阅读说明：本技术 定子的制造方法 (Method for manufacturing stator ) 是由 丹下宏司 于 2020-01-27 设计创作，主要内容包括：提供一种可提高定子的占空系数的定子的制造方法。定子的制造方法是包括具有沿轴向贯穿的多个切槽的定子芯部的定子的制造方法,包括：将线圈线多次卷绕于卷绕模具(100)以形成环状的线圈束的工序；以及从切槽的轴向下侧向上侧将线圈束插入切槽的工序。卷绕模具(100)包括：主体(110),所述主体在轴向下侧具有供线圈线卷绕的下侧卷绕面；以及分隔件(120),所述分隔件配置于主体(110)的轴向上侧,在轴向上侧具有供线圈线卷绕的上侧卷绕面(121)。在将线圈线卷绕于卷绕模具(100)时,上侧卷绕面(121)位于比下侧卷绕面更靠径向内侧的位置,并且随着朝向轴向下侧而位于径向内侧地倾斜。(Provided is a method for manufacturing a stator, which can improve the space factor of the stator. The method for manufacturing a stator includes a stator core having a plurality of slots penetrating in an axial direction, and includes: a step of winding a coil wire around a winding die (100) a plurality of times to form an annular coil bundle; and a step of inserting the coil bundle into the slot from the lower side to the upper side in the axial direction of the slot. The winding die (100) comprises: a main body (110) having a lower winding surface on which a coil wire is wound, on an axial lower side; and a separator (120) which is disposed on the upper side in the axial direction of the main body (110) and has an upper winding surface (121) on the upper side in the axial direction on which the coil wire is wound. When the coil wire is wound around a winding die (100), an upper winding surface (121) is positioned radially inward of a lower winding surface, and is inclined radially inward as it goes axially downward.)

1. A method of manufacturing a stator including a stator core having a plurality of slots penetrating in an axial direction, comprising:

winding a coil wire around a winding die a plurality of times to form an annular coil bundle; and

a step of inserting the coil bundle into the slit from the lower side to the upper side in the axial direction of the slit,

the winding die includes:

a main body having a lower winding surface on which the coil wire is wound, on a lower side in an axial direction; and

a separator disposed on an axially upper side of the main body and having an upper winding surface on the axially upper side on which the coil wire is wound,

when the coil wire is wound around the winding die, the upper winding surface is located radially inward of the lower winding surface, and is inclined radially inward toward the lower side in the axial direction.

2. The method of manufacturing a stator according to claim 1,

the winding die includes a plurality of the separators, and axial positions of the upper winding surfaces are different.

3. The method of manufacturing a stator according to claim 2,

at least a portion of each of the separators overlap when viewed axially.

4. The method of manufacturing a stator according to claim 1 or 2,

the two circumferentially opposite surfaces of the main body have side winding surfaces on which the coil wire is wound in the axial direction, and the side winding surfaces and the upper winding surface have a gap in the radial direction.

5. The method of manufacturing a stator according to any one of claims 1 to 4,

in the forming step, a passing portion is formed in the coil bundle, the passing portion being formed of the coil wire extending between the main body and the separator and having a circumferential width smaller than a radial opening width of the slit.

6. The method of manufacturing a stator according to any one of claims 1 to 5,

in the forming step, the coil wire is wound around the winding die by moving a winding wire nozzle for supplying the coil wire to the winding die by using a robot.

7. The method of manufacturing a stator according to any one of claims 1 to 6,

the upper winding surface has a groove along a direction in which the coil wire is wound.

8. The manufacturing method of a stator according to any one of claims 1 to 7,

the winding die further includes a first guide that moves at least in the axial direction and abuts against the coil wire wound around the upper winding surface.

9. The method of manufacturing a stator according to any one of claims 1 to 8,

in the forming step, the plurality of coil wires are simultaneously wound around the winding die.

10. The method of manufacturing a stator according to claim 9,

the separator has a wall portion that is demarcated by a sum of diameters of the plurality of coil wires wound simultaneously and extends in a direction in which the coil wires are wound.

11. The method of manufacturing a stator according to any one of claims 1 to 10,

the two circumferentially opposing surfaces of the main body are provided with the side winding surfaces, and the circumferential intervals of the side winding surfaces are narrowed toward the radially inner side.

12. The method of manufacturing a stator according to claim 11,

in the forming step, a wedge-shaped jig or wedge is attached to the winding jig, and the coil wire is wound.

13. The manufacturing method of a stator according to any one of claims 1 to 12,

the method further includes compressing the coil wire wound around the body.

14. The manufacturing method of a stator according to any one of claims 1 to 13,

the winding die further includes a second guide that moves at least in the radial direction and abuts the coil wire on an axially upper side of the main body.

Technical Field

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

Background

Conventionally, a method of manufacturing a stator by inserting a coil into a slot of a stator core is known. For example, japanese patent laying-open No. 2000-125521 (patent document 1) discloses a coil insertion device for inserting a ring-shaped coil into a slot of a stator core.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open No. 2000-125521

Disclosure of Invention

Technical problem to be solved by the invention

In order to reduce the loss of the motor, the stator needs to have a coil wound in the slot of the stator core so as to reduce the gap. In order to increase the space factor in the slots of the stator, it is necessary to regularly arrange the coils, that is, to perform so-called aligned winding or the like.

As a method of inserting a coil into an integrated stator core, there is a method of press-fitting an annular coil from a slot opening. However, in the above method, aligned winding cannot be achieved, and the space factor is low.

In view of the above problems, the present invention provides a method for manufacturing a stator capable of improving a space factor of the stator.

Technical scheme for solving technical problem

A method of manufacturing a stator according to a first aspect of the present invention is a method of manufacturing a stator including a stator core having a plurality of slots penetrating in an axial direction, the method including: winding a coil wire around a winding die a plurality of times to form an annular coil bundle; and a step of inserting the coil bundle into the slot from the lower side to the upper side in the axial direction of the slot, the winding die including: a main body having a lower winding surface on an axial lower side thereof, on which a coil wire is wound; and a separator arranged on an axially upper side of the main body, the separator having an upper winding surface on the axially upper side, on which the coil wire is wound, the upper winding surface being positioned radially inward of the lower winding surface and inclined radially inward as it goes axially downward when the coil wire is wound in the winding die.

Effects of the invention

The invention can provide a method for manufacturing a stator capable of improving the space factor of the stator.

Drawings

Fig. 1 is a sectional view of a stator in a section perpendicular to an axial direction.

Fig. 2 is a schematic view mainly showing a coil bundle.

Fig. 3 is a schematic view mainly showing a bent coil bundle.

Fig. 4 is a schematic view of a winding die.

Fig. 5 is a schematic view of the coil wire wound around the winding die.

Fig. 6 is a schematic view mainly showing a winding die.

Fig. 7 is a schematic view of the first separator.

Fig. 8 is a schematic view of a second separator.

Fig. 9 is a schematic view of the third separator.

Fig. 10 is a view showing a manufacturing process of the stator.

Fig. 11 is a schematic view mainly showing a winding wire mouth.

Fig. 12 is a cross-sectional view showing a coil side portion.

FIG. 13 is a schematic view of the installation of a wedge-shaped clamp or wedge to the winding die.

Fig. 14 is a schematic diagram showing a process of performing insertion.

Fig. 15 is a schematic diagram showing a process of performing insertion and a process of performing compression.

Fig. 16 is a schematic diagram showing a compression step.

Fig. 17 is a schematic diagram showing a recovery step.

Fig. 18 is a schematic diagram showing a process of storing.

Fig. 19 is another schematic diagram showing a process of storing.

Fig. 20 is another schematic view showing a process of storing.

Detailed Description

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following drawings, the same or corresponding portions are denoted by the same reference numerals, and description thereof will not be repeated.

In the following description, the direction in which the central axis of the stator 1 extends, that is, the penetrating direction of the slots is referred to as the "axial direction". One side in the axial direction is set as an upper side, and the other side is set as a lower side. The vertical direction is used to define the positional relationship, and is not limited to an actual direction. That is, the lower direction does not necessarily refer to the direction of gravity. The axial direction is not particularly limited, and includes a vertical direction, a horizontal direction, and a direction intersecting the vertical direction and the horizontal direction.

The direction perpendicular to the central axis of the stator 1 is referred to as a "radial direction". One side in the radial direction is set as an inner side, and the other side is set as an outer side. The direction along an arc centered on the central axis of the stator 1 is referred to as the "circumferential direction".

In the drawings used in the following description, for the purpose of emphasizing a characteristic portion, a characteristic portion may be enlarged for convenience. Therefore, the dimensions and proportions of the respective constituent elements are not necessarily the same as actual ones. In some cases, portions that are not characteristic are omitted from the drawings for the same purpose.

(stator)

As shown in fig. 1, the stator 1 is a component of a motor, and interacts with a rotor, not shown, to generate a rotational torque. The stator 1 includes a coil bundle 10, a stator core 20, an insulating paper 30, and a wedge 40. The stator 1 of the present embodiment is wound in a distributed manner such that the coil is wound across a plurality of slots 21.

< stator core >

The stator core 20 of the present embodiment is an integrated stator core 20. In addition, a split type stator core may be used. The stator core 20 is formed in a hollow cylindrical shape. The stator core 20 is formed by laminating thin silicon steel plates. The stator core 20 is formed with a plurality of pole teeth 23 in a radial shape. The teeth 23 are formed with a slot 21 therebetween. The teeth 23 extend radially across the slots 21.

The slit 21 has a slit opening 22 as a radial opening portion of the slit 21. The slot opening 22 is smaller than the circumferential width of the space in the slot 21 that accommodates the coil side 11. The notch opening 22 is formed in the central portion of the notch 21 in the circumferential direction.

< coil bundle >

The coil bundle 10 is formed by winding a coil wire in a ring shape. The direction in which the coil wires of the coil bundle 10 are arranged in a bundle is the radial direction. The coil wire of the present embodiment is a round wire, but is not particularly limited thereto, and may be a flat wire or the like.

Fig. 2 schematically shows a coil bundle showing the blades 131 and 132, the coil moving mechanism 150, and the coil stoppers 160, which will be described later. As shown in fig. 2, the coil bundle 10 has: two coil side portions 11; and a coil transition 12.

The two coil sides 11 are housed in the slits 21. The coil side 11 extends in the axial direction. Specifically, the slit 21 for accommodating one coil side 11 is different from the slit 21 for accommodating the other coil side 11. The slit 21 for accommodating one coil side 11 and the slit 21 for accommodating the other coil side 11 may be adjacent to each other, or may be arranged in the circumferential direction with another slit interposed therebetween.

The coil side 11 is wound in alignment. That is, in the aligned winding, the coil side portions 11 are regularly stacked in a predetermined direction. The coil side 11 of the present embodiment is regularly stacked in the circumferential direction in the slit 21, but is not limited to this.

The coil transition portion 12 connects the two coil side portions 11. The coil transition portions 12 are disposed on both sides in the axial direction. Specifically, the coil transition portion 12 located on the upper side in the axial direction is an upper coil side end that connects the upper end portions of the two coil side portions 11. The coil transition portion 12 located axially downward is a lower coil side end connecting the lower ends of the coil side portions 11.

< insulating paper >

As shown in fig. 1, the insulating paper 30 covers the coil side 11 formed of the plurality of coil wires inserted into the slit 21. The insulating paper 30 is disposed along the teeth defining the space on the radially inner side of the cutout groove 21. The insulating paper 30 of the present embodiment has a U-shape when viewed in the axial direction.

Wedge

The wedge 40 is disposed between the coil wire disposed in the slot 21 and the slot opening 22. The coil bundle 10 may be covered with the insulating paper 30 or may not be covered with the insulating paper 30. The wedge 40 blocks the slotted opening 22.

The wedge 40 of the present embodiment is disposed at an upper end portion in the notch 21. The wedge member of the present embodiment has a U-shape when viewed in the axial direction. The axial length of the wedge 40 is less than the axial length of the slot 21. In addition, the wedge 40 may be omitted.

[ winding mold ]

The winding die 100 of the present embodiment will be described with reference to fig. 3 to 9. As shown in fig. 3 to 9, the winding mold 100 includes a main body 110, a partition 120, a first guide 140, a second guide 141, and a pressing member 115. The winding die 100 is wound with the coil wire to form a meander coil bundle as shown in fig. 3.

< bending coil bundle >

Fig. 3 schematically shows a bending coil bundle showing the first separator 120a, the second separator 120b, and the third separator 120c of the winding die 100, and the blades 131 and 132 used in the insertion step (S30) described later. The bent coil bundle is a coil bundle in which the upper end of the coil bundle is inclined radially inward.

The meander coil bundle has a first layer 16, a second layer 17 and a third layer 18 as a plurality of coil groups. The second layer 17 is located on the outer peripheral side of the first layer 16. The third layer 18 is located on the outer peripheral side of the second layer 17.

The first layer 16 to the third layer 18 differ in axial position at the axially upper side. In the present embodiment, on the axially upper side of the coil bundle 10, the third layer 18, the first layer 16, and the second layer 17 are positioned in this order from the axially upper side. That is, the third layer 18 is an upper-layer coil bundle, the first layer 16 is an intermediate-layer coil bundle, and the second layer 17 is a lower-layer coil bundle.

The axial positions of the axially lower sides of the coil bundles are aligned. That is, the lower coil transition portion 12 is located on the same plane.

The axial lengths of the first, second and third layers 16, 17, 18 are different from one another. In the present embodiment, the axial lengths of the second layer 17, the first layer 16, and the third layer 18 are sequentially smaller.

The first layer 16, the second layer 17, and the third layer 18 are each arranged with one or more rows of coil wires in the circumferential direction. In each column, a plurality of coil lines are arranged in a radial direction.

The bending coil bundle has an inclined portion 14. Specifically, each of the first to third layers 16 to 18 has the inclined portion 14. The inclined portion 14 of the third layer 18, the inclined portion 14 of the first layer 16, and the inclined portion 14 of the second layer 17 are positioned in this order from the axial upper side.

The inclined portion 14 is inclined with respect to the coil side portion 11 extending in the axial direction. The inclined portion 14 includes a coil transition portion 12, and the coil transition portion 12 connects the two coil side portions 11. The inclined portion 14 has a passing portion 15, and the passing portion 15 passes through the notch opening 22 in an insertion step (S30) described later. The passing portion 15 has a coil wire stacked in the axial direction. The circumferential length of the passing portion 15 is smaller than the circumferential length of the notch opening 22.

< body >

Fig. 4 schematically shows the winding die 100 as viewed from the side. Fig. 5 schematically shows a state in which a coil wire is wound around the separator 120 of the winding die 100. As shown in fig. 4 and 5, the body 110 extends in an axial direction.

The body 110 includes a winding surface on which the coil wire is wound. As shown in fig. 4, the winding surface of the body 110 has a lower winding surface 111 and a side winding surface 112. The lower winding surface 111 is provided axially downward. In detail, the lower winding surface 111 is provided on the lower surface of the body 110. The side winding surfaces 112 are provided on opposite surfaces of the body 110. Specifically, the side winding surfaces 112 extend in the axial direction and are provided on side surfaces facing each other.

As shown in fig. 6, the shape of the side winding surface 112 is the same as the circumferential shape of the slit 21. Identity refers to identity with dimensional tolerances removed.

Further, the circumferential interval of the side winding surface 112 becomes narrower toward the radially inner side. The interval of the opposite side winding surfaces 112 is the same as the interval of the two slits 21 into which the coil bundle is inserted. The same means the same except for the dimensional tolerance and the gap at the time of winding. The axial length of the side winding surface 112 is the same as or shorter than the axial length of the cut groove 21.

< separator >

As shown in fig. 4 and 5, the spacer 120 is disposed at an upper side in the axial direction of the main body 110 with a space from the main body 110. The circumferential length of the spacer 120 may be the same as the circumferential length of the body 110. The position of the partition 120 is fixed. That is, the partition 120 does not move in the radial and axial directions. In addition, the separator 120 may also maintain a position and rotate when wound.

The winding die 100 includes a plurality of separators 120 whose axial positions are different. At least a portion of the partitions 120 overlap when viewed axially. As shown in fig. 4, the winding die 100 of the present embodiment has a first separator 120a, a second separator 120b, and a third separator 120c positioned in this order from the axial lower side. In the present specification, at least one of the first to third separators 120a to 120c is also simply referred to as the separator 120.

Each separator 120 includes a winding surface on which the coil wire is wound. The winding surface of the separator 120 has an upper winding surface 121 and a side winding surface 122.

The upper winding surface 121 is provided on the axial upper side. In detail, the upper winding surface 121 is provided on the upper surface of the separator 120. The axial positions of the upper winding surfaces 121a to 121c are different.

When the coil wire is wound around the winding die 100, the upper winding surface 121 is located radially inward of the lower winding surface 111 of the body 110, and is inclined radially inward as it goes axially downward. That is, when the coil wire is wound around the upper winding surface 121 of the separator 120, the diameter of the coil bundle decreases toward the inside in the radial direction.

The radially inner end of the upper winding surface 121 is located radially inward of the radially inner end of the lower winding surface 111 of the body 110. In fig. 4, a part of the upper winding surface 121 and a part of the lower winding surface 111 overlap each other when viewed in the axial direction, but the upper winding surface 121 and the lower winding surface 111 may be different in radial position when viewed in the axial direction.

Further, the upper winding surface 121 is inclined axially downward as it goes radially inward. The upper winding surface 121 has a gap in the radial direction from the side winding surface 112 of the body 110. This makes it possible to easily form a row of the coil lines on the upper winding surface 121.

The side winding surfaces 122 are provided on opposite surfaces of the separator 120. In detail, the side winding surfaces 122 are provided on opposite side surfaces. The side winding surface 122 is inclined radially inward toward the axially upper side. Further, the side winding surface 122 is inclined axially upward as it goes radially inward.

Fig. 7 to 9 are enlarged schematic views of the separators 120 as viewed from the side. The shape of the separator in fig. 7 to 9 is different from that in fig. 4 and 5, but can be used as appropriate depending on the shape of the slit 21 of the stator to be manufactured. The structure of the minute part of the separator 120 will be described with reference to fig. 7 to 9.

As shown in fig. 7 to 9, the upper winding surface 121 has a groove 125 along the direction in which the coil wire is wound. The side winding surface 122 has a groove 126 in the direction in which the coil wire is wound. The coil wire is guided by the slots 125, 126 and wound.

Each separator 120 has a wall portion 127 that is demarcated by the sum of diameters of a plurality of coil wires wound simultaneously and extends in a direction in which the coil wires are wound. In fig. 6 to 8, ten coil wires are wound at the same time, and therefore, the diameter × 10 of the coil wires is the distance L between the wall portions 127.

As shown in fig. 7, the upper winding surface 121a of the first separator 120a has a plurality of surfaces having different axial positions. That is, the faces do not lie on the same plane. In detail, the two upper mounting surfaces 121a delimited by the wall portion 127 are parallel to each other. However, the direction in which the plurality of surfaces of the upper winding surface 121 extend deviates by an integral multiple of the diameter of the coil wire. In fig. 7, the right upper winding surface 121a defined by the wall 127 is located axially above the left upper winding surface 121a by an amount corresponding to the diameter of the coil wire.

Here, the winding frame including the lower winding surface 111 and the side winding surface 112 of the body 110 and the upper winding surface 121a and the side winding surface 122a of the first separator 120a is referred to as a lower winding frame. The winding frame composed of the lower winding surface 111 and the side winding surface 112 of the body 110 and the upper winding surface 121b and the side winding surface 122b of the second separator 120b is referred to as an intermediate winding frame. The winding frame including the lower winding surface 111 and the side winding surface 112 of the body 110 and the upper winding surface 121c and the side winding surface 122c of the third separator 120c is referred to as an upper winding frame.

< first guide part >

As shown in fig. 4 and 5, the first guide 140 moves at least in the axial direction and abuts against the coil wire wound around the upper winding surface 121. The winding die 100 of the present embodiment includes a plurality of first to third guides 140a to 140c having different axial positions. The first to third guides 140a to 140c are provided on the separators 120a to 120c, respectively.

The first guide 140 moves in a direction in which the upper winding surface 121 extends. In fig. 4, the first guide 140 moves in the axial and radial directions. Specifically, the first guide 140 moves radially inward as it moves axially downward. The coil wire wound around the separator 120 abuts against the coil wire while moving in a direction perpendicular to the direction in which the coil wire is wound around the separator 120. The coil wire can be prevented from being shifted in the upper winding surface 121 by the first guide 140.

The first guide 140 is a positioning guide that determines the position of the inclined portion 14. The first guide 140 holds the position of the coil wire wound around the separator 120. As such a first guide, for example, an actuator is used.

< second guide part >

The second guide 141 moves at least in the radial direction and abuts the coil wire on the upper side in the axial direction of the main body 110. The second guide 141 moves parallel to the lower winding surface 111 of the body 110. The second guide 141 moves along with the movement of the first guide 140. For example, when the first guide 140 moves downward by a distance corresponding to the diameter of the coil wire, the second guide 141 moves inward in the radial direction by a distance corresponding to the diameter of the coil wire. The second guide member 141 can apply tension to the coil wire in a direction opposite to the moving direction. In fig. 5, the second guide 141 applies tension to the coil wire at the radially outer end of the lowermost layer.

The second guide 141 is disposed at an upper end of the side winding surface 112 of the body 110. The second guide 141 is a positioning guide for determining a bending start position of the upper end portion of the coil bundle. The second guide 141 has, for example, a wedge shape.

In fig. 5, three layers of coil wires are arranged at the upper end of the side winding surface 112. Fig. 5 shows a state in which the second guide 141 biases the coil at the radially outer end of the lowermost layer. The second lead member 141 also applies tension to the coil wire of the upper layer thereof. In this case, the second guide 141 is moved in the radial direction while being in contact with the coil wire while being moved upward in the axial direction compared to fig. 5 and maintaining the axial position.

< pressing Member >

As shown in fig. 6, a pressing member 115 is provided at a position facing the side winding surface 112. In the pressing member 115, the shape of the surface in contact with the coil wire is the same as the shape of the circumferential side surface of the slit 21. Identity refers to identity with dimensional tolerances removed. The pressing member 115 advances and retreats toward the main body 110 by, for example, a pneumatic cylinder.

[ method for manufacturing stator ]

A method of manufacturing the stator 1 of the present embodiment will be described with reference to fig. 1 to 20.

< Retention of coil bundle >

First, as shown in fig. 10, the coil wire is wound around the winding die 100 a plurality of times to form a bent coil bundle shown in fig. 3 (step S10). The above step (S10) is performed, for example, in the following manner.

First, as shown in fig. 4 and 5, the coil wire is wound around the main body 110 and the second separator 120b (middle layer winding frame) (step S11). By performing the above-described step (S11), the first layer 16 having the inclined portion 14 as the middle-layer bending coil bundle can be formed.

In the present embodiment, the coil wire is wound in order from the upper end to the lower end of the upper winding surface 121b of the second separator 120b, and the coil wire is wound in order from the radial outer side to the inner side of the side winding surface 112 of the main body 110. Specifically, the coil wire wound around the upper end of the upper winding surface 121b is wound around the radially outer end of the side winding surface 112 of the body 110. At this time, the coil wire at the upper end of the upper winding surface 121b of the separator 120b is positioned by the first guide 140, and the coil wire at the upper end of the side winding surface 112 of the body 110 is positioned by the second guide 141. Next, the first guide 140 is moved downward, and the second guide 141 is moved radially inward. Next, the coil wire is wound between the coil wire wound on the upper winding surface 121b and the first guide 140, and is wound on the side winding surface 112 so as to be positioned between the coil wire wound on the upper end of the side winding surface 112 and the second guide. Thus, the following steps are repeated: when the coil wire is wound on the upper winding surface 121b, the first guide 140 is moved downward, and when the coil wire is wound on the side winding surface 112, the second guide 141 is moved radially inward.

In addition, the position at which winding of the coil wire is started can be set arbitrarily. That is, the winding may be started from the winding surface of the body 110, or may be started from the separator 120. Further, the separator 120b may be wound from the lower side to the upper side. In the above case, the first guide 140b moves from the lower end to the upper end of the upper winding surface 121 b.

In the step of winding the coil wire (S11), the winding wire nozzle 116 (see fig. 11) that supplies the coil wire to the winding die 100 is moved by using a robot to wind the coil wire around the winding die. The robot is not particularly limited, but an actuator can be used, for example. In the present embodiment, a three-axis robot is used.

Specifically, as shown in fig. 11, the coil wire 10a wound around the bobbin 117 is drawn out, and the coil wire 10a is supplied from the winding wire nozzle 116 to the winding die 100. The winding nozzle 116 is moved by a robot. When the winding nozzle 116 is moved, the middle layer winding frame may be rotated.

One coil wire may be wound around the intermediate layer winding frame, or a plurality of coil wires may be simultaneously wound around the intermediate layer frame. In the latter case, a plurality of coil wires arranged in the radial direction, which is the direction of the lower winding surface 111 of the body 110 and the upper winding surface 121b of the second separator 120b, are wound at the same time. The plurality of coil wires 10a may be supplied from the winding wire nozzle 116 to the middle layer winding frame, or the plurality of winding wire nozzles 116 that feed out one coil wire may be arranged in parallel and the plurality of coil wires 10a may be supplied to the middle layer winding frame.

The coil wire is guided and wound by the slots 125, 126 of the second separator 120 b. Further, a plurality of coil wires wound simultaneously are arranged in an area demarcated by the wall portion 127 of the second separator 120 b. In fig. 8, ten coil wires are wound at the same time.

Thereby, the first layer 16 in which the plurality of coil wires are arranged from the radially inner side to the radially outer side is formed. When the coil wire is wound around the middle layer winding frame, the upper winding surface 121b of the second separator 120b is positioned radially inward of the lower winding surface 111 and is inclined with respect to the lower winding surface 111, and therefore, the first layer 16 has the inclined portion 14.

In addition, in the above step (S11), as shown in fig. 3, a passing portion 15 is formed at the coil bundle, the passing portion 15 is formed of a coil wire that spans between the main body 110 and the separator 120, and the circumferential width is smaller than the opening width in the radial direction of the slit. That is, the passing portion 15 having a width smaller than the opening width of the notch opening 22 is provided in the inclined portion 14. The passing portion 15 is formed by applying a large tension when winding the coil wire around the second separator 120b, for example. The passing portion 15 may be formed by compression. In the present embodiment, the passing portion 15 is formed so that the gap between the coil wires is reduced in the radial direction and the axial direction.

Next, as shown in fig. 5, the coil wire is wound around the main body 110 and the first separator 120a (lower layer winding frame) (step S12). By performing the above-described step (S12), the second layer 17 having the inclined portion 14 as the lower-layer bending coil bundle can be formed. In the step (S12), the coil wire is wound around the lower-layer winding frame in the same manner as the formation of the first layer 16 (S11). Thereby, the second layer 17 is formed, which is disposed on the outer peripheral side of the first layer 16 and in which the plurality of coil wires are arranged from the radially inner side to the radially outer side.

Next, the coil wire is wound around the main body 110 and the third separator 120c (upper layer winding frame) (step S13). By performing the above-described step (S13), the third layer 18 having the inclined portion 14 as the upper-layer bending coil bundle is formed. In the step (S13), the coil wire is wound around the upper-layer winding frame in the same manner as the formation of the first layer 16 (S11). Thus, the third layer 18 is formed, which is disposed on the outer peripheral side of the second layer 17 and in which the plurality of coil wires are arranged from the radially inner side to the radially outer side.

Next, the lower side of the coil bundle is compressed (step S14). That is, in the coil bundle, the coil wire wound around the body 110 is compressed. In the step (S14), the coil wire wound around the body 110 is compressed so that the axial cross-sectional shape of the coil wire becomes the axial cross-sectional shape of the slot 21. That is, the coil side 11 in which the coil wire is wound around the winding frame having the same shape as the shape of the slot 21 is compressed in accordance with the shape of the slot 21. By the compression, the cross-sectional area of the coil side 11 in the cross-section perpendicular to the axial direction is the same as the cross-sectional area of the slit 21 in the cross-section perpendicular to the axial direction. In addition, "identical" means identical except for dimensional tolerance. The circumferential length of the coil side 11 is larger than the circumferential opening width of the notch opening 22.

As shown in fig. 6, the compression is performed using the pressing member 115. The pressing member 115 is provided at a position facing the side winding surface 112. In the pressing member 115, the shape of the surface in contact with the coil wire is the same as the shape of the circumferential side surface of the slit 21. Identity refers to identity with dimensional tolerances removed. By pressing the pressing member 115 against the coil bundle wound on the main body 110, the gap of the coil wire can be reduced.

By performing these steps (S10), the bending coil bundle shown in fig. 3 can be formed.

In the coil side 11 of the insertion slit 21 of the coil bundle formed as described above, as shown in fig. 12, a plurality of rows of coil wires are arranged in the circumferential direction, and the coil bundle can be formed such that the plurality of coil wires are arranged in the radial direction in each row. In the present embodiment, a plurality of coil wires 6 are arranged in six rows in the circumferential direction. At both ends in the circumferential direction, ten coil wires are arranged in the radial direction. At the center portion except for both ends in the circumferential direction, twenty coil wires are arranged in the radial direction. In six circumferential rows in fig. 12, the first layer 16, the second layer 17, and the third layer 18 are shown every two rows from below.

In the present embodiment, the coil side 11 is formed such that the shape of the cross section perpendicular to the axial direction of the coil side 11 corresponds to the shape of the cross section perpendicular to the axial direction of the notch 21. Specifically, the number of coil wires arranged in the radial direction in each circumferential row is matched to the shape of the slot 21 as much as possible.

In the steps (S11, S12, S13) of forming the first layer 16, the second layer 17, and the third layer 18 of the present embodiment, as shown in fig. 13, the coil wire is wound while the wedge-shaped jig 41 or the wedge 40 is attached to the winding jig 100. The wedge shape is a shape of a member for closing the radial opening portion of the notch opening 22.

In the case of mounting the wedge 40 to the winding die 100, the wedge 40 is deformed in such a manner that the wedge 40 sandwiches the radially inner end portion of the coil bundle. In the compressing step (S14), the coil wire wound around the body 110 and the wedge 40 are compressed at the same time. Specifically, the coil wire wound around the body 110 and the axial sectional shape of the wedge 40 are compressed so as to be changed to the axial sectional shape of the slit 21. By pressing the pressing member 115 against the coil bundle wound on the main body 110, the gap between the wedge 40 and the coil wire can be reduced.

< Retention of coil bundle >

Fig. 14, 15, and 17 show only a part of the upper and lower surfaces of the stator core 20 in order to show the slot 21 into which the coil bundle is inserted. As shown in fig. 14, the coil bundle is held by the plurality of blades 131 and 132 arranged radially inward of the stator core 20 (step S20). In addition, the blades 131 and 132 may partially enter the slot 21 from the slot opening 22. In the holding step (S20), the inclined portion 14 is disposed between the blades 131 and 132.

The holding step (S20) may be performed in the insertion step (S30) described later. In the above case, as shown in fig. 15, the blades 131 and 132 are disposed corresponding to the teeth 23. In detail, the plurality of blades 131 and 132 and the pole teeth 23 are opposed to each other in the radial direction and have the same circumferential position. Therefore, in the step of housing (S60) described later, the coil bundle is inserted into the slit opening 22 from between the plurality of blades 131 and the blade 132. The blades 131 and 132 are disposed radially outward of the coil moving mechanism 150, which will be described later.

< insertion groove >

Next, the coil bundle is inserted into the slot 21 from the lower side to the upper side in the axial direction of the slot 21 (step S30). That is, the coil bundle is inserted into the slit 21 from the upper side after being bent. In the above step (S30), the bent coil bundle is inserted into the slot 21 from the lower side to the upper side in the axial direction of the two slots 21 of the stator core 20. In the present embodiment, the two slits 21 into which the bending coil bundle is inserted are provided as one slit 21 and the other slit 21 sandwiching the four slits 21, but the present invention is not limited to this.

Specifically, as shown in fig. 14, the bent coil bundle is disposed axially below the stator core 20. At this time, the bent coil bundle is arranged with respect to the stator core 20 in a state where the passing portion 15 is located axially below the slot opening 22. In a state where the inclined portion 14 is directed radially inward, the bent coil bundle is arranged with respect to the stator core 20.

Next, as shown in fig. 15, the bending coil bundle is moved upward in the axial direction. Thereby, the coil side portion 11 is inserted into the slit 21. The lower coil transition portion 12 straddles between the slots 21 at the bottom of the stator core 20. The inclined portion 14 passes radially inward of the coil side portion 11. The passing portion 15 of the inclined portion 14 passes through the cut opening 22.

In the step of inserting (S30), the coil bundle is inserted into the slot by the coil moving mechanism 150. Specifically, the coil bundle is brought into contact with the coil moving mechanism 150, and the coil moving mechanism 150 is moved upward. Thereby, the inner side of the coil bundle 10 is pulled upward in a state of being caught by the coil moving mechanism 150. The coil moving mechanism 150 has, for example, a disc shape in order to reduce the load on the coil bundle.

The coil moving mechanism 150 may also have fins. The diameter of the fin increases toward the axially lower side. In a step (S60) of storing, which will be described later, the coil bundle 10 is pressed from the radially inner side to the radially outer side by the fin having an enlarged diameter. The coil bundle 10 held by the blades 131 and 132 is inserted into the slot 21 from the slot opening 22.

In the step of inserting (S30), the wedge-shaped jig 41 or the wedge 40 is inserted into the slit 21 together with the coil bundle. A wedge-shaped clamp 41 or wedge 40 is located radially inwardly in the cutting slot 21,

< compression of the non-inserted portion of the coil bundle not inserted into the slit >

As shown in fig. 15, the coil bundle is compressed on the axially lower side of the stator core 20 (step S40). That is, the non-inserted portion of the coil bundle, which is not inserted into the slit 21, is compressed. As shown in fig. 16, in the above step (S40), the coil bundle is compressed so that the axial sectional shape of the coil bundle becomes the axial sectional shape of the slit 21.

As shown in fig. 15 and 16, in the above step (S40), the coil bundle is compressed at a position where the axial sectional position of the coil bundle overlaps the axial sectional position of the slit 21. In addition, at least a part of the axial cross-sectional position of the coil bundle may overlap with the axial cross-sectional position of the slit 21, but the larger the overlapping portion, the better.

In the step (S40), the coil bundle is compressed sequentially while changing the axial position at which the coil bundle is compressed. It is desirable to compress the coil bundle immediately before inserting the slit 21. The coil bundle can be compressed in stages in the axial direction, and therefore, the compression load can be reduced, and the miniaturization of the apparatus for compression can be achieved.

The step of performing insertion (S30) and the step of performing compression (S40) are performed simultaneously. "simultaneously" means that the insertion step and the compression step overlap in time series. The start time and the end time of each step may be the same or different. The insertion step and the compression step are performed at the same timing, and the coil bundle is moved upward in the axial direction, whereby the coil bundle is compressed in stages in the axial direction. In the present embodiment, immediately before being inserted, the coil bundle is compressed directly below the slit 21. That is, the compressed portion of the coil bundle is inserted into the slit 21 immediately after being compressed. The axial movement of the coil bundle for changing the compression position also becomes the axial movement of the coil bundle for insertion into the slit 21.

In the step (S40), the coil bundle inserted into the plurality of slits 21 is compressed at the same time. The term "simultaneously" means that the step of compressing the coil bundle inserted into one slot 21 and the step of compressing the coil bundle inserted into the other slot 21 are overlapped in time series. The start time and the end time of each compression step may be the same or different.

In fig. 15 and 16, the coil bundles inserted into the adjacent incision slits 21 are compressed at the same time. In addition, one coil bundle and the other coil bundle may be compressed at the same time, or different portions of one coil bundle may be compressed at the same time.

Here, a method of compressing the coil inserted into one slot 21 by the compressing device 20 will be described. First, the compression device 200 will be explained.

As shown in fig. 16, the compressing device 200 includes a first jig 210, a second jig 220, a third jig 230, and a connecting member 240. The first jig 210 has a first side surface 211 disposed on one circumferential side and a second side surface 212 disposed on the other circumferential side. The second jig 220 is disposed at a circumferential side of the first jig 210 with a space therebetween. A third jig 230 is disposed at a distance on the other circumferential side of the first jig 210. The radially inner side of the circumferential spacing of the first clamp 210 and the second clamp 220 is narrower than the radially outer side. The radially inner side of the circumferential spacing of the first clamp 210 and the third clamp 230 is narrower than the radially outer side.

The second jig 220 and the third jig 230 are connected by a connecting member 240. The connecting member 240 is located radially inward of the cut groove. In detail, the connection member 240 includes: a portion 241 extending radially inward from the second clamp 220; a portion 242 extending radially inward from the third clamp 230; and a fastening member 243 fastening the respective portions 241, 242.

In addition, the compressing device 200 may further include a moving member that moves the second and third clamps 220 and 230. The moving member is, for example, an actuator or the like.

Next, a method of compressing the coil bundle on the lower side in the axial direction of the stator core 20 using the compression device 200 will be described.

One circumferential end of the coil bundle is brought into contact with the first jig 210. The second jig 220 presses the other end of the coil bundle in the circumferential direction. The second jig 220 abuts on each coil bundle from the circumferential direction. The second jig 220 is moved to the other circumferential side in such a manner that the second jig 220 approaches the first jig 210.

Further, the other end of the coil bundle in the circumferential direction is brought into contact with the first jig 210. The third jig 230 presses the other end of the coil bundle in the circumferential direction. The third jig 230 abuts on each coil bundle from the circumferential direction. The third jig 230 is moved in the circumferential direction in such a manner that the third jig 230 approaches the first jig 210.

In the present embodiment, the coil bundles inserted into the adjacent slits 21 are compressed at the same time. Specifically, one circumferential end of the coil bundle inserted into one slot 21 is brought into contact with the first side surface 211 of the first jig 210. One circumferential end of the coil bundle inserted into the other slit 21 is brought into abutment with the second side surface 212 of the first jig 210. Next, the second jig 220 presses the other end side in the circumferential direction of the coil bundle inserted into one slit 21. The third jig 230 presses the other end side in the circumferential direction of the coil bundle inserted into the other slit 21. The second jig 220 and the third jig 230 are simultaneously moved toward the first jig 210 side.

In the step of compressing (S40), the radially outer end of the coil bundle is brought into contact with the first jig 210. The coil bundle is compressed in the circumferential direction and the radial direction by the above structure.

In the step of forming the coil bundle (S10), the coil bundle is formed using a coil wire of a round wire. In the step of compressing (S40), the cross-sectional shape of the coil wire is deformed into a square shape. By the compression, the cross-sectional shape of the round wire is deformed, thereby increasing the space factor.

In the step of compressing (S40), the compressing may be performed without using a compressing apparatus including the jigs 210, 220, and 230. For example, in the step of compressing (S40), the coil bundle is compressed using a roller.

By performing the above-described step (S40), the annular coil bundle is compressed on the lower side in the axial direction of the stator core 20, and the compressed portion is inserted into the slot 21. Therefore, the compressed and densified coil wire can be inserted into the slot 21. Therefore, the space factor of the stator 1 can be increased.

In the present embodiment, the step of folding the coil assembly in multiple layers (S10) and then compressing the coil assembly (S14) is performed, but one of the step of compressing (S14) and the step of compressing (S40) may be omitted. Specifically, the step of compressing the coil bundle (step S40) in the lower side in the axial direction of the stator core may be performed without performing the step of compressing (step S14) of the step of forming the coil bundle (S10). Further, the step of compressing (step S14) of the step of forming the coil bundle (S10) may be performed without performing the step of compressing (S40) the coil bundle on the lower side in the axial direction of the stator core.

< recovery of coil bundle >

Next, the bending coil bundle is restored to the original shape (step S50). The step (S50) is to reduce the angle of the inclined portion 14 in order to restore the bending coil bundle to its original shape. That is, the step (S50) includes a step of returning the bending coil bundle to the same shape as the original shape and a step of returning the bending coil bundle to a state closer to the original shape than the bent state.

Specifically, the bending coil bundle is deformed to an original shape. Specifically, the inclined portions 14 of the respective layers are rotated upward in the direction of the arrow shown in fig. 17 and are parallel to the coil side portions 11 in the axial direction. Thereby, the upper coil transition portion 12 straddles the slot 21.

Specifically, the inclined portion 14 of the third layer 18 is restored to the original shape (step S51). Next, the inclined portion 14 of the first layer 16 is restored to the original shape (step S52). Next, the inclined portion 14 of the second layer 17 is restored to the original shape (step S53).

In the above steps (S51 to S53), as shown in fig. 17, the coil stopper 160 is brought into contact with the lower end portion in the axial direction of the coil bundle. The coil stopper 160 is disposed axially below the lower end of the stator core 20. The coil stopper 160 abuts against a portion of the coil bundle located below the slit 21. The coil stopper 160 can apply a force radially outward to the lower end portion and the upper end portion of the coil bundle. Therefore, the coil bundle can be easily inserted into the slit 21.

In the step (S50), the coil moving mechanism 150 is moved to return the upper side of the coil bundle to the original shape. Further, the blade 132 is raised as the coil moving mechanism 150 is raised.

In the step (S50), the blades 131 sandwiching the inclined portion 14 from the inner side in the circumferential direction of the coil bundle are positioned axially below the blades 132 sandwiching the inclined portion 14 from the outer side in the circumferential direction of the coil bundle. For example, the blade 131 moves in a direction opposite to the insertion direction. This prevents interference with the blade 131 when the bent inclined portion 14 is restored. For example, the axial position of the blade 131 is moved so as to correspond to the height of the inclined portion 14 of the first to third layers 16 to 18.

< receiving in a notch >

The upper side in the axial direction of the coil bundle is accommodated in the slit 21 from the slit opening 22, which is a radial opening of the slit 21 (step S60). In the step (S60), the row of the rows shown in fig. 12 that overlaps the notch opening 22 at the notch inner circumferential position is finally stored.

In the present embodiment, the notch opening 22 is located at the circumferential central portion of the notch 21. The plurality of columns is three or more columns. Therefore, in the step of housing (S60), at least one row is housed in one circumferential side of the notch 21. At least one row is received in the other side of the slit 21 in the circumferential direction. At least one row is finally accommodated in the circumferential central portion of the slit 21.

Specifically, the inclined portion of the third layer 18 is restored to the original shape (step S51). Next, as shown in fig. 18, two rows of the inclined portions of the third layer 18 are accommodated in the slits 21 on one side (upper side in fig. 18) in the circumferential direction of the slits 21 (step S61). When the third layer 18 is restored to the same shape as the original shape, the inclined portion of the third layer 18 is accommodated in the notch 21.

Next, the inclined portion of the first layer 16 is restored to the original shape (step S52). Next, as shown in fig. 19, two rows of the inclined portions of the first layer 16 are accommodated in the other circumferential side (lower side in fig. 19) of the slits 21 (step S62).

Finally, the inclined portion of the second layer 17 is restored to the original shape (step S53). Next, as shown in fig. 20, two rows of the inclined portions of the second layer 17 are accommodated in the circumferential center portions of the slits 21 (step S63).

In this way, the coil bundle can be inserted from a row not facing the slit opening 22 on the upper side in the axial direction. Therefore, by moving the row inserted first into the slit 21 toward one side and the other side in the circumferential direction away from the slit opening 22, the resistance at the time of inserting the next inserted row can be reduced. Therefore, the insertion resistance of the coil at the slot opening 22 can be reduced.

In the present embodiment, the coil wire is wound so that the second layer 17 is positioned at the lowermost layer when the coil bundle is formed. Therefore, the second layer 17 can be finally accommodated in the slit 21 from the slit opening 22.

In fig. 18 to 20, the coil wires of two rows are accommodated in the slot 21 from the slot opening 22, but the present invention is not limited to this. The number of rows in which the circumferential width of the coil wire received from the slot opening 22 is smaller than the circumferential width of the slot opening 22 can be arbitrarily selected.

Further, the insulating paper 30 may be disposed in the slot 21 in advance, and the coil bundle may be inserted into the slot 21. Further, the coil bundle covering the insulating paper 30 may be inserted into the slit 21.

When the wedge-shaped jig 41 is attached to the winding jig and the coil wire is wound, the wedge-shaped jig 41 is removed. Subsequently, the wedge 40 is inserted into the space where the jig 41 is disposed.

By performing the above steps (S10 to S60), the stator 1 can be manufactured as shown in fig. 1. According to the present embodiment, the coil wire can be wound in a state in which the upper winding surface 121 of the separator 120 is inclined radially inward toward the axially lower side. This makes it possible to form the inclined portion 14 inclined with respect to the body portion of the coil bundle wound around the body 110 at a position above the body portion. Therefore, the main body portion of the coil bundle can be inserted into the slit 21, and the inclined portion 14 of the coil bundle can be inserted into the slit 21 from the slit opening 22. For example, the space factor of the stator can be increased by compressing the body portion.

(modification 1)

In the above embodiment, the third layer 18, the first layer 16, and the second layer 17 are positioned in this order from the axially upper side of the coil bundle 10, but the present invention is not limited to this. The third layer 18, the second layer 17, and the first layer 16 may be positioned in this order from the axially upper side of the coil bundle. In the above case, the coil wire as the first layer 16 is wound on the first separator 120 a. A coil wire as the second layer 17 is wound on the second separator 120 b. A coil wire as the third layer 18 is wound on the third separator 120 c.

Further, the first layer 16, the third layer 18, and the second layer 17 may be positioned in this order from the axial upper side of the coil bundle. Further, the first layer 16, the second layer 17, and the third layer 18 may be positioned in this order from the axial upper side of the coil bundle.

In this way, the position of the inclined portion 14 of the coil bundle is not particularly limited. Therefore, the order of the step of forming each layer and the step of bending (S11 to S16) is not limited to fig. 10.

(modification 2)

In the above embodiment, the axial positions of the axially lower sides of the coil bundles 10 are aligned, but not limited thereto. On the axially lower side, a coil bundle having a plurality of layers with different axial positions may be formed. For example, the third layer 18, the first layer 16, and the second layer 17 may be positioned in this order from the axial upper side of the coil bundle. Further, the third layer 18, the second layer 17, and the first layer 16 may be positioned in this order from the axial upper side on the axial lower side of the coil bundle.

In the present modification, when the layers are moved upward in the axial direction in the step of inserting the slits 21 (S30), the movement may be stopped at the lower end portion of the coil bundle. When the third layer 18, the first layer 16, and the second layer 17 are positioned in this order from the axially upper side of the coil bundle, the following is performed. The rising of the third layer 18 is stopped at the lower coil transition portion 12, and the inclined portion 14 of the third layer 18 is restored. Next, the rise of the first layer 16 is stopped at the lower coil transition portion 12, and the inclined portion 14 of the first layer 16 is restored. Next, the rise of the second layer 17 is stopped at the lower coil transition portion 12, and the inclined portion 14 of the second layer 17 is restored.

(modification 3)

In the above embodiment, the axial lengths of the first to third layers 16 to 18 are different from each other, but the axial lengths of the layers may be the same. By controlling the axial positions of the upper and lower sides of the coil bundle as in modification examples 1 and 2, the axial length of each layer can be arbitrarily set.

(modification 4)

The winding die 100 of the above embodiment has been described as an example in which a plurality of coil bundles having different axial positions are formed on the upper side in the axial direction, but the invention is not limited thereto. The winding die 100 forms a coil bundle having at least one inclined portion, and therefore, the separator 120 may be one or more.

One or more coil bundles may be inserted into one slot 21. In the latter case, the loop-shaped coil bundle is inserted into the slot plural times.

(modification 5)

In the above embodiment, the main body 110 is separated from the partition 120, but may be integrated.

The embodiments disclosed herein are merely illustrative in all respects, and are not intended to be limiting. The scope of the present invention is indicated by the claims rather than the foregoing embodiments, and all changes that come within the meaning and range of equivalency of the claims are intended to be embraced therein.

(symbol description)

1, a stator; 10 coil bundles; 10a coil wire; 11 a coil edge; 12 a coil transition; 14 an inclined portion; 15 a passing portion; 16. 17, 18 layers; 20a stator core; 21, cutting grooves; 22 cutting a slot opening; 23 pole teeth; 30 of insulating paper; a 40 wedge; 41 a clamp; 100, winding the die; 110 a main body; 111 lower side winding surface; 112. 122, 122a, 122b, 122c side winding surfaces; 115 a pressing member; 116 winding wire nozzle; 117 a bobbin; 120a separator; 120a first separator; 120b a second separator; 120c a third separator; 121. 121a, 121b, 121c upper winding surfaces; 125. 126 slot; 127 a wall portion; 131. 131 blades; 140. 140a, 140b, 140 c; 141 a second guide; 150 coil moving mechanism; 160 a coil limit piece; 200 a compression device; 210. 220, 230 clamps; 240 connect the members.