阅读说明：本技术 定子的制造方法以及定子 (Stator manufacturing method and stator ) 是由 丹下宏司 于 2020-02-15 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着轴向贯穿的多个切槽的定子芯部的定子的制造方法,包括：将多个线圈线同时卷绕于卷绕模具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。线圈线以沿着径向排列的方式卷绕于卷绕模具,使多个线圈线朝卷绕模具卷绕的径向位置移动是在多个线圈线卷绕于卷绕模具的轴向上侧的第一卷绕面和下侧的第二卷绕面中的至少一方的卷绕面的期间内。(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: simultaneously winding a plurality of coil wires around a winding die 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 coil wire is wound around the winding die so as to be aligned in the radial direction, and the plurality of coil wires are moved to the radial position where the plurality of coil wires are wound around the winding die in a period in which the plurality of coil wires are wound around at least one of the first winding surface on the upper side and the second winding surface on the lower side in the axial direction of the winding die.)

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

simultaneously winding a plurality of coil wires around a winding die 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,

a plurality of the coil wires are wound around a winding die so as to be arranged in a radial direction,

the plurality of coil wires are moved to the radial position where the plurality of coil wires are wound around the winding die in a period in which the plurality of coil wires are wound around at least one of the winding surface of the winding die in the axial direction, the first winding surface being on the upper side and the second winding surface being on the lower side.

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

the winding die is also provided with a third winding surface and a fourth winding surface which extend along the axial direction and are opposite to each other,

the circumferential width of the coil wire wound around the third winding surface and the fourth winding surface is matched to the circumferential width of the slit.

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

the winding die is also provided with a third winding surface and a fourth winding surface which extend along the axial direction and are opposite to each other,

the radial length of the coil wire wound on the third winding surface and the fourth winding surface is matched to the radial length of the slit.

4. The method of manufacturing a stator according to any one of claims 1 to 3,

the moving distance of the plurality of coil wires toward the radial position where the winding surface is wound is the radial length of the plurality of coil wires.

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

the difference between the radial length of the plurality of coil wires and the radial length of the slit divided by a natural number is smaller than the diameter of the coil wire.

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

the winding die is also provided with a third winding surface and a fourth winding surface which extend along the axial direction and are opposite to each other,

the third winding surface and the fourth winding surface have the same shape as the circumferential side surface of the cutout groove.

7. The method of manufacturing a stator according to claim 6,

the forming step includes:

winding the coil wire on the third winding surface and the fourth winding surface; and

a step of pressing the coil wire using a pressing member and the third winding surface and the fourth winding surface,

in the pressing member, a shape of a surface in contact with the coil wire is the same as a shape of a circumferential side surface of the cutout.

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

the first winding surface has a wall portion that is delimited by a sum of diameters of a plurality of coil wires that are wound simultaneously and extends in a direction in which the coil wires are wound.

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

further comprising a step of bending one side of the coil bundle,

in the step of inserting, the insertion is performed from the one side.

10. A stator, comprising:

a stator core having a plurality of slots penetrating in an axial direction; and

a coil bundle formed by annularly winding a plurality of coil wires,

the coil bundle has:

two coil side portions housed in the cutout groove; and

a coil transition portion connecting the two coil side portions and disposed at both axial sides of the stator core portion,

moving the radial position of the plurality of coil wires is at the coil transition.

11. The stator of claim 10,

in the coil transition portion, a plurality of coil wires move a radial position as one body,

the moving distance of the radial position is a radial length of the plurality of coil wires.

Technical Field

The invention relates to a method for manufacturing a stator and 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 of manufacturing a stator and a stator that can improve the 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: simultaneously winding a plurality of coil wires around a winding die to form an annular coil bundle; and inserting the coil bundle into the slot from the lower side to the upper side in the axial direction of the slot, wherein the plurality of coil wires are wound around the winding die so as to be arranged in the radial direction, and the plurality of coil wires are moved to the radial position where the winding die winds the plurality of coil wires during a period when the plurality of coil wires are wound around at least one of the winding surface of the first winding surface and the second winding surface on the upper side and the lower side in the axial direction of the winding die.

A stator according to a second aspect of the present invention includes: a stator core having a plurality of slots penetrating in an axial direction; and a coil bundle formed by annularly winding a plurality of coil wires, the coil bundle having: two coil side portions housed in the cut groove; and a coil transition portion that connects the two coil side portions and is disposed on both sides in the axial direction of the stator core portion, and that shifts the radial positions of the plurality of coil wires at the coil transition portion.

Effects of the invention

The invention provides a method for manufacturing a stator capable of improving the space factor of the stator and 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 an enlarged view of a coil transition portion.

Fig. 4 is a schematic view mainly showing the bent coil bundle.

Fig. 5 is a schematic view of the winding die as viewed from the side.

Fig. 6 is a schematic view of the winding die as viewed from above.

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 diagram showing a process of forming a coil.

Fig. 12 is a schematic view showing a winding wire nozzle.

Fig. 13 is another schematic diagram showing a process of forming a coil.

Fig. 14 is another schematic diagram showing a process of forming a coil.

Fig. 15 is another schematic diagram showing a process of forming a coil.

Fig. 16 is another schematic diagram showing a process of forming a coil.

Fig. 17 is another schematic diagram showing a process of forming a coil.

Fig. 18 is another schematic diagram showing a process of forming a coil.

Fig. 19 is another schematic diagram showing a process of forming a coil.

Fig. 20 is a sectional view taken along line XX-XX of fig. 19.

FIG. 21 is a schematic view of the installation of a wedge-shaped clamp or wedge to a winding clamp.

Fig. 22 is a schematic diagram showing a process of performing insertion.

Fig. 23 is a schematic diagram showing a process of performing insertion and a process of performing compression.

Fig. 24 is a schematic diagram showing a compression step.

Fig. 25 is a schematic diagram showing a recovery process.

Fig. 26 is a schematic diagram showing a process of storing.

Fig. 27 is another schematic view showing a process of storing.

Fig. 28 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 along 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 an inner side, and the other side is 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, a characteristic portion may be enlarged for convenience in order to emphasize the characteristic portion. 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 along 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 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.

As shown in fig. 3, the radial position of the plurality of coil wires is shifted at the coil transition portion 12. Specifically, the radial positions of the plurality of coil wires are shifted by at least one of the coil transition portion 12 located on the upper side and the coil transition portion 12 located on the lower side. That is, at least one of the coil wires constituting the coil transition portion 12 crosses. On the other hand, in the coil side portion 11, the radial positions of the plurality of coil wires do not move. That is, the coil wires constituting the coil side 11 do not cross. The crossing means a radial positional deviation of the coil wire.

In the coil transition portion 12, the plurality of coil wires move the radial position as one body. The moving distance L of the radial position is the radial length of the plurality of coil wires. In the case where the N coil wires are moved together in the radial direction position, the moving distance of the radial direction position is the diameter × the number (N) of the coil wires.

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. 4 to 9. As shown in fig. 1 to fig. 1, the winding mold 100 includes a main body 110, a partition 120, a plurality of blades 131, 132, and a support member 140. The winding die 100 is wound with the coil wire to form a meander coil bundle as shown in fig. 4.

Bending coil bundle

Fig. 4 schematically shows a bundle of meander coils showing a first separator 120a, a second separator 120b, a third separator 120c and leaves 131, 132. The bent coil bundle is formed by bending an annular coil bundle using a winding die 100 in a step (S13, S14, S16) of bending an upper side of the coil bundle, which will be described later. The term "bent" refers to inclining the upper end portion of the coil bundle 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. In detail, the first layer 16 to the third layer 18 each have 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.

Main body

As shown in fig. 5, the body 110 extends in an axial direction. The body 110 has a substantially rectangular parallelepiped shape.

The body 110 includes a winding surface on which the coil wire is wound. The winding surface of the body 110 has a lower winding surface 111 (second winding surface) and a side winding surface 112 (third winding surface and fourth winding surface). 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. 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 winding die 100 includes a plurality of separators 120 whose axial positions are different. The winding die 100 of the present embodiment has the first separator 120a, the second separator 120b, and the third separator 120c positioned in this order from the axial lower side. In addition, in this specification, at least one of the first to third separators 120a to 120c is also simply referred to as the separator 120.

In the present embodiment, each separator 120 is disposed at a position radially inward of the blades 131 and 132, where the diameter of the coil bundle increases toward the axially upper side. Specifically, the diameter of the coil bundle wound around the third separator 120c is larger than the diameter of the coil bundle wound around the second separator 120 b. The diameter of the coil bundle wound around the second separator 120b is larger than the diameter of the coil bundle wound around the first separator 120 a.

Each of the partitions 120 is supported by a support member 140. Each support member 140 moves in a radial direction. In detail, each support member 140 rotates in a radial direction. The rotation axes T of the support members 140 coincide. By the rotation of each support member 140, each partition 120 is moved in the radial direction by the rotational motion. That is, each of the spacers 120 moves in a radial direction with respect to the main body 110. The separators 120 are moved about a common axis T. That is, the plurality of spacers 120 are moved in the radial direction about the single axis T. This allows the radial position of each separator 120 to be changed by a common drive mechanism, thereby simplifying the winding die 100.

In this way, since each of the spacers 120 moves in the radial direction, each of the spacers 120 can be disposed in an arbitrary region on the upper side of the main body 110. Specifically, a relief region a, a winding region B, and a bending region C are provided on the upper side of the main body 110 from the radially outer side to the radially inner side. The winding region B is a region where the separator 120 used in the step of winding the coil wire is disposed. The winding region B is located directly above the body 110. The bending region C is a region in which the separator 120 used in the step of bending the coil bundle in which the coil wire is wound is disposed. The bending region C is located radially inward of the main body 110. The relief area a is an area where the separator is disposed, the separator being not subjected to the step of winding the coil wire and the step of bending the coil bundle. The escape area a is located radially outward of the main body 110.

In the present embodiment, the radial position of each separator 120 before the coil wire is wound is different from the radial position when the coil wire is wound. Each separator 120 is located in the escape area a before the coil wire is wound, and is located in the winding area B when the coil wire is wound.

Further, the radial position of each separator 120 after the coil wire is wound is different from the radial position when the coil wire is wound. Each separator 120 is located in the winding region B when the coil wire is wound, and moves to the bending region C after the coil wire is wound.

At least a part of each of the separators 120 overlaps with each other when viewed in the axial direction, at a position radially inward of the blades 131 and 132. The positions of the separators 120 in the step of winding the coil wire around the winding die 100 overlap each other when viewed in the axial direction. In addition, each of the separators 120 moves in the radial direction, and therefore, at least a part of each of the separators 120 overlaps when viewed in the axial direction by moving.

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 position of each upper winding surface 121 is different.

The upper winding surface 121 is located radially inward and inclined as it goes toward the axially lower side. When the coil wire is wound, the diameter of the coil bundle decreases toward the radially inner side on the upper winding surface 121 of the separator 120. Further, the upper winding surface 121 is located axially downward and inclined 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.

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 located radially inward and inclined as it goes to the axially upper side. Further, the side winding surface 122 is located axially upward and inclined as it goes radially inward.

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 along 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. That is, the wall portion 127 is delimited by the radial length of the plurality of coil wires supplied from the nozzle. The coil wires wound simultaneously can be arranged in a row on the winding surface between the wall portions 127. 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 L1 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 heights at which the plurality of faces of the upper winding face 121 extend are offset 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.

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.

< blade >

As shown in fig. 6, the plurality of blades 131 and 132 are disposed radially inward of the body 110. As shown in fig. 3, the plurality of blades 131, 132 extend in the axial direction. The blades 131 and 132 are rod-shaped members. The blades 131 and 132 may be attached to the body 110 or may be separated.

The pair of blades 131, 132 sandwich the coil wire that spans between the main body 110 and the separator 120 from the circumferential inside and outside of the coil bundle 10. The circumferential direction of the coil bundle 10 is defined as a direction in which the opposing side of the two coil side portions 11 is an inner circumferential side and the opposing side is an outer circumferential side with respect to the coil bundle. As shown in fig. 3, the pair of blades 131 and 132 are disposed at both circumferential ends of the main body 110. That is, the pair of blades 131 and 132 are arranged in two sets with respect to one main body 110.

As shown in fig. 4, the axial upper end portions of the pair of blades 131, 132 have a rounded shape and are opposed to each other. That is, the blades 131 and 132 have rounded shapes on the surfaces facing each other at the upper ends thereof. The rounded shape is provided for the purpose of facilitating the guiding of the coil wire to the blade. The fillet shape is a shape curved in an arc shape. By having the round shape, the coil wire is smoothly guided between the blades 131 and 132 in a process of winding the coil wire, which will be described later.

The blades 131 sandwiching the coil wire from the inner circumferential side of the coil bundle are configured to be movable in the axial direction. The blade 131 of the present embodiment is moved in the axial direction by a coil moving mechanism 150 described later. By moving the vane 131 in the axial direction, the change in position with respect to the radial direction of the partition 120 can avoid the generation of the cushion.

The circumferential distance between the blades 131, 132 sandwiching the coil wire from the inner and outer sides in the circumferential direction of the coil bundle is smaller than or the same as the circumferential width of the slit opening 22 as the radial opening portion of the slit 21. Thus, in the step (S30) of inserting the coil bundle into the slot 21, which will be described later, the row of the coil wire passing through the slot opening 22 can be easily formed.

The blades 131 and 132 are also used in the step of holding the coil bundle (S20). The blades 131 and 132 are also used in the step of inserting the coil bundle into the slot 21 (S30). The blades 131 and 132 are also used for a step of accommodating the coil bundle in the slot 21 (S60). That is, the blades 131 and 132 used in the step of bending the upper side of the coil bundle are common to the blades used in the step of holding (S20), the step of inserting (S30), and the step of storing (S60).

[ method for manufacturing stator ]

A method of manufacturing the stator 1 according to the present embodiment will be described with reference to fig. 1 to 28.

Formation of loop 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. 4 (step S10). The above step (S10) is performed, for example, in the following manner.

First, as shown in fig. 11, the coil wire is wound around the main body 110 and the second separator 120b (middle layer winding frame) to form the first layer 16 as the middle layer coil bundle (step S11).

Specifically, the first separator 120a and the third separator 120c are disposed in the escape region a, and the second separator 120B is disposed in the winding region B. In the winding region B, the upper winding surface 121B of the second separator 120B may be parallel to the lower winding surface 111 of the main body 110, but is inclined in the present embodiment. In the above case, the coil wire can be suppressed from loosening when the second separator 120b is moved in the radial direction, and therefore, the coil side ends can be shortened.

In the step (S11), the plurality of coil wires are wound around the intermediate layer winding frame so as to be arranged in the radial direction. That is, a plurality of coil wires are simultaneously wound around the intermediate layer winding frame. Specifically, a plurality of coil wires arranged in a radial direction, which is a direction along 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 are moved to the radial position where the middle-layer winding frame is wound while the plurality of coil wires are wound around at least one of the upper winding surface 121b of the separator 120b and the lower winding surface 111 of the main body 110.

Specifically, as shown in fig. 5, a plurality of coil wires 10a are supplied from the winding wire nozzle 116 to the winding die 110. The winding wire nozzle 116 is a member for supplying the coil wire to the winding die. The winding wire nozzle 116 includes a member that feeds out the coil wire. The winding wire nozzle 116 may also further include a member that controls movement of the coil wire.

Specifically, as shown in fig. 12, 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 middle layer winding frame of the winding die 100. In fig. 4, a plurality of winding wire mouths 116 shown in fig. 12 that feed out one coil wire are provided side by side. The plurality of coil wires 10a may be supplied from the winding wire nozzle 116 to the middle layer winding frame.

In the step of winding the coil wire around the winding die 100, at least one of the winding wire nozzle 116 and the winding die 100 moves. In the present embodiment, the winding wire nozzle 116 that feeds out the coil wire moves. The winding nozzle 116 moves along an upper winding surface 121b, a side winding surface 122b, a side winding surface 112, and a lower winding surface 111, the upper winding surface 121b and the side winding surface 122b form the upper coil transition portion 12 by winding the coil wire, the side winding surface 112 forms two coil side portions 11 by winding the coil wire, and the lower winding surface 111 forms the lower coil transition portion 12 by winding the coil wire. In the above case, the movement of the winding wire nozzle 116 in the radial direction is at the timing of feeding the coil wire to at least one of the upper winding surface 121b and the lower winding surface 111. That is, when the coil wire is supplied to the side winding surface 112 of the body 110, the winding wire nozzle 116 does not move in the radial direction.

The distance of movement of the plurality of coil wires to the radial position of winding of the winding surface is the radial length of the plurality of coil wires. The radial length of the coil wire is the diameter x the number of the coil wires.

In addition, both the winding wire nozzle 116 and the winding die may be moved. Further, only the winding die may be moved.

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. 7, 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. Subsequently, as shown in fig. 13, the second partition 120b is moved to the avoidance region a.

Next, as shown in fig. 14, the coil wire is wound around the main body 110 and the first separator 120a (lower layer winding frame) to form the second layer 17 as a lower layer coil bundle (step S12). In the above-described step (S12), the plurality of coil wires are wound around the lower-stage winding frame so as to be aligned in the radial direction, and the plurality of coil wires are moved to the radial position where they are wound around the lower-stage winding frame, during a period in which the plurality of coil wires are wound around at least one of the upper winding surface 121a and the lower winding surface 111 of the lower-stage winding frame.

Specifically, the first separator 120a is moved from the avoidance region a to the winding region B. In the same manner as the formation of the first layer 16 (S11), the coil wire is wound around the lower layer winding frame. 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, as shown in fig. 15, the second layer 17 is bent upward in the axial direction (step S13). In the above-described step (S13), the blades 131 and 132 sandwich the coil wire (see fig. 4) that spans between the main body 110 and the first separator 120a from the inner and outer sides in the circumferential direction of the coil bundle, and the first separator 120a moves in the radial direction with respect to the main body 110. In fig. 4, the upper sides of the first layer 16 and the third layer 18 in the middle layer are also inclined, but in the step (S13), the upper side of the first layer 16 is not bent, and the third layer 18 is not formed.

Specifically, the first partitioning member 120a is rotated radially inward. At this time, the upper end portion of the second layer 17 is inclined inward in the radial direction while being supported by the first separator 120 a. Thereby, the first separator 120a moves to the bending region C. By performing the above-described step (S13), the second layer 16 having the inclined portion 14 can be formed as a lower-layer bending coil bundle.

Next, as shown in fig. 16, the first layer 16 is bent upward in the axial direction (step S14). Specifically, the second separator 120B disposed in the avoidance region a as shown in fig. 14 is moved to the winding region B as shown in fig. 15, and is further moved to the bending region C as shown in fig. 16. In the same manner as the step of bending the second layer 17 (S13), the axially upper side of the first layer 16 is inclined radially inward in the bending region C. By performing the above-described step (S14), the first layer 16 having the inclined portion 14 can be formed as the intermediate-layer bending coil bundle.

Next, as shown in fig. 17, the coil wire is wound around the main body 110 and the third separator 120c (upper layer winding frame) to form the third layer 18 (step S15). In the step (S15), the plurality of coil wires are wound around the upper-layer winding frame so as to be aligned in the radial direction, and the plurality of coil wires are moved to the radial position where the plurality of coil wires are wound around the upper-layer winding frame, during a period in which the plurality of coil wires are wound around at least one of the upper winding surface 121c and the lower winding surface 111 of the upper-layer winding frame.

Specifically, the third separator 120c is moved from the avoidance region a to the winding region B. The coil wire is wound around the upper layer winding frame, as in the second layer 17. 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, as shown in fig. 18, the third layer 18 is bent upward in the axial direction (step S16). Specifically, in the same manner as in the step of bending the second layer 17 (S13), the third layer 18 is inclined radially inward in the axially upper direction in the bending region C. By performing the above-described step (S16), the third layer 18 having the inclined portion 14 can be formed as the upper-layer bending coil bundle.

In the above-described steps (S11 to S16) of forming the first layer 16 to the third layer 18 having the upper side folded, the plurality of spacers 120 are moved in the radial direction about the single axis T. Each of the partitions 120 is moved in a radial direction by a rotational motion.

In the step of folding the second layer 17, the first layer 16, and the third layer 18 (S13, S14, S16), a passing portion 15 (see fig. 4) having a width smaller than the opening width of the notch opening is provided in each inclined portion 14. The passing portion 15 is formed by compression. In the present embodiment, the passing portion 15 is compressed so that the gap between the coil wires becomes smaller in the radial direction and the axial direction. At least a part of the passing portions 15 of the layers 16 to 18 overlap each other when viewed in the axial direction.

Next, the lower side of the coil bundle is compressed (step S17). That is, in the coil bundle, the coil wire wound around the body 110 is compressed. Specifically, as shown in fig. 6, the circumferential width L2 of the coil wire wound around the side winding surface 112 is matched to the circumferential width of the slot 21. The radial length L3 of the coil wire wound on the side winding surface 112 is matched to the radial length of the slot 21.

In this way, the axial sectional shape of the coil wire wound around the body 110 is compressed so as to be changed to the axial sectional shape of the slit 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 becomes 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.

The compression is performed using, for example, the pressing member 115. 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. 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. 4 and 19 can be formed. According to the present embodiment, the coil wire spanning between the main body 110 and the separator 120 can be sandwiched from the circumferential inner side and the circumferential outer side by the plurality of blades 131, 132, so that the separator 120 is located radially inward with respect to the main body 110. This makes it possible to form the inclined portion 14 inclined with respect to the body portion of the coil bundle 10 wound around the body 110 at a position above the body portion. Therefore, the main body portion of the coil bundle 10 can be inserted into the slot 21, and the inclined portion 14 of the coil bundle 14 can be inserted into the slot 21 from the slot opening 22. For example, the space factor of the stator can be increased by compressing the body portion.

In the coil side 11 of the insertion slit 21 of the coil bundle formed as described above, as shown in fig. 20, 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 along 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 lines are arranged in the radial direction. In six circumferential rows in fig. 18, the first layer 16, the second layer 17, and the third layer 19 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, S15) of forming the first layer 16, the second layer 17, and the third layer 18 of the present embodiment, as shown in fig. 21, 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 addition, fig. 21 schematically shows a portion where one cutout groove 21 is inserted.

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 (S17), 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. 22, 23, and 25 show only a part of the upper and lower surfaces of the stator core 20 in order to show the slots into which the coil bundles are inserted. As shown in fig. 22, 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. The blades holding the coil bundle are not particularly limited, but the blades 131 and 132 of the winding die 100 are used. Specifically, the blades 131 and 132 used in the holding step (S20) are used in the step (S13, S15, S18) of bending one side of the coil bundle. 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. 23, 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 132. The blades 131 and 132 are disposed radially outward of the coil moving mechanism 150, which will be described later.

Insertion slot

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. 22, the meander 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. 23, 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 to move the coil moving mechanism 150 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 inside to the outside in the radial direction 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 uninserted portion of the coil bundle not inserted into the slit

As shown in fig. 23, 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. 24, 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. 23 and 24, 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 along 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 along 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. 23 and 24, 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. The compression apparatus 200 will be described with reference to fig. 24.

The compressing device 200 includes a first clamp 210, a second clamp 220, a third clamp 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 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 made square. The cross-sectional shape of the round wire is deformed by compression, 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 (S17) is performed, but one of the step of compressing (S17) 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 S17) of the step of forming the coil bundle (S10). Further, the step of compressing (step S17) 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 bent coil bundle is deformed to the original shape. Specifically, the inclined portions 14 of the respective layers are rotated upward in the direction of the arrow shown in fig. 25 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. 25, 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 on a portion of the coil bundle located below the slit 21. A force directed radially outward can be applied to the lower end portion and the upper end portion of the coil bundle by the coil stoppers 160. Therefore, the coil bundle can be easily inserted into the slit 21.

In the step (S50), as shown in fig. 25, 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.

Accommodated in the slot

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), of the rows shown in fig. 20, the row that overlaps the notch opening 22 at the circumferential position within the notch 21 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. 26, two rows of the inclined portions of the third layer 18 are accommodated in the slits 21 on one side (upper side in fig. 26) 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. 27, two rows of the inclined portions of the first layer 16 are accommodated in the other circumferential side (lower side in fig. 27) 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. 28, two rows of the inclined portions of the second layer 17 are housed 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 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.

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. 29, the difference between the radial length L4 of the plurality of coil wires and the radial length L5 of the slot divided by a natural number is smaller than the diameter of the coil wire. The difference between the radial length L4 of the plurality of coil wires and the maximum value of the radial length L5 of the slot 21 divided by a natural number may be smaller than the diameter of the coil wire. The length L4 is the radial length of the plurality of coil wires wound simultaneously. The natural number is the maximum value of the number of times the coil wire is wound at the same time. In the central portion except for both ends in fig. 27 to 29, ten coil wires are wound in two times in the radial direction on the inner side and the outer side at the same time, and therefore the natural number is 2.

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 shown in fig. 1 can be manufactured. In the present embodiment, the plurality of coil wires are moved in the radial direction of winding of the winding surfaces while the plurality of coil wires are wound around at least one of the first winding surface facing the upper side in the axial direction of the winding jig 100 (the upper winding surface 121 of the separator 120) and the second winding surface facing the lower side (the lower winding surface 111 of the main body 110). According to the present embodiment, a plurality of coil wires can be wound around the winding die 100 at the same time. Then, when the coil wire is wound around at least one of the first winding surface on the upper side and the second winding surface on the lower side in the axial direction of the winding die 100, the radial position is moved. That is, the coil wires cross at the coil side end of at least one of the upper side and the lower side in the axial direction. Thus, when the coil wire is wound around the winding surface (the side winding surface 112 of the main body 110) extending in the axial direction, the radial position does not need to be moved. Therefore, the coil bundles inserted into the slit 21 are aligned such that the coil wires do not cross. Therefore, the space factor of the stator can be increased.

(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 third 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. 9.

(modification 2)

In the above embodiment, the axial positions of the axially lower sides of the coil bundles 10 are aligned, but the present invention is not limited to this. 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 layer 16 to the third layer 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 coil bundle having a plurality of layers at different axial positions is 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 step of bending the upper side of the coil bundle (S13, S14, S16) is performed, but the step of bending (S13, S14, S16) may be omitted. In this case, in the step of inserting (S30), the annular bundle of coils that is not bent is inserted into the slot 21.

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 a support member; 150 coil moving mechanism; 160 a coil limit piece; 200 a compression device; 210. 220, 230 clamps; 240 a connecting member; a, avoiding a region; a winding area B; a C-bend region.