JP7487697B2 - Manufacturing method of the stator - Google Patents

Description

The present invention relates to a method for manufacturing a stator.

Conventionally, a coil insertion method is known in which an annular coil bundle with coil wire wound thereon is inserted into a slot in a stator core. For example, JP 1-274645 A (Patent Document 1) discloses a coil insertion method in which, when a coil driven by a stripper nearly comes into contact with an end face of the stator core, a movable blade is moved together with the stripper to protrude a predetermined length from the opposite end face of the stator core, and then retracted to a coil removal position.

Japanese Patent Application Laid-Open No. 5-236712

However, the coil insertion method of Patent Document 1 leaves room for improvement in terms of shortening the length of the coil end protruding from the stator core (hereinafter also referred to as the coil end).

In view of the above problems, the present invention aims to provide a method for manufacturing a stator that shortens the coil ends.

The method for manufacturing a stator from a first aspect of the present invention is a method for manufacturing a stator having a stator core with multiple slots penetrating in the axial direction, and includes a forming step of forming an annular coil in which a coil wire is wound multiple times, a holding step of holding the coil on multiple circumferentially arranged blades extending in the axial direction on the radial inside of the stator core, an insertion step of moving a coil moving mechanism arranged on the radial inside of the blade in the axial direction to insert the coil into the slot from one axial side to the other, and a moving step of moving the coil ends of the coils held on the radial inside of the blade to the radial outside of the blade and the other axial side of the stator core, in which the coil ends are divided into multiple groups and moved for each group.

The present invention can provide a method for manufacturing a stator that shortens the coil ends.

FIG. 1 is a schematic diagram of a cross section perpendicular to the axial direction of a stator. FIG. 2 is a perspective view that illustrates a method for manufacturing the stator according to the embodiment. FIG. 3 is a cross-sectional view that illustrates a method for manufacturing the stator according to the embodiment. FIG. 4 is a flowchart showing a method for manufacturing the stator according to the embodiment. FIG. 5 is a cross-sectional view that illustrates a method for manufacturing the stator according to the embodiment. FIG. 6 is a perspective view that illustrates the interlocking process according to the embodiment. FIG. 7 is a cross-sectional view that illustrates a method for manufacturing the stator according to the embodiment. FIG. 8 is a perspective view that illustrates a release step according to the embodiment. FIG. 9 is a perspective view that illustrates the returning step of the embodiment. FIG. 10 is a cross-sectional view that illustrates a method for manufacturing the stator according to the embodiment. FIG. 11 is an enlarged view that illustrates a schematic diagram of a method for manufacturing a stator according to an embodiment. FIG. 12 is a cross-sectional view that illustrates a method for manufacturing the stator according to the embodiment. FIG. 13 is an enlarged view that illustrates a manufacturing method of the stator according to the embodiment. FIG. 14 is a cross-sectional view that illustrates a method for manufacturing the stator according to the embodiment. FIG. 15 is an enlarged view that illustrates a manufacturing method of the stator according to the embodiment.

The following describes an embodiment of the present invention with reference to the drawings. Note that the same or corresponding parts in the following drawings are given the same reference symbols, and their description will not be repeated.

In the following description, the direction in which the central axis of the stator 1 extends, i.e., the direction in which the slots penetrate, is referred to as the "axial direction." One side along the axial direction is referred to as the lower (rear) side, and the other side as the upper (front) side. The up-down (front-rear) directions are used to specify positional relationships, and do not limit the actual directions. In other words, the downward direction does not necessarily mean the direction of gravity. The axial direction is not particularly limited, and includes the vertical direction, the horizontal direction, and directions that intersect with these directions.

The direction perpendicular to the central axis of the stator 1 is defined as the "radial direction". One side along the radial direction is defined as the inside, and the other side is defined as the outside. Furthermore, the direction along the arc centered on the central axis of the stator 1 is defined as the "circumferential direction".

The drawings used in the following explanation may show characteristic parts enlarged for the purpose of emphasizing the characteristic parts. Therefore, the dimensions and proportions of each component are not necessarily the same as the actual ones. Also, for the same purpose, non-characteristic parts may be omitted from the illustrations.

(Stator)
1, a stator 1 is a component of a motor, and generates a rotational torque by interacting with a rotor (not shown). The stator 1 of this embodiment has a distributed winding in which a coil wire is wound across several slots 21. The stator 1 includes a coil 10 and a stator core 20.

<Stator core>
The stator core 20 is formed in a hollow cylindrical shape. The stator core 20 is formed by stacking thin silicon steel plates. A plurality of teeth 23 are formed radially in the stator core 20. Slots 21 are formed between the teeth 23. The teeth 23 extend in the radial direction via the slots 21. The slots 21 are formed with slot openings 22 that are radial openings. The stator core 20 of this embodiment is an integrated stator core.

<Coil>
The coil 10 is an annular coil bundle in which a coil wire is wound in a circular shape. The coil wire in this embodiment is a round wire, but is not particularly limited thereto, and may be a rectangular wire or the like.

The coil 10 has two coil sides and a coil end. The two coil sides are housed in slots 21. Specifically, the slot 21 in which one coil side is housed is different from the slot 21 in which the other coil side is housed. The slot 21 in which one coil side is housed and the slot 21 in which the other coil side is housed may be arranged in the circumferential direction via another slot as shown in FIG. 1, or may be adjacent to each other (not shown).

<Wedge>
The wedge 30 is disposed between the coil 10 disposed in the slot 21 and the slot opening 22. The wedge 30 closes the slot opening 22. The wedge 30 insulates the stator core 20 and the coil 10. The axial length of the wedge 30 is greater than the axial length of the slot 21.

The wedge 30 of this embodiment is U-shaped when viewed in the axial direction. In detail, it includes a circumferential portion that extends in the circumferential direction, and two radial portions that extend radially outward from both ends of the circumferential portion. The circumferential portion and the radial portion may be made of a single member, or different members may be connected to each other.

<Insulating paper>
As shown in Fig. 1, the insulating paper 40 covers the coil 10 inserted into the slot 21. The insulating paper 40 is arranged along the teeth that define the space in the slot 21 except for the radially inner side. The insulating paper 40 in this embodiment is U-shaped. In Fig. 1, the opening of the insulating paper 40 and the opening of the wedge 30 are in opposite directions to each other.

In addition, the insulating paper 40 may have a cuff portion (not shown) that protrudes from one axial end face of the stator core 20 and is folded back, and the insulating paper 40 may have a cuff portion (not shown) that protrudes from the other axial end face of the stator core 20 and is folded back.

(Coil insertion device)
The coil insertion device 100 will be described with reference to Figures 1 to 3. The coil insertion device 100 shown in Figures 2 and 3 inserts an annular coil 10, around which a coil wire is wound, into a plurality of slots 21 that axially penetrate a stator core 20 by relatively moving the coil 10 from one axial side to the other. In detail, the coil insertion device 100 inserts the coil 10 from each slot opening 22 so as to straddle several slots 21 of the stator core 20.

The coil insertion device 100 includes a plurality of blades 110 shown in Figures 2 and 3, a stripper 120 as a coil moving mechanism, and a blade base 130 shown in Figure 3.

<Blade>
2 and 3 , the blades 110 hold the coils 10. The blades 110 are disposed radially inside the stator core 20 and radially outside the stripper 120 in the circumferential direction of the stator core 20 and extend in the axial direction. The blades 110 make it easy to insert the coils 10 into the slots 21.

The blade 110 moves in the axial direction at least in the movement step (S40) described below. This reduces the load on the coil 10 in the insertion step (S30) and movement step (S40) described below. The blade 110 in this embodiment is a movable blade that moves in the axial direction.

The blades 110 are arranged in a line in the circumferential direction of the stator core 20. Here, the blades 110 are arranged via a number of teeth 23. In detail, the multiple blades 110 are arranged on the same circumference in correspondence with the teeth 23.

The blade 110 has a shape that allows it to be placed in the slot opening 22. The blade 110 is a rod-shaped member that extends in the axial direction.

In this embodiment, the radially outer edge of the blade 110 is located radially inward from the radially inner edge of the stator core 20, but may be located radially outward from the radially inner edge of the stator core 20.

<Stripper>
The stripper 120 is a coil moving mechanism that moves the coil 10. The stripper 120 is disposed radially inside the stator core 20, and moves in the axial direction.

The stripper 120 inserts the coil 10 from one axial side to the other. The stripper 120 comes into contact with the coil 10. The stripper 120 causes the coil 10 to move axially along the radial inside of the stator core 20, while a portion of the coil 10 is inserted into the slot 21 through the slot opening 22. Specifically, the stripper 120 hooks the radial inside of the coil 10 and pulls the coil 10 up along the blade 110.

<Blade base>
The blade base 130 is disposed radially inward of the stator core 20 and on one axial side of the stripper 120. The blade base 130 holds the blades 110. Here, the blade base 130 holds one end of the multiple blades 110.

The blade base 130 and the multiple blades 110 may be made of a single member or may be made of separate members.

The stripper 120 has a shape that allows it to be placed in the slot opening 22. In this embodiment, the other axial end of the stripper 120 is hemispherical.

In this embodiment, the radially outer edge of the stripper 120 is located radially inward from the radially inner edge of the stator core 20, but it may also be located radially outward from the radially inner edge of the stator core 20.

(Method of manufacturing the stator)
1 to 15, a method for manufacturing a stator 1 including a stator core 20 having a plurality of slots 21 penetrating therethrough in the axial direction will be described. In this embodiment, the stator 1 is manufactured using the coil insertion device 100 described above.

First, as shown in FIG. 4, a forming process (S10) is carried out to form an annular coil in which the coil wire is wound multiple times. In the forming process (S10), the coil wire is wound in an annular shape to form the coil 10 having two coil sides housed in the slots 21 and coil ends that connect the two coil sides and are positioned on both axial sides of the stator core 20.

In this embodiment, as shown in FIG. 2, the coil end C on the other axial side of the coil 10 is inclined radially inward. The coil ends C are divided into a first set C1, a second set C2, and a third set C3. In the state shown in FIG. 1 where the coil side portion is inserted into the slot 21, the first set C1, the second set C2, and the third set C3 are positioned radially from the outside toward the inside.

Next, a holding step (S20) is performed to hold the coil 10 on the blades 110 that are arranged in the circumferential direction and extend in the axial direction on the radial inside of the stator core 20. In the holding step (S20), as shown in FIG. 3, a coil insertion device 100 is arranged on one axial side of the stator core 20. Also, a stripper 120 is arranged in the radial center of the blades 110 on one axial side. Then, as shown in FIG. 2, the annular coil 10 formed in the forming step (S10) is arranged so that the coil 10 is held between the blades 110.

Next, an insertion step (S30) is performed in which the stripper 120, which serves as a coil moving mechanism arranged radially inside the blade 110, is moved in the axial direction to insert the coil 10 into the slot 21 from one axial side to the other. In this insertion step (S30), as shown in Figures 3 to 5, the stripper 120 is moved from one axial side to the other axial side.

In this embodiment, in order to insert the coil side portions of the coil 10 into the slots 21, the blade 110 and the stripper 120 are moved from one axial side to the other as shown in FIG. 6 (hereinafter, this process is also referred to as the "linking process"). This positions the two coil side portions of the coil 10 in the slots 21. At this time, the coil end on one axial side straddles between the slots 21 on one side of the stator core 20. Meanwhile, the coil end C on the other axial side is held radially inside the blade 110 without protruding from the end face on the other axial side of the stator core 20 (hereinafter, also referred to as the "other end face").

Next, a moving step (S40) is performed to move the coil ends C of the coil 10, which are held radially inside the blade 110, to the radially outside of the blade 110 and to the other axial side of the stator core 20. In the moving step (S40), the coil ends C are divided into a plurality of groups, and each group is moved. In this manner, in the moving step (S40), the coil ends C are divided into a plurality of groups, and each group is moved radially outside the blade 110 and to the other axial side of the stator core 20. By moving the coil ends C in a plurality of steps, the coil ends C can be shortened compared to moving the coil ends C radially outside the blade 110 and to the other axial side of the stator core 20 in one step.

In the moving step (S40), it is preferable to move the coil ends C in two or more to four groups, and more preferably in three groups. In the moving step (S40) of this embodiment, the coil ends C are moved in three groups. This allows the coil ends C to be shortened, and the time required for the moving step (S40) to be shortened.

In detail, in the moving step (S40), the coil ends C are divided into a first group C1, a second group C2, and a third group C3, and are moved in the order of the first group C1, the second group C2, and the third group. That is, the moving step (S40) includes a first moving step (S41) of moving the first group C1, a second moving step (S42) performed after the first moving step (S41) of moving the second group C2, and a third moving step (S43) performed after the second step (S42) of moving the third group C3.

In the first movement step (S41), as shown in FIG. 7, an interlocking step is performed to cause the first set C1 to protrude from the other end face of the stator core 20. In this state, as shown in FIG. 8, the stripper 120 and the blades 110 are moved to one axial side (hereinafter, this step is also referred to as the "release step"). As a result, the stripper 120 no longer presses the coil 10 to the other axial side, so that the coil 10 can be prevented from being pinched by the blades 110.

Next, as shown in FIG. 9, the stripper 120 is stopped and the blade 110 is moved to one axial side (hereinafter, this process is also referred to as the "return process"). Thus, here, the release process is performed before the return process is performed. No other process is performed between the release process and the return process. By performing the return process, the blade 110 is returned to the vicinity of the other end face of the stator core 20 as shown in FIG. 10. By this return process, as shown in FIG. 11, the first set C1 of the coil ends C is not held by the blade 110, and the second set C2 and the third set C3 of the coil ends C are held by the blade 110.

Then, as shown in FIG. 12, an interlocking process is performed to move the blades 110 and the stripper 120 in the axial direction. By performing this interlocking process, as shown in FIG. 13, the first set C1 of the coil ends C can be moved radially outward of the blades 110 and to the other axial side of the stator core 20.

Next, the second movement step (S42) is performed. In the second movement step (S42), similar to the first movement step (S41), the release step and return step are performed to return the blade 110 to the vicinity of the other end face of the stator core 20. In this state, the linking step is performed to move the blade 110 and the stripper 120 as shown in FIG. 14. This allows the second set C2 to be moved radially outward of the blade 110 and to the other axial side of the stator core 20 as shown in FIG. 15.

Next, the third movement process (S43) is performed. In the third movement process (S43), unlike the first movement process (S41) and the second movement process (S42), the release process and return process are not performed, but the interlocking process is performed. This allows the third set C3 to be moved radially outward of the blades 110 and to the other axial side of the stator core 20.

In this way, when the movement process is performed n times (divided into n groups), the release process and return process are performed in the 1st to (n-1)th times to push out the coil end C (moving the coil end C radially outward of the blade 110 and to the other axial side of the stator core 20). In the nth time, the release process and return process for pushing out are not performed.

In addition, in the movement process (S40), the position of the blade 110 is different in at least two sets. Also, the position of the blade 110 is not a common position in all sets.

In the movement step (S40), the position of the blade 110 when the last set is moved is on the other axial side than the position of the blade 110 when at least one of the other sets is moved. That is, when the movement step (S40) is performed n times (divided into n sets), the position of the blade 110 in the nth movement step is on the other axial side than the position of the blade 110 in at least one of the 1st to (n-1)th movement steps. This reduces insertion failures of the wedge 30 and coil 10 into the slot 21. In this embodiment, in the movement step (S40), the position of the blade 110 when the last set is moved is on the other axial side than the position of the blade 110 when the first set is moved.

In this embodiment, the position of the blade 110 when moving the third group C3 in the third movement step (S43) is on the other axial side of the position of the blade 110 when moving the first group C1 in the first movement step (S41). In particular, the position of the blade 110 when moving the second group C2 in the second movement step (S42) is on the other axial side of the position of the blade 110 when moving the first group C1 in the first movement step (S41). And, the position of the blade 110 when moving the third group C3 in the third movement step (S43) is on the other axial side of the position of the blade 110 when moving the second group C2 in the second movement step (S42).

In addition, in the moving step (S40), the number of coil wires in the last set to be moved is at least 1/4 of the number to be inserted into one slot. This ensures that the last set of coil wires to be moved can be secured, reducing insertion failures into the wedge slot 21.

In this embodiment, the number of coil wires in the first set C1, the second set C2, and the third set C3 are approximately the same. When the moving step (S40) divides the coil end C into two sets and moves them, the number of coil wires in the last set to be moved is less than the number of coil wires in the first set. When the moving step (S40) divides the coil end C into four sets and moves them, the number of coil wires in the last set is more than the number of coil wires in the previous set.

By carrying out the above steps (S10 to S40), the stator 1 shown in FIG. 1 can be manufactured. In the stator 1 manufactured in this manner, the height of the coil end C on the other axial side of the coil 10 (the protruding height of the coil 10 protruding from the other end face of the stator core 20) can be reduced.

Although the wedge 30 is not shown in Figures 2, 3, and 5 to 15, when inserting the coil 10, the wedge 30 is inserted into the slot 21 using a wedge guide, wedge pusher, or the like.

Although the insulating paper 40 is not shown in Figures 2, 3, and 5 to 15, the method further includes a step of covering the coil 10 to be inserted into the slot 21 with the insulating paper 40. In this step, the insulating paper 40 may be placed in the slot 21 beforehand, and the coil 10 may be inserted into the slot 21. Also, the coil 10 covered with the insulating paper 40 may be inserted into the slot 21.

The above-described method for manufacturing a stator is suitable for manufacturing a stator for an N-phase motor.
In this case, the inserting step (S30) and the moving step (S40) are performed for each phase, and in the moving step (S40), the position of the blade 110 is different in at least two phases.

In the movement process (S40), the position of the blade 110 when moving the last phase is on the other axial side than the position of the blade 110 when moving at least one of the other phases. For example, when manufacturing a stator 1 for a three-phase motor, the position of the blade 110 in the movement process (S40) of the W phase, which is inserted last, is on the other axial side than the position of the blade 110 in the movement process (S40) of the U phase, which is inserted first. The insertion resistance of the wedge 30 is large for the last phase to be inserted (W phase) due to the influence of the coil ends of the already inserted phases (U phase, V phase). Here, by positioning the blade 110 on the other axial side in the movement process (S40) of the last phase to be inserted (W phase), the insertion resistance of the wedge 30 can be reduced.

(Modification)
In the above-described embodiment, as shown in FIG. 1, the two slots 21 into which the coils are inserted are one slot 21 and another slot 21 sandwiched between three slots 21, but the present invention is not limited to this.

In the above embodiment, a method of inserting one coil 10 into two slots 21 has been described as an example. Multiple coils 10 may be inserted simultaneously into four or more slots 21.

The embodiments disclosed herein should be considered to be illustrative and not restrictive in all respects. The scope of the present invention is indicated by the claims, not by the embodiments described above, and is intended to include all modifications within the meaning and scope of the claims.

1: Stator 10: Coil 20: Stator core 21: Slot 100: Coil insertion device 110: Blade 120: Stripper 130: Blade base C: Coil end C1: First group C2: Second group C3: Third group

Claims (8)

A method for manufacturing a stator including a stator core having a plurality of slots extending therethrough in an axial direction, comprising the steps of:
A forming step of forming an annular coil by winding a coil wire a plurality of times;
a retaining step of retaining the coil on a plurality of blades arranged in a circumferential direction on a radially inner side of the stator core and extending in an axial direction;
an insertion step of axially moving a coil moving mechanism disposed radially inside the blade to insert the coil into the slot from one axial side to the other axial side;
a moving step of moving a coil end of the coil, the coil end being held on the radially inner side of the blade, to the radially outer side of the blade and to the other axial side of the stator core;
Equipped with
In the moving step,
The coil moving mechanism is stopped and the blade is moved to one axial direction.
A method for manufacturing a stator, comprising: dividing the coil ends into a plurality of groups and moving each group. The method for manufacturing a stator according to claim 1 , wherein the moving step includes a step of moving the coil moving mechanism and the blades to one side in the axial direction. The method for manufacturing a stator according to claim 1 or 2 , wherein in the moving step, positions of the blades are different in at least two of the sets. The method for manufacturing a stator according to claim 3 , wherein in the moving step, the position of the blade when the last set is moved is on the other axial side than the position of the blade when at least one of the other sets is moved. 1. A method for manufacturing a stator for an N-phase motor, comprising the steps of:
The inserting step and the moving step are performed for each of the phases,
The method for manufacturing a stator according to claim 1 , wherein in the moving step, positions of the blades are different in at least two of the phases. The method for manufacturing a stator according to claim 5 , wherein in the moving step, a position of the blade when the last one of the phases is moved is on the other axial side than a position of the blade when at least one of the other phases is moved. 7. The method for manufacturing a stator according to claim 1 , wherein in the moving step, the number of the coil wires of the set moved last is equal to or greater than ¼ of the number of coil wires to be inserted into one of the slots. The method for manufacturing a stator according to claim 1 , wherein the moving step moves the coil ends in three groups.

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