US20240022147A1 - Method of manufacturing stator and device for manufacturing stator - Google Patents
Method of manufacturing stator and device for manufacturing stator Download PDFInfo
- Publication number
- US20240022147A1 US20240022147A1 US18/372,920 US202318372920A US2024022147A1 US 20240022147 A1 US20240022147 A1 US 20240022147A1 US 202318372920 A US202318372920 A US 202318372920A US 2024022147 A1 US2024022147 A1 US 2024022147A1
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- winding
- coil
- winding coil
- region
- jig
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 34
- 238000004804 winding Methods 0.000 claims abstract description 129
- 238000003780 insertion Methods 0.000 claims abstract description 50
- 230000037431 insertion Effects 0.000 claims abstract description 50
- 239000000463 material Substances 0.000 claims description 31
- 238000000034 method Methods 0.000 claims description 27
- 230000005484 gravity Effects 0.000 claims description 3
- 239000000470 constituent Substances 0.000 description 10
- 238000009413 insulation Methods 0.000 description 6
- 230000002708 enhancing effect Effects 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 239000010409 thin film Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
- H02K15/0464—Lap windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/024—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with slots
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
- H02K15/0442—Loop windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/06—Embedding prefabricated windings in machines
- H02K15/062—Windings in slots; salient pole windings
- H02K15/065—Windings consisting of complete sections, e.g. coils, waves
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21F—WORKING OR PROCESSING OF METAL WIRE
- B21F23/00—Feeding wire in wire-working machines or apparatus
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/16—Stator cores with slots for windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/024—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with slots
- H02K15/026—Wound cores
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/06—Embedding prefabricated windings in machines
- H02K15/062—Windings in slots; salient pole windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/06—Embedding prefabricated windings in machines
- H02K15/062—Windings in slots; salient pole windings
- H02K15/065—Windings consisting of complete sections, e.g. coils, waves
- H02K15/066—Windings consisting of complete sections, e.g. coils, waves inserted perpendicularly to the axis of the slots or inter-polar channels
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/08—Forming windings by laying conductors into or around core parts
- H02K15/085—Forming windings by laying conductors into or around core parts by laying conductors into slotted stators
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/5313—Means to assemble electrical device
- Y10T29/53143—Motor or generator
Definitions
- Exemplary embodiments relate to a method of manufacturing a stator and a device for manufacturing a stator and, more particularly, to a method of manufacturing a stator provided with a winding coil and a device for manufacturing the stator.
- Motors converting electric energy into kinetic energy include stators and rotors.
- stators and rotors In order to enhance efficiency of such a motor and reduce energy loss that occurs in a coil wound around a stator, a space factor of the coil disposed in a stator core needs to be improved.
- the coil in a wound state is mounted to a separate jig, and then, the jig is inserted into the slots of the stator core.
- a separate insertion member is provided between the stator core and the coil during insertion of the coil.
- the thin film of the coil becomes thinner, and insulation performance of the coil is deteriorated.
- a considerable force is also applied to the separate insertion member described above during insertion of the coil, and thus, the insertion member needs to be replaced periodically.
- the thin film of the coil is scratched by the insertion member, and insulation performance of the coil is deteriorated.
- the slots of the stator core are designed, the size and assemblability of the insertion member as well as the outer diameter of the wound coil have to be taken into consideration. Thus, the sizes of the slots are increased, and overall performance of the motor is deteriorated.
- a device for manufacturing a stator including a winding jig configured to wind a coil and to manufacture a winding coil, and an insertion jig configured to receive the winding coil from the winding jig and to insert the winding coil into a stator core, wherein the winding jig comprises a body extending along a longitudinal direction (L 1 ), a power supply unit configured to make the body revolve around a central shaft of the body, and a protrusion formed on a surface of the body.
- the protrusion may have a closed curve shape that extends along a circumferential direction (C 1 ) of the body.
- the protrusion may have an open curve shape that extends along a circumferential direction (C 1 ) of the body.
- the protrusion may be provided in plurality, and the plurality of protrusions may be spaced apart from each other along the longitudinal direction (L 1 ) of the body.
- the protrusion may include an upper surface and a lower surface, and the upper surface may include an upper inclined section inclined downward in a width direction (R 1 ) of the body.
- the upper inclined section may be formed at an end of the upper surface away from the body in the width direction (R 1 ).
- the lower surface may include a lower horizontal section extending horizontally along the width direction (R 1 ) of the body.
- the insertion jig may include a first region having a first recessed portion disposed therein, and a second region coupled to one side of the first region and having a second recessed portion disposed therein.
- Each of the first region and the second region may include an upper portion provided in each of upper zones of the first region and the second region, and a lower portion provided in each of the lower zones of the first region and the second region and may be connected to the upper portion, respectively, wherein the first recessed portion may be formed in the lower portion provided in the first region, and wherein the second recessed portion may be formed in the lower portion provided in the second region.
- the first region and the first recessed portion may extend longitudinally in a radial direction (R 2 ) of a virtual circle, and the second region and the second recessed portion may extend longitudinally in the radial direction (R 2 ) of the virtual circle.
- the first recessed portion or the second recessed portion may be configured such that an inner width (WI) of an inner region in the radial direction (R 2 ) may be different from an inner width (WO) of an outer region in the radial direction (R 2 ).
- the first recessed portion or the second recessed portion may be configured such that an inner width (WI) of an inner region in the radial direction (R 2 ) may be greater than an inner width (WO) of an outer region in the radial direction (R 2 ).
- the first region or the second region may include a protrusion section formed at an end of the outer region in the radial direction (R 2 ) and may protrudes toward the first recessed portion or the second recessed portion, respectively.
- the protrusion section may be provided on each of two inner surfaces defining the first recessed portion in the first region, face each other in a circumferential direction (C 2 ) of the virtual circle, or is provided on each of two inner surfaces defining the second recessed portion in the second region, face each other in the circumferential direction (C 2 ) of the virtual circle.
- the widths of two outer surfaces of the lower portion provided in the first region or the second region may face each other in a circumferential direction (C 2 ) of the virtual circle may be formed uniformly along the radial direction (R 2 ) of the first region or the second region.
- a method of manufacturing a stator including preparing a coil material and a stator core having a plurality of slots provided along a circumferential direction (C), forming a winding coil by rotating a winding jig after disposing the coil material on an outer surface of the winding jig, wherein one or more protrusion parts arranged along a longitudinal direction (L 1 ) of a body are formed in the winding jig, transferring the winding coil from the winding jig to an insertion jig, wherein the insertion jig comprises a first region that has a first recessed portion having a recessed shape and a second region that has a second recessed portion having a recessed shape and is coupled to one side of the first region, and installing the winding coil into the slots after positioning the winding coil to a region above at least a portion of the plurality of slots, wherein the forming of the winding coil comprises accommodating the winding coil in the first
- the installing of the winding coil may include lowering the winding coil into the slots by gravity.
- the method may include forming a through-hole (G) in a central region of the stator core, and the plurality of slots communicate with the through-hole (G), wherein the installing of the winding coil may include lowering the winding coil into the slots after the winding coil is positioned to the inside of the through-hole (G).
- the installing of the winding coil may include the stator core being configured such that the plurality of slots are arranged in a vertical direction, and the winding coil may move in a horizontal direction and is positioned to the inside of the through-hole (G).
- the preparing of the coil material may include preparing the coil material using a first material and a second material provided separately from the first material, wherein the winding coil may include a first winding coil provided by winding the first material and a second winding coil provided by winding the second material.
- the first winding coil and the second winding coil may be spaced apart from each other with the protrusion part therebetween.
- FIG. 1 is a perspective view illustrating a winding jig of a device for manufacturing a stator according to the present disclosure.
- FIG. 2 is a side view illustrating the winding jig of the device for manufacturing a stator according to the present disclosure.
- FIG. 3 is an enlarged side view illustrating a protrusion part formed in the winding jig according to the present disclosure.
- FIG. 4 is a side view illustrating a state in which a winding coil is wound around the winding jig according to the present disclosure.
- FIG. 5 is a view illustrating a state before an insertion jig of the device for manufacturing a stator according to the present disclosure enters a through-hole of a stator core.
- FIG. 6 is a view illustrating a state after the insertion jig of the device for manufacturing a stator according to the present disclosure enters the through-hole of the stator core.
- FIG. 7 is a perspective view illustrating the insertion jig of the device for manufacturing a stator according to the present disclosure.
- FIG. 8 is a view illustrating a shape of a recessed portion formed in the insertion jig according to the present disclosure and illustrating a state in which winding coils are arranged inside recessed portions.
- FIG. 9 is an enlarged view illustrating lower portions and protrusion sections of the insertion jig according to the present disclosure.
- FIG. 1 is a perspective view illustrating a winding jig of a device for manufacturing a stator according to the present disclosure
- FIG. 2 is a side view illustrating the winding jig of the device for manufacturing a stator according to the present disclosure
- FIG. 3 is an enlarged side view illustrating a protrusion part formed in the winding jig according to the present disclosure
- FIG. 4 is a side view illustrating a state in which a winding coil is wound around the winding jig according to the present disclosure.
- the device for manufacturing a stator may include a winding jig 100 that winds a coil and manufactures a winding coil.
- the winding jig 100 may include a body 110 extending along a longitudinal direction L 1 and including a central shaft 112 , a power supply unit (not shown) that makes the body 110 revolve around the central shaft 112 of the body 110 , and a protrusion part 130 formed on a surface of the body 110 and protruding outward.
- the body 110 may have a quadrangular pillar shape except for the central shaft 112 as illustrated in FIGS. 1 to 4 .
- the body 110 may have various shapes such as a cylindrical shape unlike those illustrated in FIGS. 1 to 4 .
- the protrusion part 130 may be configured such that a plurality of winding coils 400 provided separately are spaced apart from each other along the longitudinal direction L 1 of the body 110 as illustrated in FIG. 4 .
- the plurality of winding coils 400 may be space apart from each other with the protrusion part 130 therebetween.
- the protrusion part 130 is provided on the surface of the body 110 and may have a shape extending along a circumferential direction C 1 of the body 110 .
- the protrusion part 130 may be formed only in a portion of the circumference of the body 110 as illustrated in FIGS. 1 and 2 . This may be understood as meaning that the protrusion part 130 has an open curve shape extending along the circumferential direction C 1 of the body 110 .
- the protrusion part 130 may be formed on only a portion of the four surfaces formed along the circumferential direction C 1 of the body 110 .
- FIGS. 1 and 2 illustrate, as an example, a state in which protrusion parts 130 are formed on the two facing surfaces among the four surfaces formed along the circumferential direction C 1 of the body 110 .
- the protrusion part 130 may have a closed curve shape extending along the circumferential direction C 1 of the body 110 .
- the protrusion parts 130 may be formed on all of the four surfaces formed along the circumferential direction C 1 of the body 110 , and the protrusion parts 130 formed on the respective surfaces may be connected to each other.
- the protrusion part 130 may be provided in plurality. More specifically, the plurality of protrusion parts 130 may be spaced apart from each other along the longitudinal direction L 1 of the body 110 .
- FIGS. 1 and 2 illustrate, as an example, a state in which five protrusion parts 130 are provided at equal intervals along the longitudinal direction L 1 of the body 110 , but the number of the protrusion parts 130 is not limited to that illustrated in the drawing.
- the protrusion part 130 may include an upper surface 132 and a lower surface 134 .
- the upper surface 132 may include an upper horizontal section 132 a which extends horizontally along a width direction R 1 of the body 110 and an upper inclined section 132 b which is inclined downward toward the outside in the width direction R 1 of the body 110 .
- the lower surface 134 may include a lower horizontal section 134 a which extends horizontally along the width direction R 1 of the body 110 and a lower inclined section 134 b which is inclined upward toward the outside in the width direction R 1 of the body 110 . More specifically, the upper horizontal section 132 a and the lower horizontal section 134 a described above may meet perpendicularly the body 110 .
- the upper inclined section 132 b and the lower inclined section 134 b may be connected to the upper horizontal section 132 a and the lower horizontal section 134 a , respectively, and may be formed at an outer end of the upper surface in the width direction R 1 of the body 110 .
- the outer edge region of the protrusion part 130 in the width direction R 1 may have a curved shape. This is to minimize damage to the winding coil due to the protrusion part 130 .
- FIG. 5 is a view illustrating a state before an insertion jig of the device for manufacturing a stator according to the present disclosure enters a through-hole of a stator core
- FIG. 6 is a view illustrating a state after the insertion jig of the device for manufacturing a stator according to the present disclosure enters the through-hole of the stator core
- FIG. 7 is a perspective view illustrating the insertion jig of the device for manufacturing a stator according to the present disclosure
- FIG. 8 is a view illustrating a shape of a recessed portion formed in the insertion jig according to the present disclosure and illustrating a state in which winding coils are arranged inside recessed portions.
- FIG. 9 is an enlarged view illustrating lower portions and protrusion sections of the insertion jig according to the present disclosure.
- the device for manufacturing a stator may include an insertion jig 200 which receives the winding coil 400 from the winding jig 100 (see FIG. 1 , etc.) and inserts the winding coil 400 into a stator core 300 .
- the insertion jig 200 may be divided into a plurality of regions. More specifically, the insertion jig 200 may include a first region 210 , a second region 220 coupled to one side of the first region 210 , a third region 230 coupled to one side of the second region 220 , and a fourth region 240 coupled to one side of the third region 230 .
- the insertion jig 200 may have a structure in which the first to fourth regions 210 , 220 , 230 , and 240 are individually manufactured and then assembled.
- the first to fourth regions 210 , 220 , 230 , and 240 may be integrally formed.
- a first recessed portion 211 having an upwardly recessed shape may be formed in the first region 210
- a second recessed portion 221 having an upwardly recessed shape may be formed in the second region 220
- a third recessed portion 231 having an upwardly recessed shape may be formed in the third region 230
- a fourth recessed portion 241 having an upwardly recessed shape may be formed in the fourth region 240 .
- the recessed portions 211 , 221 , 231 , and 241 formed in the insertion jig 200 may form spaces for accommodating the winding coil 400 provided from the winding jig 100 .
- each of the first to fourth regions 210 , 220 , 230 , and 240 may include an upper portion 202 provided in each of upper zones of the first to fourth regions 210 , 220 , 230 , and 240 and a lower portion 204 provided in each of the lower zones of the first to fourth regions 210 , 220 , 230 , and 240 and connected to the upper portion 202 .
- the upper portion 202 and the lower portion 204 may have different widths.
- FIGS. 5 to 7 illustrate a state in which the width of the upper portion 202 is greater than the width of the lower portion 204 .
- first recessed portion 211 may be formed in a lower surface of the lower portion 204 provided in the first region 210
- a second recessed portion 221 may be formed in a lower surface of the lower portion 204 provided in the second region 220
- a third recessed portion 231 may be formed in a lower surface of the lower portion 204 provided in the third region 230
- a fourth recessed portion 241 may be formed in a lower surface of the lower portion 204 provided in the fourth region 240 .
- 5 to 7 illustrate, as an example, a state in which the first to fourth recessed portions 211 , 221 , 231 , and 241 extend to the upper portions 202 provided in the first to fourth regions 210 , 220 , 230 , and 240 , respectively.
- the first to fourth recessed portions 211 , 221 , 231 , and 241 may be formed only in the lower portions 204 provided in the first to fourth regions 210 , 220 , 230 , and 240 , respectively.
- the first to fourth regions 210 , 220 , 230 , and 240 provided in the insertion jig 200 according to the present disclosure may be sequentially arranged along a circumferential direction C 2 of a virtual circle A.
- the inner regions of the first to fourth regions 210 , 220 , 230 , and 240 may be arranged toward the center of the virtual circle A, and the first to fourth regions 210 , 220 , 230 , and 240 may be arranged in parallel to a radial direction R 2 of the virtual circle A.
- first region 210 and the first recessed portion 211 may extend longitudinally in the radial direction R 2 of the virtual circle A
- the second region 220 and the second recessed portion 221 may extend longitudinally in the radial direction R 2 of the virtual circle A
- the third region 230 and the third recessed portion 231 may extend longitudinally in the radial direction R 2 of the virtual circle A
- the fourth region 240 and the fourth recessed portion 241 may extend longitudinally in the radial direction R 2 of the virtual circle A.
- widths of the recessed portions formed in the insertion jig may be different from each other depending on the regions.
- the first to fourth recessed portions 211 , 221 , 231 , and 241 may be configured such that an inner width WI of an inner region in the radial direction R 2 of the virtual circle A is different from an inner width WO of an outer region in the radial direction R 2 of the virtual circle A. More preferably, the first to fourth recessed portions 211 , 221 , 231 , and 241 may be configured such that the inner width WI of the inner region in the radial direction R 2 of the virtual circle A is greater than the inner width WO of the outer region in the radial direction R 2 of the virtual circle A.
- the insertion jig 200 may receive the winding coil 400 from the winding jig 100 .
- the winding coil 400 may have the numbers of wires, which are different from each other depending on regions.
- the number of wires represents the number of strands in coils which are arranged along the width direction of the winding coil.
- the number of wires in a portion positioned in the inner region in the radial direction R 2 may be greater than the number of wires in a portion positioned in the outer region in the radial direction R 2 .
- regions of the winding coil 400 passing through the page of the drawing are shown as circles for convenience of description. Based on the above, FIG.
- the number of wires in the winding coil is one in a portion positioned in the outer region in the radial direction R 2 (that is, a region corresponding to WO), and the number of wires in the winding coil is two in a portion positioned in the inner region in the radial direction R 2 (that is, a region corresponding to WI).
- each of the first to fourth regions 210 , 220 , 230 , and 240 may include a protrusion section 206 which is formed at an end of the outer region in the radial direction R 2 and protrudes toward the first to fourth recessed portions 211 , 221 , 231 , and 241 .
- the protrusion section 206 may be provided on each of two inner surfaces which, among inner surfaces defining the first recessed portion 211 in the first region 210 , face each other in the circumferential direction C 2 of the virtual circle A, or may be provided on each of two inner surfaces which, among inner surfaces defining the second recessed portion 221 in the second region 220 , face each other in the circumferential direction C 2 of the virtual circle A.
- the protrusion section 206 may be provided on each of two inner surfaces which, among inner surfaces defining the third recessed portion 231 in the third region 230 , face each other in the circumferential direction C 2 of the virtual circle A, or may be provided on each of two inner surfaces which, among inner surfaces defining the fourth recessed portion 241 in the fourth region 240 , face each other in the circumferential direction C 2 of the virtual circle A.
- the first to fourth recessed portions 211 , 221 , 231 , and 241 may be configured such that the inner width WI of the inner region in the radial direction R 2 of the virtual circle A is greater than the inner width WO of the outer region in the radial direction R 2 of the virtual circle A.
- the protrusion sections 206 are formed at the end of the outer region in the radial direction R 2 .
- the inner width WO of the outer region of the first to fourth recessed portions 211 , 221 , 231 , and 241 in the radial direction R may be defined as the distance between two neighboring protrusion sections 206 .
- each of widths of two outer surfaces which, among outer surfaces of the lower portion 204 provided in each of the first to forth regions 210 , 220 , 230 , and 240 , face each other in the circumferential direction C 2 of the virtual circle A may be formed uniformly along the radial direction R 2 of the first to forth regions 210 , 220 , 230 , and 240 .
- a method of manufacturing a stator may include: a preparation process of preparing a coil material and a stator core 300 having a plurality of slots S provided along a circumferential direction C; a winding process of forming a winding coil 400 by rotating a winding jig 100 after disposing the coil material on an outer surface of the winding jig 100 , wherein one or more protrusion parts 130 arranged along a longitudinal direction L 1 of a body 110 are formed in the winding jig 100 ; a transfer process of transferring the winding coil 400 from the winding jig 100 to an insertion jig 100 , wherein the insertion jig 200 includes a first region 210 that has a first recessed portion 211 having a recessed shape and a second region 220 that has a second recessed portion 221 having a recessed shape and is coupled to one side of the first region 210 ; and an insertion process of
- the winding coil 400 may fall into the slots S by gravity.
- the winding coil 400 may be inserted into the slots S without receiving separate external power in the insertion process, and thus, it is possible to prevent the winding coil 400 from being damaged while the winding coil 400 is inserted into the slots S of the stator core 300 .
- a through-hole G may be formed in a central region of the stator core 300 , and the plurality of slots S may communicate with the through-hole G.
- the winding coil 400 may fall into the slots S after the winding coil 400 is positioned to the inside of the through-hole G. That is, referring to FIGS. 5 and 6 , the insertion jig 200 , in which the winding coil is inserted, may be positioned in the outside of the through-hole G prior to the insertion process as illustrated in FIG. 5 .
- the insertion jig 200 in which the winding coil is inserted, may be positioned in the inside of the through-hole G as illustrated in FIG. 6 . More preferably, the insertion jig 200 and the winding coil may move in parallel to the page in the insertion process.
- the stator core 300 in the insertion process, may be configured such that the plurality of slots S are arranged in a vertical direction. In the insertion process, the winding coil moves in a horizontal direction and may be positioned to the inside of the through-hole G.
- the coil material may be prepared which includes a first material and a second material provided separately from the first material.
- the winding coil 400 may be provided which includes a first winding coil 410 provided by winding the first material and a second winding coil 420 provided by winding the second material.
- the coil material may be prepared which further includes a third material and a fourth material.
- the winding coil 400 may be provided which further includes a third winding coil 430 provided by winding the third material and a fourth winding coil 440 provided by winding the fourth material.
- the first winding coil 410 and the second winding coil 420 may be spaced apart from each other with the protrusion part 130 therebetween.
- the winding coil includes the first to fourth winding coils 410 , 420 , 430 , and 440
- the first to fourth winding coils 410 , 420 , 430 , and 440 may be spaced apart from each other with protrusion parts 130 therebetween in the winding process.
- the number of wires in a portion positioned in the inner region in a radial direction R 2 of a virtual circle A may be greater than the number of wires in a portion positioned in the outer region in the radial direction R 2 .
- the recessed portions 211 , 221 , 231 , and 241 may be configured such that, due to protrusion sections 206 , an inner width WI of the inner region in the radial direction R 2 of the virtual circle A is greater than an inner width WO of the outer region in the radial direction R 2 of the virtual circle A.
- the content described above with respect to the device for manufacturing a stator according to the present disclosure may also be applied, in the same manner, to the method of manufacturing a stator according to the present disclosure, and vice versa.
- the insulation performance of the coil may be enhanced by minimizing stress that occurs in the coil when the coil is inserted into the stator core. Also, by deleting the insertion member used in the related art, the sizes of slots formed in the stator core may be minimized while enhancing the insulation performance of the coil.
- the present disclosure provides for enhancing insulation performance of a coil by minimizing stress that occurs in the coil when the coil is inserted into a stator core, and further provide for minimizing sizes of slots formed in the stator core, while enhancing the insulation performance of the coil, by deleting an insertion member used in the related art.
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- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
Provided is a device for manufacturing a stator, the device including a winding jig configured to wind a coil and to manufacture a winding coil, and an insertion jig configured to receive the winding coil from the winding jig and to insert the winding coil into a stator core, wherein the winding jig comprises a body extending along a longitudinal direction (L1), a power supply unit configured to make the body revolve around a central shaft of the body, and a protrusion formed on a surface of the body.
Description
- This application is a divisional application of U.S. patent application Ser. No. 17/705,945, filed on Mar. 28, 2022, which claims the benefit under 35 USC § 119(a) of Korean Patent Application No. 10-2021-0157551, filed on Nov. 16, 2021, in the Korean Intellectual Property Office, the entire disclosure of which is incorporated herein by reference for all purposes.
- Exemplary embodiments relate to a method of manufacturing a stator and a device for manufacturing a stator and, more particularly, to a method of manufacturing a stator provided with a winding coil and a device for manufacturing the stator.
- Motors converting electric energy into kinetic energy include stators and rotors. In order to enhance efficiency of such a motor and reduce energy loss that occurs in a coil wound around a stator, a space factor of the coil disposed in a stator core needs to be improved.
- Also, according to the related art, in order to insert a coil into a stator core having slots, the coil in a wound state is mounted to a separate jig, and then, the jig is inserted into the slots of the stator core. Here, in order to prevent a thin film formed on a surface of the coil from contacting the stator core, a separate insertion member is provided between the stator core and the coil during insertion of the coil.
- However, according to the related art, due to high stress that occurs while the coil is inserted into the stator core, the thin film of the coil becomes thinner, and insulation performance of the coil is deteriorated. Also, according to the related art, a considerable force is also applied to the separate insertion member described above during insertion of the coil, and thus, the insertion member needs to be replaced periodically. In addition, the thin film of the coil is scratched by the insertion member, and insulation performance of the coil is deteriorated. Also, according to the related art, when the slots of the stator core are designed, the size and assemblability of the insertion member as well as the outer diameter of the wound coil have to be taken into consideration. Thus, the sizes of the slots are increased, and overall performance of the motor is deteriorated.
- This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
- In one general aspect, there is provided a device for manufacturing a stator, the device including a winding jig configured to wind a coil and to manufacture a winding coil, and an insertion jig configured to receive the winding coil from the winding jig and to insert the winding coil into a stator core, wherein the winding jig comprises a body extending along a longitudinal direction (L1), a power supply unit configured to make the body revolve around a central shaft of the body, and a protrusion formed on a surface of the body.
- The protrusion may have a closed curve shape that extends along a circumferential direction (C1) of the body.
- The protrusion may have an open curve shape that extends along a circumferential direction (C1) of the body.
- The protrusion may be provided in plurality, and the plurality of protrusions may be spaced apart from each other along the longitudinal direction (L1) of the body.
- The protrusion may include an upper surface and a lower surface, and the upper surface may include an upper inclined section inclined downward in a width direction (R1) of the body.
- The upper inclined section may be formed at an end of the upper surface away from the body in the width direction (R1).
- The lower surface may include a lower horizontal section extending horizontally along the width direction (R1) of the body.
- The insertion jig may include a first region having a first recessed portion disposed therein, and a second region coupled to one side of the first region and having a second recessed portion disposed therein.
- Each of the first region and the second region may include an upper portion provided in each of upper zones of the first region and the second region, and a lower portion provided in each of the lower zones of the first region and the second region and may be connected to the upper portion, respectively, wherein the first recessed portion may be formed in the lower portion provided in the first region, and wherein the second recessed portion may be formed in the lower portion provided in the second region.
- The first region and the first recessed portion may extend longitudinally in a radial direction (R2) of a virtual circle, and the second region and the second recessed portion may extend longitudinally in the radial direction (R2) of the virtual circle.
- The first recessed portion or the second recessed portion may be configured such that an inner width (WI) of an inner region in the radial direction (R2) may be different from an inner width (WO) of an outer region in the radial direction (R2).
- The first recessed portion or the second recessed portion may be configured such that an inner width (WI) of an inner region in the radial direction (R2) may be greater than an inner width (WO) of an outer region in the radial direction (R2).
- The first region or the second region may include a protrusion section formed at an end of the outer region in the radial direction (R2) and may protrudes toward the first recessed portion or the second recessed portion, respectively.
- The protrusion section may be provided on each of two inner surfaces defining the first recessed portion in the first region, face each other in a circumferential direction (C2) of the virtual circle, or is provided on each of two inner surfaces defining the second recessed portion in the second region, face each other in the circumferential direction (C2) of the virtual circle.
- The widths of two outer surfaces of the lower portion provided in the first region or the second region, may face each other in a circumferential direction (C2) of the virtual circle may be formed uniformly along the radial direction (R2) of the first region or the second region.
- In another general aspect, there is provided a method of manufacturing a stator, the method including preparing a coil material and a stator core having a plurality of slots provided along a circumferential direction (C), forming a winding coil by rotating a winding jig after disposing the coil material on an outer surface of the winding jig, wherein one or more protrusion parts arranged along a longitudinal direction (L1) of a body are formed in the winding jig, transferring the winding coil from the winding jig to an insertion jig, wherein the insertion jig comprises a first region that has a first recessed portion having a recessed shape and a second region that has a second recessed portion having a recessed shape and is coupled to one side of the first region, and installing the winding coil into the slots after positioning the winding coil to a region above at least a portion of the plurality of slots, wherein the forming of the winding coil comprises accommodating the winding coil in the first recessed portion and the second recessed portion.
- The installing of the winding coil may include lowering the winding coil into the slots by gravity.
- The method may include forming a through-hole (G) in a central region of the stator core, and the plurality of slots communicate with the through-hole (G), wherein the installing of the winding coil may include lowering the winding coil into the slots after the winding coil is positioned to the inside of the through-hole (G).
- The installing of the winding coil may include the stator core being configured such that the plurality of slots are arranged in a vertical direction, and the winding coil may move in a horizontal direction and is positioned to the inside of the through-hole (G).
- The preparing of the coil material may include preparing the coil material using a first material and a second material provided separately from the first material, wherein the winding coil may include a first winding coil provided by winding the first material and a second winding coil provided by winding the second material.
- The first winding coil and the second winding coil may be spaced apart from each other with the protrusion part therebetween.
- Other features and aspects will be apparent from the following detailed description, the drawings, and the claims.
- The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and together with the description serve to explain the principles of the invention.
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FIG. 1 is a perspective view illustrating a winding jig of a device for manufacturing a stator according to the present disclosure. -
FIG. 2 is a side view illustrating the winding jig of the device for manufacturing a stator according to the present disclosure. -
FIG. 3 is an enlarged side view illustrating a protrusion part formed in the winding jig according to the present disclosure. -
FIG. 4 is a side view illustrating a state in which a winding coil is wound around the winding jig according to the present disclosure. -
FIG. 5 is a view illustrating a state before an insertion jig of the device for manufacturing a stator according to the present disclosure enters a through-hole of a stator core. -
FIG. 6 is a view illustrating a state after the insertion jig of the device for manufacturing a stator according to the present disclosure enters the through-hole of the stator core. -
FIG. 7 is a perspective view illustrating the insertion jig of the device for manufacturing a stator according to the present disclosure. -
FIG. 8 is a view illustrating a shape of a recessed portion formed in the insertion jig according to the present disclosure and illustrating a state in which winding coils are arranged inside recessed portions. -
FIG. 9 is an enlarged view illustrating lower portions and protrusion sections of the insertion jig according to the present disclosure. - The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses, and/or systems described herein. However, various changes, modifications, and equivalents of the methods, apparatuses, and/or systems described herein will be apparent after an understanding of the disclosure of this application. For example, the sequences of operations described herein are merely examples, and are not limited to those set forth herein, but may be changed as will be apparent after an understanding of the disclosure of this application, with the exception of operations necessarily occurring in a certain order. Also, descriptions of features that are known may be omitted for increased clarity and conciseness.
- The features described herein may be embodied in different forms, and are not to be construed as being limited to the examples described herein. Rather, the examples described herein have been provided merely to illustrate some of the many possible ways of implementing the methods, apparatuses, and/or systems described herein that will be apparent after an understanding of the disclosure of this application
- The terminology used herein is for the purpose of describing particular examples only and is not to be limiting of the examples. The singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises/comprising” and/or “includes/including” when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
- When describing the examples with reference to the accompanying drawings, like reference numerals refer to like constituent elements and a repeated description related thereto will be omitted. In the description of examples, detailed description of well-known related structures or functions will be omitted when it is deemed that such description will cause ambiguous interpretation of the present disclosure.
- Also, in the description of the components, terms such as first, second, A, B, (a), (b) or the like may be used herein when describing components of the present disclosure. These terms are used only for the purpose of discriminating one constituent element from another constituent element, and the nature, the sequences, or the orders of the constituent elements are not limited by the terms. When one constituent element is described as being “connected”, “coupled”, or “attached” to another constituent element, it should be understood that one constituent element can be connected or attached directly to another constituent element, and an intervening constituent element can also be “connected”, “coupled”, or “attached” to the constituent elements.
- Hereinafter, a device for manufacturing a stator and a method of manufacturing a stator according to the present disclosure will be described with reference to the drawings.
- Device for Manufacturing a Stator
-
FIG. 1 is a perspective view illustrating a winding jig of a device for manufacturing a stator according to the present disclosure, andFIG. 2 is a side view illustrating the winding jig of the device for manufacturing a stator according to the present disclosure.FIG. 3 is an enlarged side view illustrating a protrusion part formed in the winding jig according to the present disclosure, andFIG. 4 is a side view illustrating a state in which a winding coil is wound around the winding jig according to the present disclosure. - Referring to
FIGS. 1 to 4 , the device for manufacturing a stator according to the present disclosure may include a windingjig 100 that winds a coil and manufactures a winding coil. The windingjig 100 may include abody 110 extending along a longitudinal direction L1 and including acentral shaft 112, a power supply unit (not shown) that makes thebody 110 revolve around thecentral shaft 112 of thebody 110, and aprotrusion part 130 formed on a surface of thebody 110 and protruding outward. - The
body 110 may have a quadrangular pillar shape except for thecentral shaft 112 as illustrated inFIGS. 1 to 4 . However, thebody 110 may have various shapes such as a cylindrical shape unlike those illustrated inFIGS. 1 to 4 . - The
protrusion part 130 may be configured such that a plurality of windingcoils 400 provided separately are spaced apart from each other along the longitudinal direction L1 of thebody 110 as illustrated inFIG. 4 . Thus, according to the present disclosure, the plurality of windingcoils 400 may be space apart from each other with theprotrusion part 130 therebetween. - The
protrusion part 130 is provided on the surface of thebody 110 and may have a shape extending along a circumferential direction C1 of thebody 110. Here, according to an example of the present disclosure, theprotrusion part 130 may be formed only in a portion of the circumference of thebody 110 as illustrated inFIGS. 1 and 2 . This may be understood as meaning that theprotrusion part 130 has an open curve shape extending along the circumferential direction C1 of thebody 110. For example, when thebody 110 has a quadrangular pillar shape, theprotrusion part 130 may be formed on only a portion of the four surfaces formed along the circumferential direction C1 of thebody 110.FIGS. 1 and 2 illustrate, as an example, a state in whichprotrusion parts 130 are formed on the two facing surfaces among the four surfaces formed along the circumferential direction C1 of thebody 110. - However, according to another example of the present disclosure unlike that described above, the
protrusion part 130 may have a closed curve shape extending along the circumferential direction C1 of thebody 110. For example, when thebody 110 has a quadrangular pillar shape, theprotrusion parts 130 may be formed on all of the four surfaces formed along the circumferential direction C1 of thebody 110, and theprotrusion parts 130 formed on the respective surfaces may be connected to each other. - Continuing to refer to
FIGS. 1 to 4 , theprotrusion part 130 may be provided in plurality. More specifically, the plurality ofprotrusion parts 130 may be spaced apart from each other along the longitudinal direction L1 of thebody 110.FIGS. 1 and 2 illustrate, as an example, a state in which fiveprotrusion parts 130 are provided at equal intervals along the longitudinal direction L1 of thebody 110, but the number of theprotrusion parts 130 is not limited to that illustrated in the drawing. - Also, as illustrated in
FIG. 3 , theprotrusion part 130 may include anupper surface 132 and alower surface 134. Here, theupper surface 132 may include an upperhorizontal section 132 a which extends horizontally along a width direction R1 of thebody 110 and an upperinclined section 132 b which is inclined downward toward the outside in the width direction R1 of thebody 110. Thelower surface 134 may include a lowerhorizontal section 134 a which extends horizontally along the width direction R1 of thebody 110 and a lowerinclined section 134 b which is inclined upward toward the outside in the width direction R1 of thebody 110. More specifically, the upperhorizontal section 132 a and the lowerhorizontal section 134 a described above may meet perpendicularly thebody 110. The upperinclined section 132 b and the lowerinclined section 134 b may be connected to the upperhorizontal section 132 a and the lowerhorizontal section 134 a, respectively, and may be formed at an outer end of the upper surface in the width direction R1 of thebody 110. Thus, as illustrated inFIG. 3 , the outer edge region of theprotrusion part 130 in the width direction R1 may have a curved shape. This is to minimize damage to the winding coil due to theprotrusion part 130. -
FIG. 5 is a view illustrating a state before an insertion jig of the device for manufacturing a stator according to the present disclosure enters a through-hole of a stator core, andFIG. 6 is a view illustrating a state after the insertion jig of the device for manufacturing a stator according to the present disclosure enters the through-hole of the stator core.FIG. 7 is a perspective view illustrating the insertion jig of the device for manufacturing a stator according to the present disclosure, andFIG. 8 is a view illustrating a shape of a recessed portion formed in the insertion jig according to the present disclosure and illustrating a state in which winding coils are arranged inside recessed portions. Also.FIG. 9 is an enlarged view illustrating lower portions and protrusion sections of the insertion jig according to the present disclosure. - Referring to
FIGS. 5 to 9 , the device for manufacturing a stator according to the present disclosure may include aninsertion jig 200 which receives the windingcoil 400 from the winding jig 100 (seeFIG. 1 , etc.) and inserts the windingcoil 400 into astator core 300. - According to the present disclosure, the
insertion jig 200 may be divided into a plurality of regions. More specifically, theinsertion jig 200 may include afirst region 210, asecond region 220 coupled to one side of thefirst region 210, athird region 230 coupled to one side of thesecond region 220, and afourth region 240 coupled to one side of thethird region 230. Theinsertion jig 200 may have a structure in which the first tofourth regions fourth regions - Here, according to the present disclosure, a first recessed
portion 211 having an upwardly recessed shape may be formed in thefirst region 210, and a second recessedportion 221 having an upwardly recessed shape may be formed in thesecond region 220. Also, a third recessedportion 231 having an upwardly recessed shape may be formed in thethird region 230, and a fourth recessedportion 241 having an upwardly recessed shape may be formed in thefourth region 240. - The recessed
portions insertion jig 200 may form spaces for accommodating the windingcoil 400 provided from the windingjig 100. - More specifically, each of the first to
fourth regions upper portion 202 provided in each of upper zones of the first tofourth regions lower portion 204 provided in each of the lower zones of the first tofourth regions upper portion 202. For example, theupper portion 202 and thelower portion 204 may have different widths.FIGS. 5 to 7 illustrate a state in which the width of theupper portion 202 is greater than the width of thelower portion 204. - Also, the first recessed
portion 211 may be formed in a lower surface of thelower portion 204 provided in thefirst region 210, a second recessedportion 221 may be formed in a lower surface of thelower portion 204 provided in thesecond region 220, a third recessedportion 231 may be formed in a lower surface of thelower portion 204 provided in thethird region 230, and a fourth recessedportion 241 may be formed in a lower surface of thelower portion 204 provided in thefourth region 240.FIGS. 5 to 7 illustrate, as an example, a state in which the first to fourth recessedportions upper portions 202 provided in the first tofourth regions portions lower portions 204 provided in the first tofourth regions - Also, as illustrated in
FIGS. 5 to 7 , the first tofourth regions insertion jig 200 according to the present disclosure may be sequentially arranged along a circumferential direction C2 of a virtual circle A. In this case, the inner regions of the first tofourth regions fourth regions - More specifically, the
first region 210 and the first recessedportion 211 may extend longitudinally in the radial direction R2 of the virtual circle A, and thesecond region 220 and the second recessedportion 221 may extend longitudinally in the radial direction R2 of the virtual circle A. Also, thethird region 230 and the third recessedportion 231 may extend longitudinally in the radial direction R2 of the virtual circle A, and thefourth region 240 and the fourth recessedportion 241 may extend longitudinally in the radial direction R2 of the virtual circle A. - Also, according to the present disclosure, widths of the recessed portions formed in the insertion jig may be different from each other depending on the regions.
- More specifically, the first to fourth recessed
portions portions - As described above, in the device for manufacturing a stator according to the present disclosure, the
insertion jig 200 may receive the windingcoil 400 from the windingjig 100. Here, the windingcoil 400 may have the numbers of wires, which are different from each other depending on regions. Herein, the number of wires represents the number of strands in coils which are arranged along the width direction of the winding coil. - More specifically, according to the present disclosure, in the winding
coil 400 accommodated in the recessedportions insertion jig 200, the number of wires in a portion positioned in the inner region in the radial direction R2 may be greater than the number of wires in a portion positioned in the outer region in the radial direction R2. InFIG. 8 , regions of the windingcoil 400 passing through the page of the drawing are shown as circles for convenience of description. Based on the above,FIG. 8 illustrates, as an example, a case in which the number of wires in the winding coil is one in a portion positioned in the outer region in the radial direction R2 (that is, a region corresponding to WO), and the number of wires in the winding coil is two in a portion positioned in the inner region in the radial direction R2 (that is, a region corresponding to WI). - Continuing to refer to
FIG. 9 , each of the first tofourth regions protrusion section 206 which is formed at an end of the outer region in the radial direction R2 and protrudes toward the first to fourth recessedportions - More specifically, according to the present disclosure, the
protrusion section 206 may be provided on each of two inner surfaces which, among inner surfaces defining the first recessedportion 211 in thefirst region 210, face each other in the circumferential direction C2 of the virtual circle A, or may be provided on each of two inner surfaces which, among inner surfaces defining the second recessedportion 221 in thesecond region 220, face each other in the circumferential direction C2 of the virtual circle A. Also, theprotrusion section 206 may be provided on each of two inner surfaces which, among inner surfaces defining the third recessedportion 231 in thethird region 230, face each other in the circumferential direction C2 of the virtual circle A, or may be provided on each of two inner surfaces which, among inner surfaces defining the fourth recessedportion 241 in thefourth region 240, face each other in the circumferential direction C2 of the virtual circle A. - That is, as described above, the first to fourth recessed
portions protrusion sections 206 are formed at the end of the outer region in the radial direction R2. That is, according to the present disclosure, the inner width WO of the outer region of the first to fourth recessedportions protrusion sections 206. - Also, as illustrated in
FIGS. 7 to 9 , according to an example, each of widths of two outer surfaces which, among outer surfaces of thelower portion 204 provided in each of the first toforth regions forth regions - Method of Manufacturing a Stator
- Referring to
FIGS. 1 to 9 , a method of manufacturing a stator according to the present disclosure may include: a preparation process of preparing a coil material and astator core 300 having a plurality of slots S provided along a circumferential direction C; a winding process of forming a windingcoil 400 by rotating a windingjig 100 after disposing the coil material on an outer surface of the windingjig 100, wherein one ormore protrusion parts 130 arranged along a longitudinal direction L1 of abody 110 are formed in the windingjig 100; a transfer process of transferring the windingcoil 400 from the windingjig 100 to aninsertion jig 100, wherein theinsertion jig 200 includes afirst region 210 that has a first recessedportion 211 having a recessed shape and asecond region 220 that has a second recessedportion 221 having a recessed shape and is coupled to one side of thefirst region 210; and an insertion process of falling the windingcoil 400 into the slots S after positioning the windingcoil 400 to a region above at least a portion of the plurality of slots S. - Particularly, in the insertion process described above, the winding
coil 400 may fall into the slots S by gravity. Thus, according to the present disclosure, the windingcoil 400 may be inserted into the slots S without receiving separate external power in the insertion process, and thus, it is possible to prevent the windingcoil 400 from being damaged while the windingcoil 400 is inserted into the slots S of thestator core 300. - More specifically, a through-hole G may be formed in a central region of the
stator core 300, and the plurality of slots S may communicate with the through-hole G. Here, in the insertion process in the method of manufacturing a stator according to the present disclosure, the windingcoil 400 may fall into the slots S after the windingcoil 400 is positioned to the inside of the through-hole G. That is, referring toFIGS. 5 and 6 , theinsertion jig 200, in which the winding coil is inserted, may be positioned in the outside of the through-hole G prior to the insertion process as illustrated inFIG. 5 . In the insertion process, theinsertion jig 200, in which the winding coil is inserted, may be positioned in the inside of the through-hole G as illustrated inFIG. 6 . More preferably, theinsertion jig 200 and the winding coil may move in parallel to the page in the insertion process. For this, as illustrated inFIGS. 5 and 6 , in the insertion process, thestator core 300 may be configured such that the plurality of slots S are arranged in a vertical direction. In the insertion process, the winding coil moves in a horizontal direction and may be positioned to the inside of the through-hole G. - Also, in the preparation process in the method of manufacturing a stator according to the present disclosure, the coil material may be prepared which includes a first material and a second material provided separately from the first material. Here, in the winding process, the winding
coil 400 may be provided which includes a first windingcoil 410 provided by winding the first material and a second windingcoil 420 provided by winding the second material. Moreover, according to the present disclosure, in the preparation process, the coil material may be prepared which further includes a third material and a fourth material. In the winding process, the windingcoil 400 may be provided which further includes a third windingcoil 430 provided by winding the third material and a fourth windingcoil 440 provided by winding the fourth material. - Particularly, according to the present disclosure, in the winding process, the first winding
coil 410 and the second windingcoil 420 may be spaced apart from each other with theprotrusion part 130 therebetween. When the winding coil includes the first to fourth windingcoils coils protrusion parts 130 therebetween in the winding process. - Also, as an example, in the transfer process, in the winding
coil 400 accommodated in the recessedportions insertion jig 200, the number of wires in a portion positioned in the inner region in a radial direction R2 of a virtual circle A may be greater than the number of wires in a portion positioned in the outer region in the radial direction R2. This may be because the recessedportions protrusion sections 206, an inner width WI of the inner region in the radial direction R2 of the virtual circle A is greater than an inner width WO of the outer region in the radial direction R2 of the virtual circle A. - Also, the content described above with respect to the device for manufacturing a stator according to the present disclosure may also be applied, in the same manner, to the method of manufacturing a stator according to the present disclosure, and vice versa.
- According to the present disclosure, the insulation performance of the coil may be enhanced by minimizing stress that occurs in the coil when the coil is inserted into the stator core. Also, by deleting the insertion member used in the related art, the sizes of slots formed in the stator core may be minimized while enhancing the insulation performance of the coil.
- The present disclosure provides for enhancing insulation performance of a coil by minimizing stress that occurs in the coil when the coil is inserted into a stator core, and further provide for minimizing sizes of slots formed in the stator core, while enhancing the insulation performance of the coil, by deleting an insertion member used in the related art.
- While this disclosure includes specific examples, it will be apparent after an understanding of the disclosure of this application that various changes in form and details may be made in these examples without departing from the spirit and scope of the claims and their equivalents. The examples described herein are to be considered in a descriptive sense only, and not for purposes of limitation. Descriptions of features or aspects in each example are to be considered as being applicable to similar features or aspects in other examples. Suitable results may be achieved if the described techniques are performed in a different order, and/or if components in a described system, architecture, device, or circuit are combined in a different manner, and/or replaced or supplemented by other components or their equivalents. Therefore, the scope of the disclosure is defined not by the detailed description, but by the claims and their equivalents, and all variations within the scope of the claims and their equivalents are to be construed as being included in the disclosure.
Claims (5)
1. A method of manufacturing a stator, the method comprising:
preparing a coil material and a stator core having a plurality of slots provided along a circumferential direction (C);
forming a winding coil by rotating a winding jig after disposing the coil material on an outer surface of the winding jig, wherein one or more protrusion parts arranged along a longitudinal direction (L1) of a body are formed in the winding jig;
transferring the winding coil from the winding jig to an insertion jig, wherein the insertion jig comprises a first region that has a first recessed portion having a recessed shape and a second region that has a second recessed portion having a recessed shape and is coupled to one side of the first region; and
installing the winding coil into the slots after positioning the winding coil to a region above at least a portion of the plurality of slots,
wherein the forming of the winding coil comprises accommodating the winding coil in the first recessed portion and the second recessed portion.
2. The method of claim 1 , wherein the installing of the winding coil comprises lowering the winding coil into the slots by gravity.
3. The method of claim 1 , further comprising:
forming a through-hole (G) in a central region of the stator core, and the plurality of slots communicate with the through-hole (G),
wherein the installing of the winding coil comprises lowering the winding coil into the slots after the winding coil is positioned to the inside of the through-hole (G).
4. The method of claim 3 , wherein the installing of the winding coil comprises,
the stator core being configured such that the plurality of slots are arranged in a vertical direction, and
the winding coil moves in a horizontal direction and is positioned to the inside of the through-hole (G).
5. The method of claim 1 , wherein the preparing of the coil material comprises preparing the coil material using a first material and a second material provided separately from the first material,
wherein the winding coil comprises a first winding coil provided by winding the first material and a second winding coil provided by winding the second material.
Priority Applications (1)
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US18/372,920 US20240022147A1 (en) | 2021-11-16 | 2023-09-26 | Method of manufacturing stator and device for manufacturing stator |
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KR10-2021-0157551 | 2021-11-16 | ||
KR1020210157551A KR20230071398A (en) | 2021-11-16 | 2021-11-16 | Method of manufacturing stator and device for manufacturing stator |
US17/705,945 US11894734B2 (en) | 2021-11-16 | 2022-03-28 | Method of manufacturing stator and device for manufacturing stator |
US18/372,920 US20240022147A1 (en) | 2021-11-16 | 2023-09-26 | Method of manufacturing stator and device for manufacturing stator |
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US17/705,945 Division US11894734B2 (en) | 2021-11-16 | 2022-03-28 | Method of manufacturing stator and device for manufacturing stator |
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US20240022147A1 true US20240022147A1 (en) | 2024-01-18 |
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US18/372,920 Pending US20240022147A1 (en) | 2021-11-16 | 2023-09-26 | Method of manufacturing stator and device for manufacturing stator |
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CN100395947C (en) * | 2002-08-08 | 2008-06-18 | 爱信艾达株式会社 | Coil forming device and coil forming method |
JP2005102402A (en) * | 2003-09-24 | 2005-04-14 | Aisin Aw Co Ltd | Stator manufacturing device |
US8384263B2 (en) * | 2008-02-14 | 2013-02-26 | Hitachi, Ltd. | Rotating electrical machine having a compact stator |
KR102415620B1 (en) | 2020-06-22 | 2022-07-04 | 마스코리아 주식회사 | Variable vehicle speed warning system including pedestrian determination system |
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2021
- 2021-11-16 KR KR1020210157551A patent/KR20230071398A/en unknown
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2022
- 2022-03-28 US US17/705,945 patent/US11894734B2/en active Active
- 2022-04-19 CN CN202210409052.9A patent/CN116137481A/en active Pending
- 2022-04-20 DE DE102022109549.5A patent/DE102022109549A1/en active Pending
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2023
- 2023-09-26 US US18/372,920 patent/US20240022147A1/en active Pending
Also Published As
Publication number | Publication date |
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CN116137481A (en) | 2023-05-19 |
US11894734B2 (en) | 2024-02-06 |
KR20230071398A (en) | 2023-05-23 |
US20230155460A1 (en) | 2023-05-18 |
DE102022109549A1 (en) | 2023-05-17 |
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