the above configuration, the high-pressure air supplied to the passage 11 blows out the high-pressure air radially outward from the cylindrical wall 9A via the plurality of branch passages 11A. The blown out high-pressure air enters the slots 4 through the gaps 6A, and further flows in the slots 4 in the axial direction, thereby flowing out from both end faces of the stator core 2 into the space surrounded by the outer dies 7A-7C.

  On the other hand, between the outer sides 7A and 7B of the resin molding device 7 and between the outer sides 7C and 7B, there are gaps for releasing the air that has flowed into these spaces from both end faces of the stator core 2 into the atmosphere as shown in the figure. It is formed.

  After the wire 5 is temporarily inserted into the slot 4 by an inserter tool or manually, the compressor is operated to supply high-pressure air to the passage 11. The high-pressure air branched from the passage 11 to the plurality of branch passages 11A blows out the high-pressure air radially outward from the opening of the branch passage 11A formed in the cylindrical wall 8A. The blown high-pressure air enters the slots 4 through the gaps 6A of the blade 6 shown in FIG. 3A, flows out from the openings on both end faces of the stator core 2, and the gaps between the outer molds 7A and 7B and the outer molds. It is released into the atmosphere through the gap between 7A and 7C.

  This flow of high-pressure air exerts a radial force on the wire 5 that protrudes into the gap 6A, as shown by the arrow in FIG. By this radial force, the wire 5 protruding from the slot 4 into the gap 6 </ b> A is pushed into the slot 4.

  In this way, the resin molding apparatus 7 is driven in a state where the wire 5 is pushed into the slot 4 by the force of the flow of high-pressure air, and the resin 9 is injected from the injection port 7D into the gap 6A by the piston 10. The injected resin enters the gap 6A downward in the figure, and further enters each slot 4 from the gap 6A. The resin 9 that has entered the slots 4 is filled in each slot 4 by moving in the slots 4 from the inner periphery toward the outer periphery.

  Filling the slot 4 with the resin 9 by the resin molding device 7 is performed in a state where the branch passage 11A is jetting high-pressure air, and the flow force of the high-pressure air flows into the slot 4 while the resin 9 is being injected. Acts as a holding force. Further, the wire 5 is reliably held in the slot 4 until the resin filling is completed by the resin 9 moving from the inner peripheral side to the outer peripheral side in the slot 4.

  According to this embodiment, the pressurizing mechanism 8 jets high-pressure air into the gap 6 </ b> A of the blade 6, and exerts a radial force that pushes the wire 5 protruding from the slot 4 into the gap 6 </ b> A into the slot 4. Therefore, the wire 5 can be densely arranged in the slot 4 and the space factor of the stator coil can be increased. Further, since the resin 9 is filled while the wire 5 is pushed into the slot 4, the opening on the inner peripheral side of the slot 4 is closed by the resin 9. This eliminates the need for a wedge conventionally required to close the slot 4, eliminates the need to provide a wedge insertion mechanism in the inserter tool, and can reduce the structure of the inserter tool accordingly.

  Further, since the resin 9 is filled while blowing high-pressure air from the branch passage 11A, an environment in which the resin 9 is difficult to protrude from the slot 4 toward the gap 6A is obtained. Therefore, it is possible to omit or reduce the trouble of removing the resin 9 remaining outside the slot 4 after the inner mold 8 is removed from the stator core 2.

  In this embodiment, high-pressure air is used as the fluid, but the fluid is not limited to high-pressure air. For example, an insulating resin varnish can be used as the fluid. The ejected varnish solidifies in the slot 4 and holds the wire 5. Therefore, the plurality of radial branch passages 11A for ejecting the varnish can also be used as the resin mold device 7, and the configuration of the stator coil manufacturing apparatus can be simplified.

  Moreover, since the high-pressure fluid that blows out radially outward from the cylindrical wall 8A pushes the wire 5 back into the slot 4 as the radial force load means, the resin molding device 7 does not have to be the same as in the first embodiment. Any type may be used as long as it has a function of injecting the resin 9 into the slot 4.

  A fourth embodiment of the present invention will be described with reference to FIG.

  This embodiment is an embodiment combined with any of the first to third embodiments. The stator coil manufacturing apparatus 1 includes rotational displacement means such as an electric motor that rotationally displaces a blade 6 as an inner diameter jig. As the rotational displacement means, the blade 6 can be rotated by human power.

  In this stator coil manufacturing apparatus 1, the resin 9 is filled in the slot 4 by any of the radial force loading means and the resin injection means described in the first to third embodiments, and before the resin 9 is solidified. The blade 6 is rotationally displaced as indicated by an arrow in FIG. 8B, and the blade 6 is opposed to the opening of the slot 4 in the radial direction. By this operation, the wire 5 can be prevented from protruding from the slot 4 until the resin 9 is solidified. Further, it is possible to prevent the resin 9 before solidifying from protruding out of the slot 4. After removing the blade 6, the work of removing the resin 9 protruding from the slot 4 becomes unnecessary.

  As described above, the present invention has been described through some specific embodiments, but the present invention is not limited to the above embodiments. Those skilled in the art can make various modifications or changes to these embodiments within the scope of the claims.

  For example, in each of the above embodiments, the wire 5 wound in a coil shape is temporarily inserted into the slot using an inserter tool, but the present invention is not limited to means for temporarily inserting the wire 5 into the slot 4. . For example, the stator coil manufacturing apparatus according to the present invention is also applicable when the wire 5 is temporarily inserted into the slot 4 manually.

DESCRIPTION OF SYMBOLS 1 Stator coil manufacturing apparatus 2 Steer core 3 Teeth 4 Slot 5 Wire 6 Blade 7 Resin molding apparatus 7A, 7B, 7C Outer mold 7D Inlet 8 Inner mold 8A Cylindrical wall 9 Resin 10 Piston 11 Path 11A Branch path 12 Base

Claims (5)

In a stator coil manufacturing apparatus in which a wire wound in advance in a coil shape is attached to a plurality of teeth formed on the inner periphery of a cylindrical stator core,
Resin injecting means for injecting resin from the inner peripheral side of the stator core into the slot after temporarily inserting the wire into the slot between the teeth;
A gap corresponding to the slot, and fitted and held on the inner periphery of the teeth during a period from the temporary insertion of the wire into the slot to the injection of the resin into the slot by the resin injection means, An inner diameter jig that is removed after injecting the resin into the slot by the injection means, and the inner diameter jig rotates after completion of the injection of the resin into the slot by the resin injection means. displaced, during the period until the resin is solidified is Ru is configured to close the slot, the stator coil manufacturing apparatus characterized by. The stator coil manufacturing apparatus according to claim 1 , further comprising a rotating unit that rotates the stator core to exert a centrifugal force on the wire. The stator coil manufacturing apparatus according to claim 1 , further comprising a pressurizing mechanism that ejects fluid from an inner peripheral side to an outer peripheral side of the stator core. 4. The stator coil manufacturing apparatus according to claim 3 , wherein the fluid is made of an insulating resin. In a stator coil manufacturing method in which a plurality of teeth formed on the inner periphery of a cylindrical stator core are attached with a wire previously wound in a coil shape,
After temporarily inserting the wire rod into the slot between the teeth, and injecting resin from the inner peripheral side of the stator core into the slot,
An inner diameter jig having a gap corresponding to the slot is fitted and held on the inner periphery of the teeth during a period from the temporary insertion of the wire into the slot to the injection of the resin into the slot. After the injection of the resin from the gap, the inner diameter jig is removed , and after the injection of the resin into the slot by the resin injection means is completed, the inner diameter jig is rotationally displaced until the resin is solidified. The stator coil manufacturing method is characterized in that the slot is closed during the period .

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