JPH11234977A - Manufacture of stator for lap winding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the space factor of a lap winding and ensure insulation effectively. SOLUTION: The first winding coil 20a and other winding coil 20 overlapped in the radial direction on the first winding coil 20a are provided over a wider range than that between tees 12 on a stator core 14. The last winding coil 20n is then pressed in the central direction of the stator core 14 through a winding coil pressing-in mechanism 24. As a result, the winding coil 20 can maintain good insulation and improve space factor without coming into sliding contact with the teeth 12.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a lap winding stator for manufacturing a stator by applying a lap winding with a plurality of winding coils to a stator core having an opening toward an outer peripheral side.

[0002]

2. Description of the Related Art For example, a stator of an electric motor is formed such that a plurality of convex portions directed in a radial direction are formed on an outer peripheral surface or an inner peripheral surface of a substantially cylindrical body, and a conductive wire is wound around a groove of the convex portion. ing.

More specifically, a lap winding coil system in which a stator core having an opening toward an outer peripheral side is prepared and a winding coil is sequentially wound over a plurality of winding teeth of the stator core has been widely adopted. I have. As shown in FIG. 10, the lap wound coil type stator 2 includes a stator core 4, and a plurality of winding teeth 6 are formed to project radially outward from a peripheral surface of the stator core 4. . For example, the teeth 6 are provided with a lap winding by a winding coil 8 over the three teeth 6.

[0004]

However, in the above-described stator 2, the winding coil 8a tends to be loosened, particularly after the winding coil 8a at the end of winding is wound around the teeth 6. For this reason, there is a possibility that the space factor of the entire lap winding decreases. Therefore, the work of pushing the last winding coil 8a inward in the radial direction of the teeth 6 is performed. However, it is pointed out that the winding coil 8a or the like slides on the teeth 6 and the insulating film is peeled off. Have been.

The present invention solves this kind of problem, and provides a method of manufacturing a lap winding stator capable of improving the space factor of the lap winding and effectively ensuring insulation. The purpose is to provide.

[0006]

In order to solve the above-mentioned problems, in a method of manufacturing a lap winding stator according to the present invention, first, a predetermined number of winding teeth of a stator core are straddled and the distance between the teeth is increased. First over a wider range
Is wound at a position shifted by one tooth in the circumferential direction from the first winding coil, and at least a part of the first winding coil is arranged in the radial direction of the stator core. An N-th (N is an integer of 2 or more) winding coil overlapping the winding coil is provided over a wider range than between a predetermined number of winding teeth of the stator core.

Next, an M-th (M is an integer of 3 or more) winding coil that does not overlap the first winding coil in the radial direction is
The stator core is provided in a range substantially equal to that between the predetermined number of winding teeth. Furthermore, a P-th (P is an integer of 4 or more) winding coil that radially overlaps the first winding coil is
The last winding coil is provided over a wider area than a predetermined number of winding teeth of the stator core, and after the last winding coil is provided, the last winding coil is pressed toward the center of the stator core.

That is, the first winding coil and the first winding coil
The other winding coil radially overlapping the winding coil is wound in advance over a wider area than between the winding teeth, and these winding coils are easily wound toward the center of the stator core after winding processing. It can be pressed and deformed. As a result, the space factor of the lap winding can be effectively improved, and the winding coil does not slide on the teeth and the insulating coating of the winding coil does not peel off. Good insulation can be ensured.

Further, the stator core is constituted by a laminated steel sheet in which a plurality of steel sheets are integrally laminated by an adhesive.

[0010]

FIG. 1 is a schematic perspective explanatory view of a winding apparatus 10 for carrying out a method for manufacturing a lap winding stator according to an embodiment of the present invention, and FIG. FIG. 3 is a schematic side view of the device 10, and FIG. 3 is a cross-sectional plan view of the winding device 10.

The winding device 10 includes a stator core 14 having a plurality of winding teeth 12 protruding radially outward from a peripheral surface thereof.
A mounting mechanism 16 intermittently rotatable in the direction,
The winding coil 20 is formed by, for example, the four teeth 12 by the winding nozzle 19 for feeding out the winding enamel wire L and the tooth positioning mechanism 18 for positioning the tooth 2. Wing former 22
A winding coil pushing mechanism 24 for pressing the winding coil 20 in the direction of the center of the stator core 14, a substrate 26 on which the wing former 22 and the winding coil pushing mechanism 24 are mounted, and the winding nozzle 19. A first drive mechanism 28 for moving the stator core 14 in the radial direction (the direction of the arrow B) and a second drive mechanism 30 for rotating the winding nozzle 19 are provided.

As shown in FIGS. 1 to 4, the placing mechanism 16 and the tooth positioning mechanism 18 are provided on a base 32, and the tooth positioning mechanism 18 is erected on the base 32. The support table 34 and the support table 34
And a cylinder 36 disposed thereon.

A positioning rod 38 extends from the cylinder 36 in the horizontal direction, and a tapered end surface 38 a of the positioning rod 38 is set to a shape that can be inserted between the teeth 12 of the stator core 14. Teeth positioning member 40
Are fixed to the substrate 26 so as to face the positioning rods 38. The teeth positioning member 40 contacts the adjacent teeth 12, 12 to position the stator core 14.

As shown in FIG. 2, the first
A first motor 42 constituting the drive mechanism 28 is provided, and a drive shaft 42a extending in a horizontal direction from the first motor 42 is provided.
The first ball screw 44 is connected coaxially. The first ball screw 44 is rotatably supported at both ends on the base 32 and is screwed to a nut 50 provided at one end of the slide base 48. Slide base 48
Are disposed on the base 32 so as to be able to advance and retreat along rails 52a and 52bb provided in parallel with each other and extending in the direction of arrow B.

As shown in FIGS. 1 and 3, on the slide base 48, a second motor 54 constituting the second drive mechanism 30 is fixed. A pulley 56 is fixed to the drive shaft 54 a of the second motor 54, and a timing belt 58 that engages with the pulley 56 engages with a pulley portion 62 provided at one end of the rotary cylinder 60. The rotating cylinder 60 is
It is rotatably mounted on the slide base 48 via a plurality of bearings 64, and an opening 68 is formed in a neck portion connected to the large diameter portion 66. A guide roller 72 is rotatably supported at the tip of a support 70 facing the inside from the opening 68.

A winding nozzle 19 is fixed to the outer periphery of the large diameter portion 66, and a plurality of guide rollers 76 are attached to the winding nozzle 19.
Are rotatably arranged. An enamel wire L can be fed out to the winding nozzle 19 via a guide roller 76. As shown in FIGS. 1 and 2, the enameled wire L is fed out from an enameled wire supply unit 80 disposed outside the base 32, is given a predetermined tension by a tensioner 82, and After passing through the central part of the body 60, it is sent to the winding nozzle 19 side via the guide roller 72.

As shown in FIG. 3, inside the large-diameter portion 66 of the rotary cylinder 60, a support cylinder 86 is provided via a bearing 84.
The substrate 26 is disposed via a spring 90 on a frame portion 88 provided integrally with the support cylinder 86 so as to be able to advance and retreat.

As shown in FIG. 4, the wing former 22
Has a left guide 92 and a right guide 94. The left guide 92 has a distal end set in a narrow plate shape.
While being fixed to the moving table 95, it is attached to the substrate 26 via a spring 96 and a guide rail 98 so as to be able to advance and retreat in the direction of arrow C. The right guide 94 is the left guide 9
Similarly to 2, it is fixed to the moving table 99 and is movable in the direction of arrow D with respect to the substrate 26 via a spring 100 and a guide rail 102.

As shown in FIGS. 1 and 3, the slide base 48 has a left guide position adjusting means 104 for moving the left guide 92 forward and backward in the arrow C direction, and a right guide 94 for moving the right guide 94 in the arrow D direction. And right guide position adjusting means 106 are provided. The left guide position adjusting means 104 includes a first position variable motor 108,
A second ball screw 110 is connected to a drive shaft 108a of the position variable motor 108. The second ball screw 110 is
The first movable body 112 is rotatably supported by a nut portion 114 of the movable body 112 via a bearing 116.

The first outer cylinder 118 is disposed in the rotary cylinder 60 so as to be able to advance and retreat in the direction of arrow B, and the second outer cylinder 120 is coaxially and rotatably connected to the tip end thereof. . The first mounting plate 1 is provided at the tip of the second outer cylinder 120.
A first pressing roller 124 is rotatably supported via the second pressing roller 22, and the first pressing roller 124 abuts on the moving table 95 to which the left guide 92 is fixed.

Like the left guide position adjusting means 104, the right guide position adjusting means 106 includes a second position variable motor 126, and a third ball screw 128 is connected to a drive shaft 126a of the second position variable motor 126. You. The third ball screw 128 is connected to the nut 132 of the second moving body 130.
And the second movable body 130 rotatably supports the first inner cylinder 136 via a bearing 134. The first inner cylinder 136 is disposed coaxially within the first outer cylinder 118, and has a second inner cylinder 138 at the distal end thereof.
Are connected coaxially and rotatably. Second inner cylinder 13
A second pressing roller 142 is rotatably supported at the distal end of the movable guide 99 via a second mounting plate 140, and the second pressing roller 142 is attached to the moving table 99 to which the right guide 94 is fixed.
Abut.

A hooking cylinder 144 is provided inside the second inner cylinder 138. This hooking cylinder 144
The rear end of the rod 146a is rotatably connected to a cylinder 145, and the cylinder 145 extends from a cylinder 146.
Is rotatably supported by a third moving body 148 connected to the second moving body 148.

A connecting pin 149 is fixed to the support cylinder 86 so as to extend in the diameter direction, and the connecting pin 149 is integrated with the second outer cylinder 120, the second inner cylinder 138 and the hooking cylinder 144. Is inserted. 2nd outer cylinder 1
The 20 and the second inner cylinder 138 are supported by the support cylinder 86 so as to be able to advance and retreat in the direction of arrow B and to be relatively non-rotatable.

As shown in FIG. 4, the winding coil pushing mechanism 24 includes a left pushing member 150 and a right pushing member 152, and the left pushing member 150 and the right pushing member 1 are provided.
52 is movable in the directions of arrows E and F via springs 154 and 156 and guide rails 158 and 160, respectively. On the base 32, a left pressing means 162 for moving the left pressing member 150 in the direction of arrow E and a right pressing means 164 for moving the right pressing member 152 in the direction of arrow F are provided.

As shown in FIGS. 1 and 3, the left pressing means 162 is mounted on a support 166 so as to be swingable.
The first pressing cylinder 16 includes a pressing cylinder 168.
A first pressing member 170, which can be in contact with the left pressing member 150, is fixed to the tip of a rod 168 a extending from the first pressing member 170. The first pressing cylinder 168 is connected to the first swing cylinder 17.
2

The right pressing means 164 is
Similarly to the second embodiment, a second pressing cylinder 176 swingable via a support 174 is provided, and a right pushing member 15 is attached to the tip of a rod 176a extending from the second pressing cylinder 176.
The second pressing member 178 that can be freely contacted with the second pressing member 178 is fixed. Second
A second swing cylinder 180 extending in the horizontal direction is engaged with the pressing cylinder 176.

As shown in FIG. 4, a side former 182 is mounted on the base 32 at right angles to the teeth positioning mechanism 18.
Is provided. The side former 182 includes opening and closing cylinders 184a and 184b that are arranged to face each other.
The rods 186 of the open / close cylinders 184a and 184b
The link pieces 188a and 188b engage with the a and 186b. The link pieces 188a, 188b are connected to the fulcrum 190a, 1
It is swingable through 90b, and side guides 192a and 192b are fixed to respective ends.

The operation of the winding device 10 thus configured will be described below in relation to the winding method according to the present embodiment.

First, the stator core 14 is placed on the mounting mechanism 16.
Is placed. The stator core 14 is formed of a laminated steel sheet in which a plurality of electromagnetic steel sheets are stacked and integrated by, for example, an adhesive or the like. After the stator core 14 is arranged at a predetermined angular position via the mounting mechanism 16, the cylinder 36 constituting the teeth positioning mechanism 18 is driven. As a result, the positioning rod 38 is displaced toward the stator core 14, and the tip end taper surface 38 a of the tooth 1
The teeth 12 are inserted between the two to position the teeth 12.

At a position facing the positioning rod 38,
The tooth positioning member 40 is provided, and the hooking cylinder 144 moves in the direction of the arrow B1 under the action of the cylinder 146. Accordingly, the support cylinder 86 is displaced in the direction of the arrow B1 via the connecting pin 149, and the tooth positioning member 40 comes into contact with the predetermined tooth 12 of the stator core 14 via the elastic force of the spring 90, thereby positioning the tooth 12. Do.

On the other hand, in the side former 182, the side guides 192a and 192b are arranged so as to have an opening toward the outer peripheral side of the stator core 14 over, for example, the four teeth 12 (see FIG. 5A). Further, the left guide 92 and the right guide 94 constituting the wing former 22 are displaced radially inward of the stator core 14 and come into contact with the stator core 14.

That is, left guide position adjusting means 104
Is driven, and the second ball screw 110 connected to the drive shaft 108a is driven.
Is rotated in a predetermined direction, the second ball screw 110
The first moving body 112 moves in the direction of the arrow B1 via the nut portion 114 into which is screwed. The first and second outer cylinders 118 are attached to the first moving body 112 via bearings 116,
The first and second outer cylinders 118 and 120 move in the rotating cylinder 60 in the direction of arrow B1.

A first pressing roller 124 is supported at the tip of the second outer cylinder 120 via a first mounting plate 122, and the first pressing roller 124 is connected to the second outer cylinder 12
It moves in the direction of arrow B1 integrally with 0. As a result, the left guide 92 moves against the arrow C against the resilience of the spring 96.
After moving in one direction, the left guide 92 enters between the predetermined teeth 12 of the stator core 14 and contacts the bottom surface of the stator core 14.

On the other hand, in the right guide position adjusting means 106, similarly to the left guide position adjusting means 104, the third ball screw 128 is driven by the second position variable motor 126.
The second moving body 130 moves in the direction of arrow B1 via.
The first and the second supported by the second moving body 130
The inner cylinders 136 and 138 move in the direction of arrow B1, and the second pressing roller 142 supported at the distal end of the second inner cylinder 138 via the second mounting plate 140 moves the right guide 94 to the arrow D1. The right guide 94 is pressed in the direction and enters between the predetermined teeth 12.

In this state, the second motor 54 constituting the second drive mechanism 30 is driven, and the pulley 56 fixed to the drive shaft 54a and the timing at which the pulley 56 and the pulley portion 62 are integrally bridged. Through the belt 58,
The rotating cylinder 60 rotates integrally with the first outer cylinder 118 and the first inner cylinder 136. The winding nozzle 19 is fixed to the rotating cylinder 60, and the winding nozzle 19 starts rotating integrally with the rotating cylinder 60, and the stator core 14 is guided by the side guides 192 a and 192 b. The enameled wire L is wound over the four teeth 12, and the first wound coil 20a is provided (see FIG. 5A).

Here, as shown in FIG. 5B, the winding nozzle 19 places the enameled wire L on the left guide 92 and the right guide 94 constituting the wing former 22, and extends over a wider range than between the teeth 12. It is wound. At this time, the winding nozzle 19 is driven by a first motor 42 constituting the first drive mechanism 28 and integrally formed with a slide base 48 having a nut portion 50 screwed to the first ball screw 44 by an arrow. Displaced in the direction B to form the first winding coil 20a.

After the first winding coil 20a is provided over the four teeth 12 and over a wider range than between the teeth 12, the left guide position adjusting means 104
And the right guide position adjusting means 106 is driven in a direction opposite to the above. For this reason, the first and second pressing rollers 124 and 142 move in the direction of arrow B2, and the left guide 9
2 and the right guide 94 are respectively provided with a spring 96,
The tooth 12 moves in the direction of arrow C2 and the direction of arrow D2 through the elastic force of 100, and retreats from the rotation locus of the tooth 12.

Further, the cylinder 36 constituting the teeth positioning mechanism 18 is driven, the positioning rod 38 is retracted, and the tip tapered surface 38a is separated from between the teeth 12. On the other hand, the hooking cylinder 144 moves in the direction of arrow B2 under the action of the cylinder 146. Therefore, the support cylinder 8
6 is displaced in the direction of arrow B2, and the teeth positioning member 40 is displaced.
Is separated from the teeth 12.

In this state, the stator core 14 rotates in the direction of arrow A by a predetermined angle via the mounting mechanism 16. Specifically, it rotates by the angle between the adjacent teeth 12. Then, after the stator core 14 is positioned and held through the teeth positioning mechanism 18, the left guide position adjusting means 104 and the right guide position adjusting means 106 are driven again, and the left guide 92 and the right guide 94 enter the teeth 12 side. .

Next, the second driving mechanism 30 is driven to rotate the winding nozzle 19, and the winding nozzle 19 swings in the direction of arrow B via the first driving mechanism 28. Thereby, the first winding coil 2 is provided on the stator core 14.
The second winding coil 20b is provided at a position shifted by one tooth 12 in the circumferential direction (the direction of arrow G) from 0a (see FIG. 6). The second winding coil 20b at least partially overlaps the first winding coil 20a in the radial direction of the stator core 14 (in the direction of arrow H).
The winding coil 20b of FIG. 1 extends over the four teeth 12 similarly to the first winding coil 20a, and
It is provided over a wider range than between the two.

Similarly, at least part of the stator core 1
In the present embodiment, the fourth winding coil 20d overlaps the first winding coil 20a in the radial direction, and after the fourth winding coil 20d is provided over a wider range than between the predetermined teeth 12, the first winding coil 20a extends in the radial direction. Does not overlap with the winding coil 20a of
In the present embodiment, the fifth winding coil 20e is wound in a range substantially equal to that between the predetermined teeth 12.

Specifically, as shown in FIG. 7A, the left guide 92 and the right guide 94 are arranged at positions separated from the bottom surface of the stator core 14, and the second drive mechanism 3
The fifth winding coil 20e is provided over the four teeth 12 by rotating the winding nozzle 19 under the action of 0.
For this reason, the fifth winding coil 20e is wound around the teeth 12 in substantially the same range, that is, around the predetermined teeth 12 without any gap (see FIG. 7B).

After the sixth winding coil 20f, like the fifth winding coil 20e, it is provided in a range substantially equal to a predetermined space between the teeth 12, and radially extends through the first winding coil 20a.
At the time of winding of the (N-2) th winding coil 20n-2 which overlaps with the winding, the winding process is performed over a wider range than between the teeth 12 so as to wind the left guide 92 and the right guide 94. Furthermore, the (N-1) th winding coil 20n-1 and the (N-2) th winding coil 20n-
2 is wound (see FIG. 8).

Next, as shown in FIG.
The first and second swing cylinders 172 and 180 constituting the right and left pushing means 164 are driven, and the first and second pushing cylinders 168 and 176 swing from the solid position, which is the retreat position, to the position indicated by the two-dot chain line. Move.

Therefore, the first and second pressing cylinders 16
8 and 176 are driven, and the first and second pressing members 17
0 and 178 move forward to press the left pushing member 150 and the right pushing member 152 in the directions of arrow E1 and arrow F1, respectively. Therefore, the left pushing member 150 and the right pushing member 152 move in the arrow E1 direction and the arrow F1 direction against the resilience of the springs 154 and 156,
The N-th winding coil 20n, which is the last winding coil, is pressed toward the center of the stator core 14 to perform a forming process (see FIG. 9).

In this case, in the present embodiment, the first winding coil 20a and the winding coils 20b, 20c, 20d, which overlap the first winding coil 20a in the radial direction of the stator core 14 (direction of arrow H). 20n-1, 20n-2 and 20n (hereinafter referred to as other winding coils 20)
Each is wound over a wider range than between the predetermined teeth 12. Therefore, after the winding process by the N-th winding coil 20n is completed, when the N-th winding coil 20n is pressed toward the center of the stator core 14 via the winding coil pushing mechanism 24, the first Of the winding coil 20a and the other winding coil 20 can be easily and reliably deformed toward the center of the stator core 14. First winding coil 20a and other winding coils 20
Because there is a gap between the first
This is because the degree of freedom of deformation of the winding coil 20a and other winding coils 20 can be improved, and the winding coil 20a can be easily and surely deformed.

As a result, the space factor of the lap winding of the winding coil 20 with respect to the stator core 14 is effectively improved, and the winding coil 20 does not slide on the teeth 12. Therefore, the effect that the insulating film (enamel) of the enameled wire L does not peel off and the insulating property of the wound coil 20 can be secured well can be obtained.

[0048]

As described above, in the method of manufacturing the lap winding stator according to the present invention, the first winding coil and the first
And other winding coils that overlap in the radial direction of the stator core are wound over a wider area than between the winding teeth, and these winding coils can be easily moved toward the center of the stator core after winding processing. And it can be reliably deformed by pressing. Thereby, the space factor of the lap winding is effectively improved, and the winding coil does not come into contact with the teeth so that the insulating coating is not peeled off, and the insulation property of the winding coil is sufficiently secured. Becomes possible.

[Brief description of the drawings]

FIG. 1 is a schematic perspective explanatory view of a winding device for carrying out a method of manufacturing a lap winding stator according to an embodiment of the present invention.

FIG. 2 is a schematic side view illustrating the winding device.

FIG. 3 is a cross-sectional plan view of the winding device.

FIG. 4 is an enlarged plan explanatory view of a main part of the winding device.

FIG. 5A is an explanatory diagram when a first winding coil is applied to a stator core, and FIG. 5B is an explanatory diagram illustrating a state in which the first winding coil is wound.

FIG. 6 is an explanatory view when a second winding coil is applied to the stator core.

FIG. 7A is an explanatory diagram when a fourth winding coil is applied to a stator core, and FIG. 7B is an explanatory diagram illustrating a winding state of the fourth winding coil.

FIG. 8 is an explanatory diagram when a final winding coil is applied.

FIG. 9 is an explanatory view when the last winding coil is pressed and deformed toward the center of the stator core.

FIG. 10 is an explanatory diagram of a winding state of a general stator.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 ... Winding apparatus 12 ... Winding teeth 14 ... Stator core 16 ... Placing mechanism 18 ... Teeth positioning mechanism 20, 20a-20n
... winding coil 22 ... wing former 24 ... winding coil pushing mechanism 26 ... substrate 28,30 ... driving mechanism

Claims (2)

[Claims] 1. A method of manufacturing a stator by applying a plurality of winding coils to a stator core having an opening toward an outer peripheral side to produce a stator, wherein the stator core extends over a predetermined number of winding teeth of the stator core. And providing the first winding coil over a wider range than between the teeth; winding at a position shifted by one tooth in the circumferential direction from the first winding coil; Providing an Nth (N is an integer of 2 or more) winding coil that overlaps the first winding coil in the radial direction of the stator core over a wider range than a predetermined number of winding teeth of the stator core; M-th non-overlapping radial coil with the first winding coil
Providing (M is an integer of 3 or more) winding coils in a range substantially equal to a predetermined number of winding teeth of the stator core; and P (P) overlapping the first winding coil in the radial direction. (P is an integer of 4 or more) in which a winding coil is provided over a wider range than a predetermined number of winding teeth of the stator core; And a step of pressing the final winding coil toward the center of the stator core to perform a forming process after providing the winding coil. 2. The method according to claim 1, wherein the stator core is formed by integrally laminating a plurality of steel plates with an adhesive.