WO2011052133A1 - ステータの製造方法及び製造装置 - Google Patents
ステータの製造方法及び製造装置 Download PDFInfo
- Publication number
- WO2011052133A1 WO2011052133A1 PCT/JP2010/005829 JP2010005829W WO2011052133A1 WO 2011052133 A1 WO2011052133 A1 WO 2011052133A1 JP 2010005829 W JP2010005829 W JP 2010005829W WO 2011052133 A1 WO2011052133 A1 WO 2011052133A1
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- Prior art keywords
- coil
- jig
- axial direction
- slot
- stator core
- Prior art date
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- 238000004519 manufacturing process Methods 0.000 title claims description 51
- 238000003780 insertion Methods 0.000 claims abstract description 86
- 230000037431 insertion Effects 0.000 claims abstract description 86
- 238000004804 winding Methods 0.000 claims abstract description 28
- 230000001105 regulatory effect Effects 0.000 claims description 54
- 238000000034 method Methods 0.000 claims description 16
- 238000005452 bending Methods 0.000 claims description 10
- 238000009413 insulation Methods 0.000 claims description 6
- 230000007480 spreading Effects 0.000 claims description 3
- 230000007246 mechanism Effects 0.000 description 39
- 230000008569 process Effects 0.000 description 11
- 230000003028 elevating effect Effects 0.000 description 10
- 239000004020 conductor Substances 0.000 description 7
- 230000002093 peripheral effect Effects 0.000 description 7
- 230000033228 biological regulation Effects 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 230000005489 elastic deformation Effects 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 230000002452 interceptive effect Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000976 Electrical steel Inorganic materials 0.000 description 1
- 230000001174 ascending effect Effects 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 230000007306 turnover Effects 0.000 description 1
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Classifications
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- 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
- H02K15/067—Windings consisting of complete sections, e.g. coils, waves inserted in parallel 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
- H02K15/04—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
- H02K15/0478—Wave windings, undulated windings
-
- 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
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
-
- 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
- the present invention relates to, for example, a stator manufacturing method and a manufacturing apparatus for a rotating electrical machine, and more specifically, a stator manufacturing method in which a coil configured by combining a plurality of rectangular wires having a rectangular cross section is arranged on a stator core by distributed winding, and It relates to a manufacturing apparatus.
- rotating electrical machines such as induction motors and direct current motors (including generators) are widely used as power sources for industrial or vehicle use, and distributed winding with high specific output is often used for the layout of the stator coils. ing.
- a motor used in a hybrid drive vehicle and an electric vehicle it has been proposed to use a rectangular wire having a high slot space factor as a magnet wire because of output / size requirements and the like.
- a part of the coil is arranged in a slot formed in a radial direction at a plurality of locations in the circumferential direction of the stator core.
- concentrated winding is used as the coil layout, the coil is formed in accordance with the shape of the slot to be arranged in advance, and the formed coil is inserted into the stator core from the axial direction.
- a folding structure is known (see Patent Document 1).
- the invention described in Patent Document 1 described above is a method of arranging concentrated winding coils on a stator core, and is difficult to apply to distributed winding coils. That is, the coil of distributed winding is composed of a plurality of linear portions and a metal wire having a plurality of continuous portions that alternately and continuously connect one end portion and the other end portion of each adjacent linear portion, Are arranged in each slot to constitute a stator.
- the concentrated winding coil has only two straight portions arranged in the slots, and the configuration is greatly different from the distributed winding in which the straight portions are arranged in a plurality of slots. Therefore, it is not easy to apply the concentrated winding coil arrangement method having different configurations to the distributed winding coil.
- the metal wire constituting the coil is a rectangular wire having a rectangular cross section
- the rectangular wire has directionality when inserted into the slot, and therefore, it is difficult to arrange the stator wire on the stator core as compared with the circular wire having a circular cross section. That is, it is necessary to insert the rectangular wire into the slot while keeping the side surface of the rectangular wire and the inner surface of the slot in parallel. For this reason, when arranging a rectangular wire in a slot by distributed winding, it is necessary to consider the directionality of a rectangular wire, and arrangement work becomes difficult. On the other hand, in the case of a round line, since there is no directionality and it is possible to arrange it in the slot while being freely deformed, the arrangement work is not as difficult as a rectangular line.
- each linear portion in the stay core it is difficult to manually arrange from the radial direction after the coil is preliminarily distributed, since the amount of elastic deformation of each continuous portion increases.
- the coil when the coil is formed of a flat wire, it is difficult to be elastically deformed because of its high rigidity.
- a structure in which one end portion of each linear portion is bent radially inward is conceivable. With such a structure, the coil is manually disposed on the stator core as described above. This is more difficult because it is difficult to elastically deform due to the presence of the bent portion.
- the coil when an insulating sheet exists between each slot and the coil, the coil is disposed in a state where the insulating sheet is disposed in each slot.
- the insulating sheet may be disposed in each slot. There is a possibility that the insulation sheet will come off or partly turn over and the insulating sheet may be caught.
- an object of the present invention is to provide a stator manufacturing method and a manufacturing apparatus capable of easily arranging coils composed of rectangular wires on a stator core by distributed winding.
- the present invention comprises a stator core (2) having slots (5) formed in a plurality of locations in the circumferential direction in the axial direction, and a plurality of linear portions (12) arranged in each slot (2).
- a coil (4) in which a plurality of rectangular wires (W) having a rectangular cross section are arranged so that the straight portions (12) are arranged in a circumferential direction and a radial direction, the coil (4) being the stator core
- the restriction jig (22) having the same number of restriction pieces (22a) as the slot (6) is arranged between the adjacent linear portions (12) of the coil (4).
- the restriction jig (22) and the coil (4) are relatively moved in the axial direction in a direction from the one end side in the axial direction of the coil (4) toward the other end side,
- the coil (4) is inserted into the stator core (2) from one axial end side while regulating the circumferential position of the linear portion (12) in the axial direction by contact with the regulating piece (22a). By inserting, the straight line portion (12) is disposed in the slot (6).
- the restricting piece (22a) After the restricting piece (22a) is arranged over the entire circumference, the restricting piece (22a) is moved in the radial direction, and a contact portion (22b) provided at the tip of the restricting piece (22a). ) Is inserted between the adjacent straight portions (12), and positioning in the circumferential direction on one end side in the axial direction of the straight portions (12) is performed.
- the restriction jig (22) is moved in a direction approaching the stator core (2) together with the coil (4), and then the restriction jig (22), the stator core (2), and the coil (4) are moved. Move relative to the axis.
- a method for producing a stator (1) comprising an insulating sheet (31) disposed between the slot (5) and the straight portion (12), After arranging the stator core (2) side by side in the axial direction on one axial end surface side of the coil (4), On the one end surface in the axial direction of the coil (4), an opening jig (29) for expanding the insulating sheet (31) arranged in the slot (5) in advance so that the linear portion (12) can be arranged, A part of the opening jig (29) (opening portion 29b) is placed in a state of being arranged in the insulating sheet (31), From this state, the coil (4) is inserted into the stator core (2) together with the opening jig (29).
- the opening jig (29) expands the insulating sheet (31) previously disposed in the slot (2) from the opening on the opposite end surface where the coil (4) of the slot (2) is inserted. And is placed on one axial end surface of the coil (4).
- the present invention comprises a stator core (2) having slots (5) formed in a plurality of locations in the circumferential direction in the axial direction, and a plurality of linear portions (12) disposed in the slots (5).
- a holding jig fixing base 25 for holding the stator core (2)
- the coil (4) is detachable in the axial direction, and the holding jig (25) and an insertion jig (21) capable of relative movement in the axial direction;
- a restriction jig (22) having a number of restriction pieces (22a) of the same number as the slot (5), and capable of relative movement in the axial direction with the insertion jig (21); In a state where the coil (4) is disposed
- the restricting jig (22) has a large number of restricting pieces (22a) arranged on the entire circumference in a circumferential direction and movably in the radial direction. And a contact portion (22b) for positioning in the circumferential direction on one end side in the axial direction of the linear portion (12) while being inserted between the adjacent linear portions (12).
- the contact portion (22b) is formed in a conical shape.
- the regulating jig (22) moves in a direction approaching the stator core (2) together with the coil (4) in a state of being arranged between the adjacent linear portions (12), and then the coil (4 ) And relative movement in the axial direction.
- the regulation piece (22a) is a stepped surface (22c) that can contact the outer diameter surface of each linear portion (12) existing at the outermost diameter in a state of being arranged between the adjacent linear portions (12). ).
- the insertion jig (21) is arranged concentrically with the stator core (2), and the distal end surface of the teeth (6) existing in the portion between the slots (5) of the stator core (2) and the radial direction
- a plurality of projecting portions projecting pins 28 provided so as to project to one end side in the axial direction at a position adjacent to In a state where the coil (4) is disposed on the insertion jig (21), one axial end side of each linear portion (12) is bent radially inward between the protrusions (28).
- a bent part (14) is arranged.
- An apparatus for manufacturing a stator (1) comprising an insulating sheet (31) disposed between the slot (5) and the straight portion (12), An opening jig (29) for spreading the insulating sheet (31) arranged in the slot (5) so that the linear portion (12) can be arranged;
- the opening jig (29) is movable in the axial direction in the slot (5) so as to widen the insulating sheet (31) arranged in the slot (5) in advance, and the stator core (2) Are arranged side by side in the axial direction on one end surface side of the coil (4) and placed on one end surface in the axial direction of the coil (4).
- the portion 29b) is configured to be disposed in the insulating sheet (31).
- the opening jig (29) expands the insulating sheet (31) previously disposed in the slot (5) from the opening on the opposite end surface of the slot (5) where the coil (4) is inserted. And is placed on one axial end surface of the coil (4).
- the coil (4) has a bent portion (14) in which one axial end side of the linear portion (12) is bent radially inward,
- the opening jig (29) covers a curved surface that continues the bent portion (14) and the outer diameter surface of the linear portion (12) in a state of being placed on the bent portion (14).
- a guide portion for guiding the outer diameter surface of the straight portion (12) into the insulating sheet (31) is provided.
- each circumferential position of each linear portion can be regulated in the axial direction by each regulating piece of the regulating jig, and in this state, the coil is stator core from one axial end side. Can be inserted inside. For this reason, it is possible to easily arrange the coils in the stator core by distributed winding, and it is possible to accurately arrange the linear portions in the slots. In particular, even if the straight portion is inclined with respect to the slot, the inclination is corrected by the restriction jig, so that the insertion resistance of the straight portion into the slot can be reduced, and this insertion operation can be performed smoothly and accurately. Yes. Further, if the insertion resistance can be reduced in this way, it is possible to prevent the insulation sheet from being damaged if an insulation sheet is disposed in the coil or slot at the time of insertion.
- the radial direction is the same in the circumferential direction along with the insertion. It is possible to appropriately perform the positioning in the circumferential direction on one end side in the axial direction of the linear portions arranged side by side.
- each linear portion can be regulated by the regulating jig at a position closer to the stator core, the coil can be inserted into the stator core with higher accuracy.
- the coil can be inserted into the stator core more easily and accurately.
- the coil is inserted into the stator core in a state where a part of the opening jig is disposed in the insulating sheet. It is difficult to interfere with the insulation sheet. For this reason, it can prevent that an insulating sheet is pushed by a coil at the time of insertion, remove
- the contact portion of the restricting piece is conical, the contact area between each restricting piece and each linear portion can be reduced, and the relative movement between the restricting jig and the coil is smoother. It can be done.
- each regulating piece when the coil is placed on the insertion jig, the circumferential position on one end side of each linear portion can be regulated, so that the arrangement of each regulating piece is between adjacent linear portions. Can be done smoothly.
- the opening jig since the opening jig has the guide portion that guides the outer diameter surface of each linear portion, the tip of the coil is an insulating sheet when the coil is inserted into the stator core. And more difficult to interfere with.
- (A) is a plan view showing one restriction jig
- (B) is a state in which a plurality of restriction jigs are arranged around an insertion jig in which coils are arranged
- (C) is a restriction piece.
- FIG. (A) is a top view which shows the relationship between the some protrusion part provided in the insertion jig
- the figure which expands and shows a part of FIG. (A) is sectional drawing which shows the state which abbreviate
- FIG. 10 which shows a 2nd process similarly.
- FIG. 10 which shows a 7th process similarly.
- FIG. 10 which shows an 8th process similarly.
- FIG. 10 which shows the 9th process similarly.
- FIG. 10 which shows a 10th process similarly.
- FIG. 10 which shows the 11th process similarly.
- FIGS. 1 and 2 An example of a stator of a rotating electrical machine (motor, generator, etc.) to be manufactured by the stator manufacturing apparatus and manufacturing method of the present invention will be described with reference to FIGS. 1 and 2.
- the stator 1 constitutes an electric motor (including a generator) together with a rotor, and the electric motor is suitable for application to an electric motor (including a generator) serving as a drive source for electric vehicles and hybrid vehicles, particularly a brushless DC motor. is there. As shown in FIG.
- the stator 1 includes a stator core 2 in which a large number of thin silicon steel plates are laminated, and a coil 4 around which a magnet wire (conductor, winding) 3 that is a predetermined material is wound.
- the stator core 2 is formed in a ring shape, and is open to the inner diameter side and both ends in the axial direction. Slots 5 and teeth 6 formed in the axial direction are alternately formed at a plurality of locations in the circumferential direction. The slots 5 and the teeth 6 are formed along the radial direction.
- the three-phase U, V, W coils 4 (4U, 4V, 4W) are wound between the two slots 5 separated by a predetermined pitch by distributed winding.
- the magnet wire 3 is formed of a rectangular wire having a rectangular cross section, and an insulating film such as an insulating resin is formed on the entire circumference of the conductor portion made of copper or the like.
- the three-phase coils 4U, 4V, 4W made of the wires 3 are arranged in the same-phase slot 5 in which a plurality of (for example, four) wires 3 having the same phase are arranged side by side in the radial direction of the stator core 2.
- one end side coil end portion 8 protruding from one end surface 7 (upper end surface in FIG.
- the U-phase coil 4U is adjacent to the coil 4U in such a way that two sets 4U1 and 4U2 are set so as to occupy two adjacent slots 5 and 5, as shown in FIG.
- the two slots 5 and 5 are configured so that the closer and far sides of the two slots 5 and 5 are connected at a predetermined interval and the two sets are connected alternately.
- Each set of coils 4U1 and 4U2 projects from the slot conductor portion 11 disposed in the slot 5 and the slot conductor portion 11 protruding from one end surface 7 of the stator core 2 and spaced apart by a predetermined distance in the inner diameter direction R1.
- the one end side coil end portion 8 (the upper coil end portion in FIG.
- both the coil end portions 8 and 10 are bent (bent) in a circumferential direction (for example, Y) or an axial direction (for example, X) to be aligned without interfering with each other in the axial direction L or the radial direction R. ing.
- Each rectangular wire W constituting the coil 4 has a plurality of straight portions 12, a plurality of continuous portions 13a and 13b, and a plurality of bent portions 14.
- Each of the straight portions 12 corresponds to the above-described slot conductor portion 11 and is disposed in each slot 5 of the stator core 2 and is formed to be parallel to each slot 5.
- the continuous portions 13a and 13b are formed by alternately bending one end portion and the other end portion of each adjacent straight line portion 12 and are bent at right angles from the respective end portions of the respective straight line portions 12. ing.
- Each bent portion 14 is formed by bending one end side of each linear portion 12 radially inward.
- the continuous portions 13a and 13b and the bent portions 14 correspond to the coil end portions 8 and 10 described above.
- one end portions of the bent portions 14 are continuous with each other by the continuous portion 13a on the one end side, and the continuous portion 13a on the one end side exists inward in the radial direction with respect to each linear portion 12.
- the continuous portion 13 b on the other end side is located on the same circumference connecting the straight portions 12 or is located radially outward from the straight portions 12.
- this continuous part 13b on the other end side is located radially outward from each straight line part 12
- the other end part of each straight line part 12 is bent radially outward and bent part 14 (FIG. 10 to be described later). 20), and the other end portions of the bent portions 14 are made continuous by the continuous portion 13b on the other end side.
- the coil 4 is formed in a substantially cylindrical shape as a whole by combining a plurality of the rectangular wires W configured in this manner so that the straight portions 12 are arranged in the circumferential direction and the radial direction. Then, the stator 1 is configured by arranging the coil 4 on the stator core 2 in a distributed winding manner.
- the manufacturing apparatus 20 includes, for example, an insertion jig 21 made of a material having sufficient rigidity, such as stainless steel, a restriction jig 22 having a plurality of restriction pieces 22a having sufficient rigidity, and an insertion jig 21. Is provided with a lifting mechanism 23 that moves (lifts) the shaft in the axial direction, a moving mechanism 24 that moves the restricting jig 22 in the radial direction, and a fixed base 25 on which the stator core 2 is placed.
- the insertion jig 21 includes a substantially cylindrical body portion 21a and one end portion (upper and lower directions in FIGS.
- the coil 4 is detachably attached to the insertion jig 21 in the axial direction (see FIGS. 10 to 20 described later). Of these, the continuous portion 13a on one end side of the coil 4 and a part of the bent portion 14 are sequentially placed on the disc portion 21b. Thereby, the axial positioning of the coil 4 with respect to the insertion jig 21 can be achieved.
- the body portion 21 a of the insertion jig 21 includes a plurality of protrusions 26 provided to protrude in a radial direction at a plurality of locations on the outer peripheral surface.
- these protrusions 26 are omitted.
- Each of these protrusions 26 is provided at a position aligned with the slot 5 of the stator core 2 to be inserted. For this reason, each protrusion 26 has the same phase and the same number as each slot 5 in the circumferential direction.
- each protrusion 26 is formed so that a cross section orthogonal to the axial direction is rectangular over the axial direction of the body portion 21a.
- the direction of the side surface on the outer diameter side of each protrusion 26 is made to correspond to the formation direction of each slot 5. That is, since the formation direction of each slot 5 is the radial direction of the stator core 2, the side surface on the outer diameter side of each protrusion 26 is a surface orthogonal to the radial direction. Incidentally, the side surface (outer peripheral surface) on the outer diameter side is made slippery than the surface of each slot 5 of the stator core 2 by improving the surface roughness, etc. It is preferable to facilitate attachment / detachment.
- each protrusion 26 is set to be slightly larger than the diameter of the inscribed circle of each tooth 6 of the stator core 2. And, as will be described later, in the state in which the radially inner side surface of each straight line portion 12 constituting the rectangular wire W having the innermost diameter among the flat wires W arranged so as to overlap each protrusion 26 is arranged in each slot 5.
- the teeth 6 are positioned radially outward from the tip surface of each tooth 6. Thereby, for example, a magnetic wedge is arranged in the opening of each slot 5, or a creeping distance between each straight portion 12 and the tip surface of each tooth 6 is secured.
- each protrusion amount of each protrusion 26 is adjusted according to the radial direction position in each slot 5 of the flat wire W existing at the innermost diameter of the coil 4.
- the circumferential width of each protrusion 26 is slightly smaller than the circumferential width of each slot 5.
- each concave portion 27 a portion of the outer peripheral surface of the body portion 21 a of the insertion jig 21 that is detached from each protrusion 26 is a recess 27.
- the diameter of the inscribed circle on the bottom surface of each concave portion 27 is slightly smaller than the diameter of the inscribed circle of each tooth 6, and the circumferential width of each concave portion 27 is the width in the circumferential direction of each tooth 6. It is slightly larger than.
- Each tooth 6 can be arranged in each recess 27.
- each recessed part 27 can pass the front-end
- a plurality of projecting pins 28, which are projecting portions supported by the ring portion 21c, are arranged so as to project to one end side in the axial direction at a plurality of circumferential positions on one end surface in the axial direction of the body portion 21a. Yes.
- Each of the protruding pins 28 is disposed at a position adjacent to the distal end surface of each tooth 6 in the radial direction (inner diameter side) in a state where the insertion jig 21 (annular portion 21 c) is disposed concentrically with the stator core 2.
- the protruding amount of each protruding pin 28 in the axial direction is such that each rectangular wire W is formed in a state where all the rectangular wires W are arranged in the insertion jig 21 to form the coil 4 as shown in FIGS. It is set as the amount which protrudes rather than the state (axial height) where each bending part 14 of line W overlapped in the axial direction.
- the protruding amount of each protruding pin 28 is assumed to be an amount for arranging the opening jig 29 as will be described later.
- each projecting pin 28 corresponds to the shape of the portion surrounded by each tooth 6 and the coil 4 as shown in FIGS. That is, as shown in FIG. 5, in a state where the coil 4 is arranged on the stator core 2 by distributed winding, the tips of the teeth 6 are surrounded by the bent portions 14 of the rectangular wires W. Since each bent portion 14 is formed in a crank shape depending on the position where it is arranged, the shape of the portion where the tip of each tooth 6 is surrounded by each bent portion 14 is shown in detail in FIG. 6 even when the area is the smallest. It becomes a substantially triangular shape.
- each projecting pin 28 is a shape corresponding to the substantially triangular shape, each projecting pin can be placed on any portion in the circumferential direction surrounded by each tooth 6 and each bent portion 14. 28 can be arranged.
- the teeth 6 are provided at both ends in the circumferential direction of the side surfaces on the teeth 6 side of the protruding pins 28.
- a protrusion 28a is provided so as to cover the tip.
- each protruding pin 28 By disposing each protruding pin 28 as described above, when the coil 4 is attached to the insertion jig 21 as will be described later, each of the bent portions 14 in the circumferential direction is brought into contact with each protruding pin 28. In contact therewith, the circumferential position of each linear portion 12 is appropriately regulated. In particular, by setting the cross-sectional shape of each protruding pin 28 as described above, the position of each linear portion in the circumferential direction can be more accurately performed.
- the shape of each protruding pin 16 is not limited to the shape described above, and may be, for example, circular in cross section as long as it can be disposed in a portion surrounded by each tooth 6 and each bent portion 14. However, if it is a shape like this embodiment, the phase of the circumference direction of each linear part 12 can be controlled more correctly.
- the lifting mechanism 23 includes a lifting plate 23a on which the insertion jig 21 is placed, a lifting shaft 23b fixed to the lower surface of the lifting plate 23a, a drive mechanism 23c for moving the lifting shaft 23b back and forth in the axial direction, and the like. .
- Such an elevating mechanism 23 is fixed to the frame 20a of the manufacturing apparatus 20, and the elevating shaft 23b is advanced and retracted in the axial direction by a drive mechanism 23c driven by electric power or hydraulic pressure.
- shaft 23b raises / lowers with respect to the flame
- the regulating jig 22 constituting the manufacturing apparatus 20 is formed by arranging a large number of regulating pieces 22a around the insertion jig 21 in the same radial direction as each tooth 6.
- Each of the restricting pieces 22a has a width corresponding to the interval between the slots 5 adjacent to each other in the circumferential direction, and is disposed between the linear portions 12 adjacent to each other in the circumferential direction of the coil 4 so as to freely advance and retract.
- Each regulation piece 22 a has a contact portion 22 b that is disposed between the straight portions 12 at the distal end thereof and that contacts the side surface of the straight portion 12. As shown in FIG. 4, the contact portion 22b has a conical shape whose diameter decreases toward the tip.
- each regulating piece 22a moves relative to each other while abutting the side surface of each linear portion 12, and therefore it is preferable to reduce the contact area in order to reduce the sliding resistance.
- each regulating piece 22a is conical as in the present embodiment, it is possible to cope with a change in the radial direction of the interval between the adjacent linear portions 12, and each linear portion 12 The contact area can be reduced.
- the shape of the abutting portion 22b may be, for example, a triangular shape that matches the change in the radial direction of the interval between the adjacent linear portions 12 if the sliding resistance may be somewhat higher.
- each regulating piece 22a has a step surface 22c at an intermediate portion (a base end portion of the contact portion 22b). That is, a step is provided in the middle portion of the restricting piece 22a, and a surface orthogonal to the axial direction ⁇ left-right direction in FIG. 4A) of the restricting piece 22a of the step is defined as a step surface 22c.
- the diameter of the stepped surface 22c is larger than the interval between the linear portions 12 that exist at the outermost diameter of the coil 4 and are adjacent to each other in the circumferential direction. Therefore, as shown in FIG. 4 (C), the stepped surface 22c of each linear portion 12 having the outermost diameter in the state where the tip portion of each regulating piece 22a is inserted between the adjacent linear portions 12 is provided. Abuts on outer diameter circle.
- step difference surface 22c can also be formed by providing a flange in the base end part of the contact part 22b of the control jig
- each restricting piece 22 a configured as described above is movable in the radial direction by the moving mechanism 24.
- the moving mechanism 24 is fixed to the frame 20a of the manufacturing apparatus 20 and is arranged around the body portion 21a of the insertion jig 21.
- the moving mechanism 24 is movable along the radial direction on the rail 24a.
- Such a moving mechanism 24 moves each slider 24b forward and backward in the radial direction by a drive mechanism driven by electric power or hydraulic pressure.
- each regulating piece 22a fixed to each slider 24b moves in the radial direction relative to the insertion jig 21 while being guided by the guide plate 24c.
- the regulating jig 22 and the moving mechanism 24 are raised together with the insertion jig 21 by the lifting mechanism 23 to a predetermined position, but are stopped after the predetermined position regardless of the raising of the insertion jig 21. That is, the regulating jig 22 and the moving mechanism 24 are disposed on the support plate 24d, and this support plate 24d is supported by the elevating plate 23a via the spring 24e. Therefore, the regulating jig 22 and the moving mechanism 24 are also raised and lowered via the support plate 24d by raising and lowering the lifting plate 23a. However, it rises in the ascending direction until it comes into contact with the fixed base 25 of the stator core 2, and thereafter, it does not rise regardless of the elevation of the elevating plate 23a.
- the elevating plate 23a is raised by the elevating mechanism 23, and the regulating jig 22 and the moving mechanism 24 are raised together with the support plate 24d. Then, in a state where a part of the moving mechanism 24 (for example, the guide plate 24c) is in contact with the fixed base 25, the support plate 24d, the regulating jig 22, and the moving mechanism 24 are stopped from rising. Then, the spring 24e is elastically deformed to allow the elevating plate 23a to rise further. On the other hand, when descending, the spring 24e descends later than the lifting plate 23a due to the relationship between the elastic restoring force and the weight of the support plate 24d, the restricting jig 22, and the moving mechanism 24.
- a part of the moving mechanism 24 for example, the guide plate 24c
- the mechanism that raises the regulating jig 22 and the moving mechanism 24 to a predetermined position in this way is lifted in conjunction with the lifting mechanism 23 to a predetermined position other than the mechanism using the spring as described above, and at a predetermined position. Any structure may be used as long as it is stopped regardless of the lifting / lowering operation of the lifting / lowering mechanism 23.
- a mechanism for lifting only the restriction jig 22 and the moving mechanism 24 may be provided.
- a fixing base 25 that is a holding jig for holding the stator core 2 in a state of being placed is disposed.
- the fixed base 25 is fixed so as to be placed on the frame 20a of the manufacturing apparatus 20 (separated in FIG. 3).
- a step 25a is provided in the central portion of the fixed base 25 so that the stator core 25 can be arranged in the step 25a without rattling.
- the stator core 2 is positioned, and the stator core 2 is arranged concentrically with the insertion jig 21.
- an insertion jig 21 having a circular hole 25b having an outer diameter larger than the circumscribed circle of each slot 5 of the stator core 2 and smaller than the outer diameter of the stator core 2 and having the coil 4 mounted in the circular hole 25b is provided. It is possible to pass.
- the holding jig may be one that grips the stator core 2 such as a chuck, for example, instead of the fixed base 25 as described above.
- a plurality of opening jigs 29 are provided to widen the insulating sheet 31 arranged in each slot 5 so that each linear portion 12 can be arranged.
- the insulating sheet 31 has a shape corresponding to the shape of each slot 5 by bending both ends in the width direction of the long plate-like sheet in the same direction.
- Each of these opening jigs 29 has a width corresponding to the circumferential width of such an insulating sheet 31 disposed in each slot 5. For this reason, for example, it has a width that is the same as or slightly larger than the width in the circumferential direction of each linear portion 12 of the coil 4.
- each opening jig 29 includes a plate-like placement portion 29a placed on each bending portion 14 positioned on one end surface (uppermost surface) in the axial direction of the coil 4, and one end portion of the placement portion 29a. It is composed of an opening 29b and a guide 29c protruding from the ⁇ right end of FIG. 7B] in the thickness direction (vertical direction of FIG. 7) of the placement portion 29a.
- each opening jig 29 is placed on the upper surface of the coil 4 in a state of being arranged around the placing jig 30. That is, the other end ⁇ the left end in FIG. 7B ⁇ of each opening jig 29 is fixed to the outer peripheral surface of the mounting jig 30, and each opening jig 29 can be moved together with the mounting jig 30. It is said.
- a mounting jig 30 has an outer diameter sufficiently smaller than the inscribed circle of each tooth 6 of the stator core 2, and can pass through the stator core 2.
- a fitting hole 30 a that can be fitted into a positioning protrusion 21 d provided on the upper end surface of the insertion jig 21 is provided at the center.
- the positioning projection 21d and the fitting hole 30a are fitted with each other so that the mounting jig 30 is positioned.
- Each opening jig 29 fixed around the mounting jig 30 is mounted on the upper surface of the coil 4.
- the tip of the opening 29b is disposed in the insulating sheet 31 disposed in each slot 5, and the end of the insulating sheet 31 is kept open.
- tip part of the opening part 29b has chamfered the corner
- the guide portion 29c causes each bent portion 14 positioned on the uppermost surface and the outermost portion that is continuous with each bent portion 14 to exist. The curved surface with the outer diameter surface of each linear portion 12 located in the diameter is covered.
- each opening jig 29 is inserted into the stator core 2 together with the coil 4 in a state where each opening jig 29 is placed on the upper surface of the coil 4.
- the opening 29b of each opening jig 29 does not close in the insulating sheet 31 disposed in the slot 5 so that the bent portions in the width direction of the insulating sheet 31 approach each other, that is, widen. Moving.
- the outer diameter surface of each linear portion 12 positioned at the outermost diameter is easily guided into the insulating sheet 31.
- the insulating sheet may interfere with the curved surface when the coil 4 is inserted, and the insulating sheet 31 may be detached from the slot 5.
- the curved surface Since this is covered with the guide portion 29c, this can be prevented from occurring.
- the continuous portion of the guide portion 29c and the placement portion 29a is curved along the curved surface described above, so that the rigidity of each opening jig 29 is easily secured. Further, it is preferable that the outer diameter surfaces of the opening 29b and the guide portion 29c are flush with the outer diameter surfaces of the respective linear portions 12 positioned at the outermost diameter, but the interference between the curved surface and the insulating sheet 31 is prevented.
- the outer diameter surfaces of the opening portion 29b and the guide portion 29c may be slightly shifted to the inner diameter side from the outer diameter surface of each linear portion 12, or the outer diameter surface of each linear portion 12 and the insulating sheet 31 As long as the clearance is within the range, the outer diameter surfaces of the opening 29b and the guide portion 29c may be slightly shifted from the outer diameter surface of each linear portion 12 to the outer diameter side.
- the structure in which the insulating sheet 31 is expanded by the respective opening jigs 29 as described above is particularly effective when the insulating sheet 31 has a shape as described below. That is, as shown in FIGS. 8 and 9, in the case of incorporating the coil 4 in which both axial ends of each linear portion 12 are inclined radially outward into the stator core 2, the end shape of each slot 5 of the stator core 2 is formed. It is necessary to incline according to the shape of the end of each linear portion 12. In this case, the insulating sheet 31 disposed in each slot 5 also needs to match the shape of each slot 5.
- the insulating sheet 31 applied to a structure in which the end portion of each slot 5 is not inclined can be formed by simply bending both end portions in the width direction of the long plate-like sheet in the same direction. Can be adapted to On the other hand, when the end portion of the insulating sheet 31 is inclined, it is matched with the shape of each slot 5 by making a cut at the end portion of the sheet. For this reason, the insulating sheet 31 is difficult to secure the rigidity of the end portion compared to the insulating sheet 31 applied to the structure in which the end portion of each slot 5 is not inclined, and the sheet of the sheet is disposed in each slot 5. The possibility of closing so that both ends approach each other increases.
- the rectangular wire W is sequentially attached to the insertion jig 21 so as to be distributed winding, and the coil 4 is attached to the insertion jig 21. That is, the flat wire W is sequentially assembled so that each bent portion 14 of the flat wire W is disposed between the predetermined protruding pins 28. And each linear part 12 is each arrange
- the straight line portion 12 of the flat wire W located at the innermost diameter is along the outer diameter surface of the protrusion 26 of the insertion jig 21 and the flat wire W is sequentially assembled so that the straight portion 12 overlaps in the radial direction.
- the coil 4 in which the linear portions 12 are arranged in the circumferential direction and the radial direction is mounted around the insertion jig 21.
- the regulating jig 22 is disposed on one axial end side between the adjacent linear portions 12 of the coil 4 and on the other axial end side with respect to each bent portion 14.
- the restricting pieces 22a are moved in the radial direction by the moving mechanism 24, and the contact portions 22b of the restricting pieces 22a are arranged between the straight portions 12.
- the stepped surface 22c is brought into contact with the outer diameter surface of each linear portion 12 having the outermost diameter.
- the width between the adjacent linear portions 12 on one end side in the axial direction becomes a width corresponding to the interval between the slots 5.
- the circumferential position of the linear portion 12 on one end side in the axial direction is positioned at an appropriate position.
- the radial position of the outer diameter surface of each linear portion 12 having the outermost diameter on the one end side in the axial direction is an appropriate position in relation to the radial position of the bottom surface of the slot 5.
- the stator core 2 placed on the fixing base 25 without rattling on the step 25 a is aligned with the fixing base 25 in the axial direction above the insertion jig 21 (on the one end surface side in the axial direction). Deploy. At this time, the fixing base 25 is fixed to a predetermined position of the frame 20a. In this state, the stator core 2, the insertion jig 21, and the coil 4 are arranged concentrically. Further, the circumferential positions of the slots 5 and the straight portions 12 of the stator core 2 are aligned. An insulating sheet 31 is disposed in advance in each slot 5 of the stator core 2.
- the mounting jig 30 to which the respective opening jigs 29 are fixed is inserted from one axial end side of the stator core 2, that is, from the opposite side of the insertion jig 21. Place on top.
- each opening jig 29 is inserted so as to spread the insulating sheet 31 previously disposed in each slot 5 from the opening on the opposite end surface (one axial end surface) where the coil 4 of each slot 5 is inserted. Is done.
- each opening jig 29 is mounted on the upper surface of each uppermost bent portion 14, and the tip of the opening portion 29b.
- the part is disposed in the insulating sheet, that is, remains. Moreover, the curved surface which continues the upper surface of each bending part 14 of the uppermost surface and the outer diameter surface of each linear part 12 of the outermost diameter is covered with the guide part 29c.
- the regulating jig 22 is moved together with the coil 4 and the insertion jig 21 toward the stator core 2, that is, toward one end in the axial direction.
- This movement is performed in conjunction with the operation of raising the insertion jig 21 by the lifting mechanism 23. That is, the elevating plate 23a is raised by the elevating mechanism 23, and the regulating jig 22 and the moving mechanism 24 are raised through the spring 24e and the support plate 24d.
- each opening jig 29 moves together with the insertion jig 21, and moves in the insulating sheet 31 arranged in each slot 5.
- each bent portion 14 and the continuous portion 13 a on one end side in the axial direction enter the stator core 2, and each linear portion 12 existing on one end side in the axial direction from the restricting jig 22 includes each slot 5. It enters into the insulating sheet 31 arranged inside. Thereby, the regulating jig 22 is brought close to the other axial end surface of the stator core 2.
- the insertion jig 21 is further raised (moved toward one end in the axial direction) while the axial position of the restriction jig 22 is fixed. That is, the restricting jig 22 stops when the guide plate 24c comes into contact with the fixed base 25, but the insertion jig 21 is further raised by elastic deformation of the spring 24e. As a result, the regulation jig 22 moves relative to the coil 4 and the insertion jig 21 in the direction from the one axial end side to the other end side of the coil 4 and the insertion jig 21.
- each regulating piece 22a of the regulating jig 22 and the side surface of each linear portion 12 are in sliding contact, and the circumferential position of each linear portion 12 is regulated over the axial direction,
- Each straight line portion 12 is inserted into each slot 5.
- the tip of each regulating piece 22 a passes through each recess 27 of the insertion jig 21.
- the recess 27 is omitted. This insertion operation is temporarily stopped before each bent portion 14 on the other axial end side of the coil 4 interferes with the regulating member 22.
- each regulating piece 22a of the regulating jig 22 is retracted radially outward by the moving mechanism 24, and the regulating piece 22a is applied.
- the contact portion 22b is separated from between the adjacent linear portions 12. That is, each regulating piece 22a is moved by the moving mechanism 24 as shown in FIG.
- the insertion jig 21 is raised again by the elevating mechanism 23, and the coil 4 is disposed at a predetermined position of the stator core 2.
- the insertion jig 21 is raised until each linear portion 12 enters a predetermined axial position in each slot 5.
- each opening jig 29 is completely removed from each slot 5.
- each opening jig 29 and the mounting jig 30 are removed, and as shown in FIG. 19, the lifting mechanism 23 is driven to lower the insertion jig 21.
- the insertion jig 21 comes out of the stator core 2, and only the coil 4 remains in the stator core 2 to form the stator 1.
- the stator 1 is removed from the fixed base 25.
- each linear portion 12 can be regulated in the axial direction by the regulating jig 22, and the coil 4 can be inserted into the stator core 2 from one axial end side in this state. That is, since each restricting piece 22a is moved in the radial direction and the contact portion 22b is inserted between the adjacent straight portions 12, they are arranged side by side in the radial direction with the same phase in the circumferential direction. Positioning in the circumferential direction on one axial end side of each linear portion 12 is appropriately performed.
- each linear portion 12 is positioned in the circumferential direction.
- each linear portion 12 is sequentially inserted into each slot 5 from one end side in the axial direction while being positioned in the circumferential direction from one end side in the axial direction as described above. For this reason, it is possible to easily arrange the coils 4 in the stator core 2 by distributed winding, and to arrange the linear portions 12 in the slots 5 with high accuracy.
- the inclination is corrected by the restriction jig 22, so that the insertion resistance of the straight line portion 12 into the slot 5 can be reduced, and this insertion work can be performed smoothly. And it can be performed with high accuracy. Further, if the insertion resistance can be reduced in this way, it is possible to prevent the coil 4 and the insulating sheet 31 disposed in the slot 5 from being damaged at the time of insertion.
- the restriction jig 22 is brought close to the stator core 2, so that each straight portion 12 can be restricted by the restriction jig 22 at a position closer to the stator core 2. 4 can be inserted into the stator core 2 with higher accuracy. Further, since the stepped surface 22a of each regulating piece 22a is moved relative to the outermost surface of each linear portion 12 having the outermost diameter, the radial position of each linear portion 12 is also regulated by the regulating jig 22. In addition, the operation of inserting the coil 4 into the stator core 2 can be performed more easily and accurately.
- the coil 4 is inserted into the stator core 2 in a state where the tip end of the opening 29 b of the opening jig 29 is disposed in the insulating sheet 31.
- the part can be kept open, and the tip of the coil 4 can hardly interfere with the insulating sheet 31 during this insertion operation. For this reason, it can prevent that the insulating sheet 31 is pushed by the coil 4 at the time of insertion, and remove
- the opening jig 29 is inserted from the opening on the opposite side end face where the coil 4 of each slot 5 is inserted, and the opening jig 29 is placed on the coil 4, By inserting, the insulating sheet 31 in each slot 5 can be reliably expanded. For this reason, the tip of the coil 4 can be less likely to interfere with the insulating sheet 31.
- the manufacturing apparatus 20 of the present embodiment performs any one or all of the arrangement of the coil 4 on the insertion jig 21, the installation of the stator core 2, the installation and removal of the opening jig 29, and the removal of the stator 1. This can be done automatically or manually. If all or at least a part is automatically performed by a machine, the stator 1 can be manufactured more efficiently and productivity can be improved.
- the insertion jig 21 and the coil 4 are moved in the axial direction (upward in FIG. 3). However, the insertion jig 21 and the coil 4 are fixed, and the stator core 2 and the regulation jig 22 are pivoted. You may make it move to a direction (for example, the downward direction of FIG. 3). In this case, for example, the fixed base 25 and the moving mechanism 24 can be moved in the axial direction.
- the method and apparatus for manufacturing a stator according to the present invention can be used for manufacturing a stator of a motor, and in particular, has a structure in which flat wires are arranged in a distributed winding like a motor stator for a hybrid vehicle. Is preferred.
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Abstract
Description
前記各平角線(W)を組み合わせて前記コイル(4)を形成し、
前記スロット(6)と同じ数の多数の規制片(22a)を有する規制治具(22)を、前記規制片(22a)が前記コイル(4)の隣り合う直線部(12)同士の間を前記スロット(6)同士の間隔に見合った幅になるようにして、前記コイル(4)の軸方向一端側に配置し、
前記規制治具(22)が前記コイル(4)の軸方向一端側から他端側に向かう方向に、該規制治具(22)と該コイル(4)とを軸方向に相対移動させて、前記規制片(22a)との当接により前記直線部(12)の周方向位置を軸方向に亙って規制しつつ、前記コイル(4)を軸方向一端側から前記ステータコア(2)内に挿入することにより、前記直線部(12)を前記スロット(6)内に配置することを特徴とするものである。
前記ステータコア(2)を前記コイル(4)の軸方向一端面側に軸方向に並べて配置した後、
予め前記スロット(5)内に配置された前記絶縁シート(31)を前記直線部(12)を配置可能に広げる開き治具(29)を、前記コイル(4)の軸方向一端面上に、該開き治具(29)の一部(開き部29b)を前記絶縁シート(31)内に配置した状態で載置し、
この状態から、前記コイル(4)を前記開き治具(29)と共に前記ステータコア(2)内に挿入する。
前記ステータコア(2)を保持する保持治具(固定台25)と、
前記コイル(4)を軸方向に着脱自在とし、且つ、前記保持治具(25)と軸方向の相対移動可能な挿入治具(21)と、
前記スロット(5)と同じ数の多数の規制片(22a)を有し、前記挿入治具(21)と軸方向の相対移動可能な規制治具(22)と、
前記コイル(4)を前記挿入治具(21)に配置した状態で、前記規制治具(22)を、前記規制片(22a)が隣り合う直線部(12)同士の間を隣り合うスロット(5)同士の間隔に見合った幅にするようにして、前記コイル(4)の軸方向一端側に配置し、
前記規制治具(22)が該コイル(4)の軸方向一端側から他端側に向かう方向に、該規制治具(22)と前記挿入治具(21)とを軸方向に相対移動させて、前記規制片(22a)との当接により前記直線部(12)の周方向位置を軸方向に亙って規制しつつ、前記挿入治具(21)と共に前記コイル(4)を軸方向一端側から前記ステータコア(2)内に挿入することにより、前記直線部(12)を前記スロット(5)内に配置する。
前記コイル(4)を前記挿入治具(21)に配置した状態で、前記各突出部(28)の間に、前記各直線部(12)の軸方向一端側を径方向内方に折り曲げた折り曲げ部(14)が配置される。
前記スロット(5)内に配置された前記絶縁シート(31)を前記直線部(12)を配置可能に広げる開き治具(29)を備え、
該開き治具(29)は、予め前記スロット(5)内に配置された前記絶縁シート(31)を広げるように、前記スロット(5)内を軸方向に移動可能で、前記ステータコア(2)を前記コイル(4)の軸方向一端面側に軸方向に並べて配置し、該コイル(4)の軸方向一端面上に載置した状態で、前記開き治具(29)の一部(開き部29b)が前記絶縁シート(31)内に配置されるように構成されている。
前記開き治具(29)は、前記折り曲げ部(14)上に載置された状態で、該折り曲げ部(14)と前記直線部(12)の外径面とを連続させる湾曲面を覆い、該直線部(12)の外径面を前記絶縁シート(31)内に案内する案内部を有する。
2 ステータコア
3 巻線(マグネットワイヤ)
4 コイル
5 スロット
6 ティース
11 スロット導体部
12 直線部
13a,13b 連続部
14 折り曲げ部
20 製造装置
21 挿入治具
22 規制治具
22a 規制片
22b 当接部
22c 段差面
25 固定台(保持治具)
28 突出ピン(突出部)
29 開き治具
29b 開き部
29c 案内部
W 平角線
Claims (15)
- 円周方向複数個所に軸方向に亙って形成されたスロットを有するステータコアと、前記各スロット内に配置される複数の直線部を有する複数個の断面矩形の平角線を、前記各直線部が周方向及び径方向に並ぶように配列したコイルと、を備え、該コイルを前記ステータコアに分布巻きで配置してなるステータの製造方法において、
前記各平角線を組み合わせて前記コイルを形成し、
前記スロットと同じ数の多数の規制片を有する規制治具を、前記規制片が前記コイルの隣り合う直線部同士の間を前記スロット同士の間隔に見合った幅になるようにして、前記コイルの軸方向一端側に配置し、
前記規制治具が前記コイルの軸方向一端側から他端側に向かう方向に、該規制治具と該コイルとを軸方向に相対移動させて、前記規制片との当接により前記直線部の周方向位置を軸方向に亙って規制しつつ、前記コイルを軸方向一端側から前記ステータコア内に挿入することにより、前記直線部を前記スロット内に配置することを特徴とするステータの製造方法。 - 前記規制片を周方向全周に亙って配置した後、該規制片を径方向に移動させて、該規制片の先端部に設けた当接部を前記隣り合う直線部同士の間に挿入し、前記直線部の軸方向一端側の周方向の位置決めを行なうことを特徴とする、請求項1に記載のステータの製造方法。
- 前記規制治具を、前記コイルと共に前記ステータコアに近づく方向に移動させてから、前記規制治具及び前記ステータコアと前記コイルとを軸方向に相対移動させることを特徴とする、請求項1又は2に記載のステータの製造方法。
- 前記規制片に設けた段差面を、最外径に存在する各直線部の外径面に当接させつつ、前記規制治具と前記コイルとを軸方向に相対移動させて、前記各直線部の径方向位置を軸方向に亙って規制しつつ、前記コイルを軸方向一端側から前記ステータコア内に挿入することを特徴とする、請求項1ないし3のうちの何れか1項に記載のステータの製造方法。
- 前記スロットと前記直線部との間に絶縁シートを配置してなるステータの製造方法であって、
前記ステータコアを前記コイルの軸方向一端面側に軸方向に並べて配置した後、
予め前記スロット内に配置された前記絶縁シートを前記直線部を配置可能に広げる開き治具を、前記コイルの軸方向一端面上に、該開き治具の一部を前記絶縁シート内に配置した状態で載置し、
この状態から、前記コイルを前記開き治具と共に前記ステータコア内に挿入することを特徴とする、請求項1ないし4のうちの何れか1項に記載のステータの製造方法。 - 前記開き治具は、前記スロットの前記コイルが挿入される反対側端面の開口から、予め該スロット内に配置された前記絶縁シートを広げるように挿入され、前記コイルの軸方向一端面上に載置されることを特徴とする、請求項5に記載のステータの製造方法。
- 円周方向複数個所に軸方向に亙って形成されたスロットを有するステータコアと、前記各スロット内に配置される複数の直線部を有する複数個の断面矩形の平角線を、前記各直線部が周方向及び径方向に並ぶように配列したコイルと、を備え、該コイルを前記ステータコアに分布巻きで配置してなるステータの製造装置において、
前記ステータコアを保持する保持治具と、
前記コイルを軸方向に着脱自在とし、且つ、前記保持治具と軸方向の相対移動可能な挿入治具と、
前記スロットと同じ数の多数の規制片を有し、前記挿入治具と軸方向の相対移動可能な規制治具と、
前記コイルを前記挿入治具に配置した状態で、前記規制治具を、前記規制片が隣り合う直線部同士の間を隣り合うスロット同士の間隔に見合った幅にするようにして、前記コイルの軸方向一端側に配置し、
前記規制治具が該コイルの軸方向一端側から他端側に向かう方向に、該規制治具と前記挿入治具とを軸方向に相対移動させて、前記規制片との当接により前記直線部の周方向位置を軸方向に亙って規制しつつ、前記挿入治具と共に前記コイルを軸方向一端側から前記ステータコア内に挿入することにより、前記直線部を前記スロット内に配置することを特徴とするステータの製造装置。 - 前記規制治具は、周方向全周に亙って、且つ、径方向に移動自在に多数の前記規制片が配置されてなり、該規制片は、その先端部に、前記隣り合う直線部同士の間に挿入された状態で、該直線部の軸方向一端側の周方向の位置決めを行なう当接部を有することを特徴とする、請求項7に記載のステータの製造装置。
- 前記当接部が円錐状に形成されていることを特徴とする、請求項8に記載のステータの製造装置。
- 前記規制治具は、前記隣り合う直線部同士の間に配置した状態で、前記コイルと共に前記ステータコアに近づく方向に移動してから、前記コイルと軸方向に相対移動可能に構成されることを特徴とする、請求項7ないし9のうちの何れか1項に記載のステータの製造装置。
- 前記規制片は、前記隣り合う直線部同士の間に配置した状態で、最外径に存在する各直線部の外径面に当接可能な段差面を有することを特徴とする、請求項7ないし10のうちの何れか1項に記載のステータの製造装置。
- 前記挿入治具は、前記ステータコアと同心に配置した状態で、該ステータコアの前記各スロットの間部分に存在するティースの先端面と径方向に隣接した位置に、軸方向一端側に突出するように設けられた複数の突出部を有し、
前記コイルを前記挿入治具に配置した状態で、前記各突出部の間に、前記各直線部の軸方向一端側を径方向内方に折り曲げた折り曲げ部が配置されることを特徴とする、請求項7ないし11のうちの何れか1項に記載のステータの製造装置。 - 前記スロットと前記直線部との間に絶縁シートを配置してなるステータの製造装置であって、
前記スロット内に配置された前記絶縁シートを前記直線部を配置可能に広げる開き治具を備え、
該開き治具は、予め前記スロット内に配置された前記絶縁シートを広げるように、前記スロット内を軸方向に移動可能で、前記ステータコアを前記コイルの軸方向一端面側に軸方向に並べて配置し、該コイルの軸方向一端面上に載置した状態で、前記開き治具の一部が前記絶縁シート内に配置されるように構成されていることを特徴とする、請求項7ないし12のうちの何れか1項に記載のステータの製造装置。 - 前記開き治具は、前記スロットの前記コイルが挿入される反対側端面の開口から、予め該スロット内に配置された前記絶縁シートを広げるように挿入され、前記コイルの軸方向一端面上に載置されることを特徴とする、請求項13に記載のステータの製造装置。
- 前記コイルは、前記直線部の軸方向一端側を径方向内方に折り曲げた折り曲げ部を有し、
前記開き治具は、前記折り曲げ部上に載置された状態で、該折り曲げ部と前記直線部の外径面とを連続させる湾曲面を覆い、該直線部の外径面を前記絶縁シート内に案内する案内部を有することを特徴とする、請求項13又は14に記載のステータの製造装置。
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JP4600580B2 (ja) * | 2008-04-21 | 2010-12-15 | 株式会社デンソー | 固定子コイルの製造方法 |
JP5617797B2 (ja) * | 2011-08-10 | 2014-11-05 | 株式会社デンソー | 回転電機の固定子の製造方法及びその製造装置 |
CN104471844B (zh) * | 2012-07-12 | 2017-02-22 | 本田技研工业株式会社 | 导电体的对齐装置及其对齐方法 |
JP5841017B2 (ja) | 2012-07-12 | 2016-01-06 | 本田技研工業株式会社 | 電気導体の挿入装置 |
JP2014180138A (ja) * | 2013-03-14 | 2014-09-25 | Toshiba Corp | 回転電機の組立機、および回転電機の製造方法 |
JP5749772B2 (ja) | 2013-09-18 | 2015-07-15 | 本田技研工業株式会社 | 挿入方法および挿入装置 |
DE102015217936A1 (de) * | 2015-09-18 | 2017-03-23 | Continental Automotive Gmbh | Verfahren und einteilige Werkzeuganordnung zum Herstellen eines Stators für eine elektrische Maschine |
DE102015217922A1 (de) * | 2015-09-18 | 2017-03-23 | Continental Automotive Gmbh | Verfahren und zweiteilige Werkzeuganordnung zum Herstellen eines Stators für eine elektrische Maschine |
JP6305471B2 (ja) * | 2016-07-25 | 2018-04-04 | 本田技研工業株式会社 | ステータの製造方法及びその装置 |
US10840785B2 (en) * | 2016-11-08 | 2020-11-17 | Digital Aerolus, Inc. | Method for fabricating brushless motor windings |
CN110892618B (zh) * | 2017-08-09 | 2022-05-13 | 株式会社爱信 | 定子的组装方法以及定子的组装装置 |
DE102017220424B4 (de) * | 2017-11-16 | 2021-01-14 | Vitesco Technologies GmbH | Werkzeug und Verfahren zur Anordnung eines Stators in ein Gehäuse |
CN108964384B (zh) * | 2018-08-17 | 2020-08-25 | 杭州江南电机股份有限公司 | 一种电机的内绕工艺 |
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