JP2008005674A - Method for manufacturing winding assembly of rotating electrical machine - Google Patents

Abstract

An improved method of manufacturing a winding assembly for a rotating electrical machine capable of preventing unnecessary deformation from occurring in first and second parallel straight portions in a displacement step.
In the displacement step, a first blade that holds the intermediate portion of the first straight portion over substantially the entire length thereof and a second blade that holds the intermediate portion of the second straight portion over the substantially entire length thereof are used. The first blade and the second blade are rotated in opposite directions to form the first and second parallel straight portions. In addition, a holding jig for holding each winding member in the winding process is also used.
[Selection] Figure 4

Description

  The present invention relates to a method for manufacturing a winding assembly of a rotating electrical machine used in a vehicle AC generator mounted on a vehicle such as a passenger car or a truck.

  The applicant of this application previously described a method for manufacturing a winding assembly of this type of rotating electrical machine in Japanese Patent Laid-Open No. 2002-176552 (Patent Document 1) and International Publication No. WO 2005 / 074105A1 (Patent Document 2). The method disclosed in the international application was proposed. In these patent documents 1 and 2, the manufacturing method of the winding assembly of the rotary electric machine including a winding process and a displacement process is proposed. In the winding step, a plurality of winding members are formed by continuously bending a plurality of wires. In this winding step, each of the plurality of winding members is wound so as to have a first turn portion, a second turn portion, a first straight portion, and a second straight portion. The first straight portion extends obliquely from the first turn portion toward the second turn portion, and connects the first turn portion and the second turn portion. The second straight portion extends obliquely from the second turn portion toward the first turn portion, and connects the second turn portion and the first turn portion. The displacement process is performed after the winding process. In this displacement step, the first straight line portion of each winding member has a first parallel straight line portion at the intermediate portion thereof, and each second straight line portion has a second parallel straight line portion at the intermediate portion thereof. The second parallel straight portions are displaced so as to be substantially parallel to each other. The first and second parallel straight portions are inserted into different slots of the iron core of the rotating electrical machine.

  Patent Document 1 proposes a method of simultaneously winding a plurality of wires in a spiral using a pair of plate-shaped cores in a winding process. In the winding process of Patent Document 1, a plurality of wires are spirally wound around the pair of plate-like cores, and a plurality of first and second turn portions and a plurality of first and second straight portions are provided. Winding members are formed simultaneously. In Patent Document 2, a rotating block, a turn mechanism having a fixed block, and a wire rod feeding mechanism are used in the winding process. In the winding process of Patent Document 2, in a state where a plurality of wires are fed onto the rotating block by the wire feeding mechanism, the rotating block is held until the plurality of wires are sandwiched between the rotating block and the fixed block. By repeating the rotating operation, a plurality of winding members having first and second turn portions and first and second straight portions are formed at the same time.

  In Patent Documents 1 and 2, in the displacement step, the upper ends of the intermediate portions of the first and second straight portions of the winding members are displaced by the pins in directions away from each other and in opposite directions, and at the same time The lower end portions of the intermediate portions of the first and second linear portions of the winding members are also displaced by the pins in directions away from each other and in opposite directions. Due to the displacement of the first and second straight portions, a first parallel straight portion is formed in the middle portion of the first straight portion, and a second parallel straight portion is formed in the middle portion of the second straight portion.

Japanese Patent Laid-Open No. 2002-176552 International application of international publication number WO2005 / 074105

  However, in the displacement process of Patent Documents 1 and 2, the first and second linear portions of each winding member are displaced by pins at the upper and lower ends of the respective intermediate portions. Since the intermediate portion between the first and second parallel straight line portions is not regulated, unnecessary deformation may occur, and the linearity of the first and second parallel straight line portions and the situation where the parallelism thereof cannot be ensured. For this reason, there is an inconvenience that the subsequent processes including the displacement process are hindered.

  Further, in the winding process and the end stage of the winding process of Patent Documents 1 and 2, the shape of each winding member wound in the winding process is broken, for example, the pitch between the first turn parts, the second turn part Unnecessary changes occur in the pitch between each other and the dimension between the first and second turn portions, and there is also a disadvantage that troubles occur in subsequent processes including the displacement process.

  The present invention proposes an improved method of manufacturing a winding assembly for a rotating electrical machine that can prevent unnecessary deformation of the first and second parallel straight portions in the displacement step.

The present invention also proposes an improved method of manufacturing a winding assembly for a rotating electrical machine that can prevent the winding member from being subjected to unnecessary deformation even after the end of the winding step and the winding step, as well as the displacement step. To do.

  A manufacturing method of a winding assembly of a rotating electrical machine according to the present invention includes a winding step of winding a plurality of winding members constituting the winding assembly of the rotating electrical machine, and a displacement step after the winding step, In the winding step, each of the plurality of winding members includes a first turn part, a second turn part, and a first part that extends obliquely from the first turn part toward the second turn part and connects them. The first winding portion is wound so as to have a straight portion and a second straight portion extending obliquely from the second turn toward the first turn portion and connecting them. The straight portion has a first parallel straight portion at an intermediate portion thereof, and the second straight portion of each of the winding members has a second parallel straight portion at an intermediate portion thereof, and the first parallel straight portion and the first parallel straight portion. The first and second portions are arranged so that two straight parallel portions are substantially parallel to each other. A method of manufacturing a winding assembly of a rotating electrical machine that displaces a wire portion, wherein in the displacement step, a first blade that holds an intermediate portion of the first straight portion over substantially the entire length thereof, and a second straight portion Using a second blade that holds the intermediate portion over substantially its entire length, and rotating the first blade and the second blade in opposite directions to form the first and second parallel straight portions; Features.

The method for manufacturing a winding assembly of a rotating electrical machine according to the present invention is further characterized in that in the winding step, each winding member is held using a holding jig.
The method for manufacturing a winding assembly of a rotating electrical machine according to the present invention is characterized in that each winding member is held using the holding jig even at the end of the winding process.

  In the method of manufacturing a winding assembly for a rotating electrical machine according to the present invention, in the displacement step, the first blade that holds the intermediate portion of the first straight portion over substantially the entire length thereof, and the intermediate portion of the second straight portion is substantially In this displacement step, the second blade that is held over the entire length is used, and the first blade and the second blade are rotated in opposite directions to form the first and second parallel straight portions. Unnecessary deformation can be prevented from occurring in the first and second parallel straight line portions, and the linearity of the first and second parallel straight line portions and the situation where the parallelism thereof cannot be ensured are eliminated, and the displacement step The subsequent manufacturing process including can be made more efficient.

  Further, in the case of holding each winding member by using a holding jig in the winding process, unnecessary deformation of each winding member in the winding process can be prevented, and also at the end stage of the winding process. In the case of holding each winding member using the holding jig, the holding jig can prevent unnecessary deformation of each winding member even at the transition stage between the winding process and the displacement process. it can.

  Several embodiments of the present invention will be described below with reference to the drawings.

  Before describing a method for manufacturing a winding assembly of a rotating electrical machine according to the present invention, a rotating electrical machine using the winding assembly manufactured according to the present invention will be described. FIG. 1 is a cross-sectional view illustrating an example of the rotating electrical machine, and FIG. 2 is a perspective view illustrating a stator assembly of the rotating electrical machine.

  A rotating electrical machine 1 shown in FIG. 1 is a vehicle AC generator mounted on various vehicles such as a passenger car and a truck, and is used for charging a battery mounted on the vehicle and supplying power to various electric loads mounted on the vehicle. Is done. The rotating electrical machine 1 includes a rotating shaft 2, a pair of brackets 3A and 3B, a rotor assembly 4, a rectifier assembly 7, and a stator assembly 8. The rotor assembly 4 includes a pair of rotor cores 4A and 4B and a field coil 5. The field coil 5 is excited through a pair of slip rings 6A and 6B disposed on the rotating shaft 2 and a pair of brushes 6C and 6D that are in contact therewith. The rotating shaft 2 is rotatably supported by a pair of brackets 3A and 3B via bearings 3a and 3b, and is driven by an engine mounted on the vehicle.

  The stator assembly 8 includes a stator core 9 and a winding assembly 10. The stator core 9 is formed in an annular shape as shown in FIG. 2, and a large number of slots 9s and a large number of teeth 9t are formed on the inner periphery at equal intervals. Each slot 9 s is formed between two adjacent teeth 9 t and extends in a direction parallel to the rotation axis 2. A winding assembly 10 is attached to the stator core 9. The winding assembly 10 includes a plurality of winding members 15, and these winding members 15 are inserted into the slots 9s. The winding assembly 10 is an armature winding assembly of the rotating electrical machine 1. When the rotor assembly 4 is driven by the engine, the rotor assembly 4 generates a rotating magnetic field, and an alternating voltage is generated in the winding assembly 10 based on the rotating magnetic field. This AC voltage is converted into a DC voltage by the rectifier assembly 7 and supplied to the battery and various electric loads.

  The manufacturing method of the winding assembly of the rotating electrical machine according to the present invention is a manufacturing method of the winding assembly 10 of the stator assembly 8 in the rotating electrical machine 1 shown in FIGS.

Embodiment 1 FIG.
The method of manufacturing a winding assembly for a rotating electrical machine according to the present invention includes a winding step TN, a displacement step FM, a pressing step PS, and an insertion step IS, and these steps TN, FM, PS, IS are executed in that order. The winding assembly 10 of the rotating electrical machine 1 is manufactured. Since the first embodiment is characterized by a displacement process FM subsequent to the winding process TN, this displacement process FM will be mainly described.

First, the winding process TN will be described. In this winding step TN, a plurality of wire rods are wound at the same time to form a winding assembly _10TN including a plurality of winding members _15TN . A plurality of windings member 15 _TN is formed by winding a respective wire a plurality of, the winding assembly 10 _TN is formed by the plurality of windings member 15 _TN. In this winding step TN, for example, a winding assembly _10TN shown in FIG. 3 is formed. Figure 3 is a front view showing a winding assembly 10 _TN formed by winding step TN. The winding assembly _10TN shown in FIG. 3 is composed of a plurality of winding members _15TN , specifically, 12 winding members _15TN .

In the winding assembly _10TN shown in FIG. 3, drawer end portions 18a to 18d are formed at the left and right ends at the same time. Leading end portion 18a, 18b is formed on the left end portion of the winding assembly _{10 TN.} Leading end portion 18a is a winding start portion of the six winding member in the twelve winding member 15 _TN, it extends to the upper side of the winding assembly 10 _TN, leading end portion 18b and the remaining 6 a winding start end portion of the winding member, and extend to the lower side of the winding assembly 10 _TN. Leading end portion 18c, 18 d are formed on the right end of the winding assembly _{10 TN.} Leading end portion 18c is a winding end portion of the six winding member in the twelve winding member 15 _TN, it extends to the upper side of the winding assembly 10 _TN, leading end portion 18d and the remaining 6 a winding end portion of the winding member, and extend to the lower side of the winding assembly 10 _TN.

This winding assembly _10TN is formed by the winding process described in FIGS. 5 to 10 of Patent Document 2, for example. In particular, a method for manufacturing the winding assembly 10 _TN having the drawer end portions 18 a to 18 d is described in FIGS. 23 to 25 of Patent Document 2 and the fourth embodiment corresponding thereto. The winding assembly _{10 TN} is twelve winding member _{15 TN} drawer end 18a, after the formation of the 18b, simultaneously turning several times repeated winding 12 of the winding member _{15 TN,} then the leading end portion 18c and 18d are formed.

Now, the dotted line in FIG. 4 shows one winding member _{15 TN} in the central portion of the winding assembly _{10 TN} shown in Fig. A winding member _15TN indicated by a dotted line in FIG. 4 is one winding member formed in the winding step TN.

In the winding step TN, 12 winding members _15TN are formed as shown by dotted lines in FIG. Each winding member _{15 TN} of the winding assembly _{10 TN} formed by winding step TN, as shown by the dotted line in FIG. 4, a plurality of first turn part 15D, and a plurality of second turn portion 15C, A plurality of first straight portions 15A and a plurality of second straight portions 15B are provided. Each first turn portion 15D is located on the lower side of the winding member _{15 TN,} the second turn portion 15C is located on its upper side. Each first linear portion 15A extends obliquely from the first turn portion 15D toward the second turn portion 15C and connects them. Each second straight portion 15B extends obliquely from the second turn portion 15C toward the first turn portion 15D and connects them. The winding member _15TN indicated by a dotted line in FIG. 4 reaches the second turn portion 15C from the first turn portion 15D through the first straight portion 15A, and further passes through the second turn portion 15C through the second straight portion 15B. It is wound so as to repeat the unit loop returning to the turn part 15D.

Although only one winding member _15TN is shown in FIG. 4, the other eleven winding members _15TN are also wound in the same shape and in parallel therewith. Two adjacent first linear portion 15A of the winding member _{15 TN} indicated by the dotted line, 15A between the respective first linear portions 15A of the other eleven winding member _{15 TN} is parallel, also shown in dotted lines winding member _{15 TN} two adjacent second linear portions 15B, between 15B, similarly the second linear portion 15B of the other eleven winding member _{15 TN} is parallel. Similarly, between the two first turn portion 15D adjacent winding member 15 _TN indicated by the dotted line, first turn portion 15D of the other eleven winding member 15 _TN is parallel, also shown in dotted lines winding member _{15 TN} two adjacent second turn portion 15C, between 15C, the second turn portion 15C of the other eleven winding member _{15 TN} is parallel. Each first linear portion 15A of each winding member _{15 TN} is located in the first plane, and each second straight portion 15B of each winding member _{15 TN} is located in a second plane parallel to said first plane.

After the winding process TN, the displacement process FM is executed. This displacement step FM, winding the first linear portion 15A of each winding member _{15 TN} in wound winding assembly _{10 TN} in step TN and the second linear portion 15B, as shown by the solid line in FIG. 4 Displace. A winding member 15 _FM indicated by a solid line in FIG. 4 is a winding member configured in the displacement step FM. Although FIG. 4 shows only one winding member 15 _FM displaced in the displacement step, the other 11 winding members 15 _FM are similarly displaced.

In the winding member 15 _FM shown by a solid line in FIG. 4, the first straight portion 15A has a first parallel straight portion 15a1 and inclined portions 15a2, 15a3, and the second straight portion 15B has a second parallel straight portion 15b1 and an inclined portion. 15b2 and 15b3 are displaced so that each first turn portion 15D and each second turn portion 15C approach each other. In each winding member 15 _FM , each first parallel straight line portion 15a1 and each second parallel straight line portion 15b1 are substantially parallel to each other. The first parallel straight portions 15a1 and the second parallel straight portions 15b1 are inserted into the slots 9s of the stator core 9 substantially in parallel with each other in a later insertion step IS.

  The inclined portions 15a2 and 15a3 are continuous above and below the first parallel straight portion 15a1, and the inclined portion 15a2 is located between the first parallel straight portion 15a1 and the second turn portion 15C and is continuous therewith, and the inclined portion 15a3. Is between the first parallel straight line portion 15a1 and the first turn portion 15D and is continuous therewith. The inclined portions 15b2 and 15b3 are continuous above and below the first parallel straight portion 15b1, and the inclined portion 15b2 is between the first parallel straight portion 15b1 and the second turn portion 15C and is continuous therewith, and the inclined portion 15b3. Is between the first parallel straight line portion 15b1 and the first turn portion 15D and is continuous therewith.

In the displacement step FM, a plurality of first blades 101A, a plurality of second blades 101B, a first restriction jig 102D, and a second restriction jig 102C shown in FIG. 4 are used. Each of the plurality of first blades 101A, arranged to hold over the intermediate portion 15a of each of the first linear portion 15A in the winding process TN winding member 15 _TN formed with its entire length, and a plurality of each of the second blade 16B, are arranged to hold over an intermediate portion 15b of the respective second linear portions 15B in the winding process TN winding member 15 _TN formed with its entire length. The intermediate portion 15a of each first straight portion 15A is a portion that is displaced to become the first parallel straight portion 15a1, and the intermediate portion 15b of each second straight portion 15B is displaced to be the second parallel straight portion 15b1. This is the part.

  Each first blade 101A is rotated counterclockwise by the drive bars 103A1 and 103A2 as the rotation center Pa in a state where the intermediate portion 15a of each first linear portion 15A is held by the drive bars 103A1 and 103A2. By this rotation, the intermediate portion 15a of the first straight portion 15A is displaced to the first parallel straight portion 15a1. The rotation center Pa is an intermediate point of the intermediate portion 15a of each first linear portion 15A. Each of the second blades 101B is rotated clockwise around the rotation center Pb while holding the intermediate portion 15b of each of the second linear portions 15B by the drive bars 103B1 and 103B2. The intermediate portion 15b of the second straight portion 15B is displaced to the second parallel straight portion 15b1. The rotation center Pb is an intermediate point of the intermediate portion 15b of each second linear portion 15B. These first and second blades 101A and 101B are rotated in the opposite directions at the same time.

First regulating jig 102D is the outer periphery of the first turn part 15D of the formed by winding process TN winding member _{15 TN} contact, and the second regulating jig 102C is the winding member _{15 TN} It arrange | positions so that it may contact | abut on the outer periphery of each 2nd turn part 15C. The first restricting jig 102D and the second restricting jig 102C move toward each other with the rotation of the first and second blades 101A and 101B, and the first and second turn portions Move 15C and 15D slightly closer together.

  Due to the rotation of the blades 101A and 101B and the movement of the restricting jigs 102C and 102D, the first straight portion 15A is displaced so as to have the first parallel straight portion 15a1 and the inclined portions 15a2 and 15a3, and the second straight portion. 15B is displaced so as to have the second parallel straight portion 15b1 and the inclined portions 15b2 and 15b3. In this displacement step FM, the first blade 101A holds the intermediate portion 15a of the first straight portion 15A over substantially the entire length, and the second blade 101B holds the intermediate portion 15b of the second straight portion 15B with the substantially full length. Therefore, unnecessary deformation does not occur in the first and second parallel straight portions 15a1 and 15b1 formed in the displacement step FM. Therefore, the subsequent processes including the displacement process FM can be performed without hindrance.

FIG. 5 shows the relationship between the blades 101A and 102B and the drive bars 103A1, 103A2, 103B1, and 103B2. In FIG. 5, the winding member ₁₅ TN, _{15 FM} is omitted are omitted, also the restricting jigs 102C, even 102D. The drive bars 103A1, 103A2, 103B1, and 103B2 are arranged in parallel to each other so as to extend in parallel with the straight line AA connecting the rotation centers Pa and Pb of the blades 101A and 101B, and in parallel with the straight line AA. Driven to move. The drive bars 103A1 and 103B1 are arranged on the upper side of the straight line AA, and the drive bars 103A2 and 103B2 are arranged on the lower side thereof. Each blade 101A is rotatably connected to the drive bar 103A1 by a pin 101a1, and is rotatably connected to the drive bar 103A2 by a pin 101a2. Each blade 101B is rotatably connected to the drive bar 103B1 by a pin 101b1, and is rotatably connected to the drive bar 103B2 by a pin 101b2.

  In FIG. 5, the drive bar 103A1 is driven to move in the left direction, and the drive bar 103A2 is driven to move in the right direction in synchronization with the drive bar 103A1. Based on the driving of the drive bars 103A1 and 103A2, each blade 101A rotates counterclockwise about the rotation center Pa, displaces each first straight portion 15A1, and the first parallel straight portion 15a1 and the inclined portion. 15a2 and 15a3 are formed. The drive bar 103B1 is driven to move in the right direction in synchronization with the drive bars 103A1 and 103A2, and the drive bar 103B2 is driven to move in the left direction in synchronization with the drive bar 103B1. . Based on the drive of the drive bars 103B1 and 103B2, each blade 101B rotates clockwise about the rotation center Pb, displaces each second linear portion 15B1, and the first parallel linear portion 15b1 and the inclined portion 15b2. , 15b3.

FIG. 6 shows the blades 101A and 101B. 6A is a plan view, FIG. 6B is a front view, and FIG. 6C is a side view. Each of the blades 101A and 101B is basically configured in the same manner, and has a pair of side walls 104 and 105 facing each other on the upper part. A holding groove 106 is formed between the side walls 104 and 105, and this holding is performed. Two pin holes 107 a and 107 b are formed along the groove 106. Holding groove 106 holds over the intermediate portion 15a1,15b1 of the linear portion 15A1,15B1 of each winding member _{15 TN} its entire length.

The side wall surface 104a of the side wall 104 is formed to be slightly inclined with respect to the blade center line AA, and an arc surface 104b is formed at the right end portion thereof. The side wall surface 105a of the side wall 105 is formed in parallel with the side wall surface 104a, and an arcuate surface 105b is formed at the left end portion thereof. Holding groove 106 is formed between the side wall surface 104a and the side wall surface 105a, the groove width is substantially equal size as the diameter of the wire constituting the winding member _{15 TN,} linear portion of each winding member _{15 TN} 15A1 , 15B1 intermediate portions 15a, 15b fit snugly and are held over their entire length. The pins 101a1 and 102a2 or the pins 101b1 and 101b2 are fitted into the pin holes 107a and 107b. The circular arc surfaces 104b and 105b function to smoothly bend the bent portions between the parallel straight portions 15a1 and 15b1 and the inclined portions 15a2, 15a3, 15b2 and 15b3 adjacent thereto.

Manufacturing method of Embodiment 1 As described above, in the displacement step FM, the first blade 101A that holds over the intermediate portion 15a of the first linear portion 15A of each winding member _{15 TN} its entire length, each winding member 15 Using the second blade 101B that holds the intermediate portion 15b of the second straight portion 15B of the _TN over its entire length, the first blade 101A and the second blade 101B are rotated in opposite directions to each other, Since the second parallel straight portions 15a1 and 15b1 are formed, unnecessary deformation of the first and second parallel straight portions 15a1 and 15b1 can be prevented, and the subsequent processes are also efficient without causing any trouble due to the deformation. There is an effect that can be manufactured.

In the pressing step PS, after the displacement step FM, a first plane winding member ₁₅ each of the first parallel straight portion 15a1 of the _TN is present, and the second plane of the second parallel straight portions 15b1 exists The winding assembly 10 _FM is pressed so as to approach each other. In the insertion process IS, the winding assembly 10 constituted by the pressing process PS is inserted into each slot 9 s of the stator core 9 of the rotating electrical machine 1.

Embodiment 2. FIG.
The method of manufacturing a winding assembly for a rotating electrical machine according to the second embodiment of the present invention further improves the winding process TN so as to prevent unnecessary deformation of each winding member _15TN in the winding process TN. is there. In the second embodiment, the displacement process FM is executed in the same manner as in the first embodiment, and unnecessary deformation of the winding member 15 _FM in the displacement process FM is also prevented.

In the manufacturing method according to the second embodiment, for example, a winding machine 20 shown in FIG. 7 is used in the winding step TN. This winding machine 20 is disclosed in FIG. FIG. 7A is a plan view of the winding machine 20, and FIG. 7B is a side view thereof. This winding machine 20 has a turn mechanism 30 and a wire feed line SL, and simultaneously winds all 12 wires constituting the winding assembly 10 in a spiral form to form a winding assembly _10TN . To do. This winding assembly _10TN is composed of 12 winding members _15TN . The wire feed line SL feeds 12 wires in parallel to each other toward the turn mechanism 30.

The turn mechanism 30 includes a rotating body 31, a rotating block 33, a fixed block 40, and an auxiliary block 50. The turn mechanism 30 includes a rotation drive mechanism 32 that rotates the rotating body 31 around the rotation axis LL, and an axis movement mechanism 39 that moves the rotation body 31 along the rotation axis LL. The rotational drive mechanism 32 intermittently rotationally drives the rotating body 31 around the rotation axis LL in the directions of arrows A1 and A2. The rotation in the direction of arrow A1 is called normal rotation, and the rotation in the direction of arrow A2 is called reverse. Arrow A1 direction of normal rotation of the rotating body 31, the rotating block 33 is rotated forward in the arrow A1 direction to form a first turn portion 15D and the second turn portion 15C to the winding member _{15 TN.} The axial movement mechanism 39 reciprocates the rotating body 31 along the rotation axis LL in a reciprocating manner with a slight dimension intermittently in the directions of the arrows B1 and B2 in parallel with the rotation axis LL. The reciprocating motion with slight dimensions in the directions of the arrows B1 and B2 adjusts the shapes of the first turn portion 15D and the second turn portion 15C.

  The rotating block 33 is arranged on one side of the rotating body 31 so as to rotate together with the connecting body 34. The rotating block 33 rotates on one side of the rotating body 31 and forms a rotating space 35 on one side of the rotating body 31. The rotating block 33 has a rotating surface 36 facing the rotating space 35 on its upper surface. 7 (a) and 7 (b), the rotation block 33 is shown in the original position, and in this original position, the rotation surface 36 extends horizontally from the position slightly below the rotation axis LL to the right. On the plane EE.

  Guide grooves 37 for guiding 12 wires supplied from the wire supply line SL are formed on the rotation surface 36 of the rotation block 33 in parallel with each other. The guide groove 37 is formed in parallel with the wire feeding line SL. A circular arc surface 38 is formed at the inner end of the rotation surface 36 located near the rotation axis LL. Each guide groove 37 opens upward when the rotary block 33 is in the original position. The bottom surface of the guide groove 37 is positioned on a plane including the wire feeding line SL when the rotary block 33 is at the original position.

  Twelve wires for constituting the winding assembly 10 are supplied on a feeding line SL of 12 wires. The twelve wire feeding lines SL are set in parallel to each other and at equal intervals. These wire feeding lines SL are set in a direction inclined by a predetermined angle α, for example, 60 degrees with respect to the rotation axis LL. Further, these feed lines SL are set on a plane parallel to the first reference plane EE, slightly below the first reference plane EE.

  The fixed block 40 is fixed in the rotation space 35 by a fixed base (not shown). The fixed block 40 has a first surface 41 and a second surface 42 that face each other and are parallel to each other. The first surface 41 extends in the horizontal direction in the right direction on a plane including the wire supply line SL slightly below the rotation axis LL. The first surface 41 is formed with twelve guide grooves 43 extending in parallel with the wire feed line SL, and the guide grooves 43 open downward. The bottom surface above the guide groove 43 is located on the first reference plane EE. The second surface 42 of the fixed block 40 extends horizontally right from slightly above the rotation axis LL, and constitutes a second reference surface FF parallel to the first reference surface EE.

  A molding surface 44 is formed at the end of the first surface 41 and the second surface 42 on the rotation axis LL side. The molding surface 44 is formed in a semicircular shape around the rotation axis LL, and the molding surface 44 swells toward the rotation surface 36. The molding surface 44 is between the first surface 41 and the second surface 42, and specifically, is formed between the first reference surface EE and the second reference surface FF. The molding surface 44 is extended along the rotation axis LL, and is opposed to the arc surface 38 formed at the inner end portion of the rotation block 33 at all portions in the extending direction, and a gap 45 is formed therebetween. is doing.

  The auxiliary block 50 is disposed to face the first surface 41 of the fixed block 40. The auxiliary block 50 has an auxiliary surface 51 that faces the first surface 41, and the auxiliary surface 51 is in contact with or close to the first surface 41. The auxiliary surface 51 prevents the wire fed to each guide groove 43 of the first surface 41 from dropping off. The twelve wires are intermittently supplied along the supply line SL. Each wire is supplied to a guide groove 43 formed on the first surface 41 of the fixed block 40 and further supplied to a guide groove 37 formed on the rotary surface 36 of the rotary block 33 at the original position.

In the winding step TN, the winding assembly _10TN is formed by repeating a unit cycle including the wire rod feeding step S1 and the wire rod turn step S2 a plurality of times. In each unit cycle, the wire feeding step S1 and the wire turning step S2 are executed in that order.

In one unit cycle, the first turn portion 15D of each winding member _{15 TN} is formed. In this unit cycle, the wire rod feeding step S1 is first executed. In this wire feeding step S1, the rotary block 33 is at the original position. In the wire rod feeding step S1, each wire rod is supplied along the feed line SL by a predetermined length by a wire rod feed mechanism (not shown). Each wire is supplied to a guide groove 43 formed on the first surface 41 of the fixed block 40 and further supplied to a guide groove 37 formed on the rotary surface 36 of the rotary block 33 at the original position. Following the wire feeding step S1, a wire turning step S2 is performed. In the wire rod turning step S2, the rotating block 33 is driven to rotate forward by the rotation driving mechanism 32 in a state where the wire rod is supplied to the guide groove 37 of the rotating surface 36, and each wire rod is bent along the molding surface 44 to be fixed blocks. Press against the second surface 42 of 40. By this operation, at the same time to form the first turn portion 15D of each winding member _{15 TN.} At the end of this wire rod turning step S2, the rotary block 33 is reversely driven by the rotary drive mechanism 32 and returned to the original position. When the rotary block 33 is driven forward, the axial motion mechanism 39 drives the rotary block 33 by a slight dimension in the direction of arrow B1, and when the rotary block 33 is driven in reverse, the rotary block 33 is moved in the direction of arrow B2. Only a few dimensions are driven. The shape of the first turn portion 15D is adjusted by a slight movement of the rotating block 33 in the directions of the arrows B1 and B2.

The following unit cycle, the second turn portion 15C of each winding member _{15 TN} is formed. In this unit cycle, the wire rod feeding step S1 is executed again. In this wire rod feeding step S1, each wire rod is again fed along the feed line SL by a predetermined length again by a wire rod feed mechanism (not shown). Each wire is supplied to a guide groove 43 formed on the first surface 41 of the fixed block 40 and further supplied to a guide groove 37 formed on the rotary surface 36 of the rotary block 33 at the original position. Subsequent to the wire feeding process S1, the wire turning process S2 is executed again. In the second wire rod turning step S <b> 2, the rotating block 33 is driven to rotate forward with the wire rod supplied to the guide groove 37 of the rotating surface 36, and each wire rod is bent along the molding surface 44. Press against the second surface 42. By this operation, at the same time to form a second turn portion 15C of each winding member _{15 TN.} At the end of the first wire rod turning step S2, the rotary block 33 is driven in reverse and returned to the original position. When the rotary block 33 is driven forward, the axial motion mechanism 39 drives the rotary block 33 by a slight dimension in the direction of arrow B1, and when the rotary block 33 is driven in reverse, the rotary block 33 is moved in the direction of arrow B2. Only a few dimensions are driven. The shape of the first turn portion 15C is adjusted by a slight movement of the rotating block 33 in the directions of the arrows B1 and B2. Thus, the winding member _15TN is wound spirally by repeating the unit cycle a plurality of times sequentially.

  In the second embodiment, the holding jig 110 shown in FIGS. 8A and 8B is used in the winding step TN. The holding jig 110 includes a center bar 111, a pair of holding bars 112 and 113, and a plurality of links 115. The pair of holding bars 112 and 113 are arranged parallel to the central bar 111 and on both sides thereof, and face each other. The pair of holding bars 112 and 113 are connected to the center bar 111 by a plurality of links 115, and the distance between them can be changed on both sides of the center bar 111 in a state parallel to the center bar 111.

The holding bars 112 and 113 can take a first state approaching each other and a second state away from the first state. The first state is shown in FIG. This first state is a narrow state in which the holding bars 112 and 113 are closest to each other as shown in FIG. 8A, and each link 115 is inclined as shown in FIG. The holding bars 112 and 113 are in a state of being pulled toward the center bar 111. The second state is shown in FIG. In this second state, the holding bars 112 and 113 are in the widest state where they are farthest from each other. In this second state, each link 115 rotates to a position orthogonal to the center bar 111, and the holding bars 112 and 113. Is moved away from the center bar 111. First state, i.e. in the narrow state, the holding jig 110 is the interior movable state of each winding member 15 _TN being sequentially wound. A second state, that is, in the wide state, the holding bars 112, 113 of the holding jig 110 holding the first turn portion 15D and the second turn portion 15C from the inside of each winding member _{15 TN,} each winding member _{15 TN} Prevent unnecessary deformation.

A plurality of pin-shaped protrusions 112 a and 113 a are provided on the outer end surfaces of the holding bars 112 and 113. The pin-like protrusions 112a and 113a are arranged along the outer end surfaces of the holding bars 112 and 113 at equal intervals. The interval between the pin-shaped protrusions 112a and 113a is an interval that can be held by sandwiching the first turn portions 15D and the second turn portions 15C of all the winding members _15TN formed in the winding step TN. .

The FIG. 8 (b), the finished winding assembly 10 _TN winding process TN is indicated by two-dot chain line. The holding jig 110 is also used in the winding assembly 10 _TN that has finished the winding process TN, and the winding member 10 _TN is used to prevent unnecessary deformation of the winding assembly 10 _TN that has finished the winding process _TN. Hold. Winding assembly 10 _TN shown in FIG. 8 (b), but then is shifted to the displacement step RM, holding jig 110 even during this transition, to prevent unnecessary deformation of the winding member 15 _TN. In FIG. 8 (b) winding assembly ₁₀ has been completed in the winding process shown in _TN, and each link 115 is perpendicular to the central bar 111 of the holding jig 110, retaining bar 112, 113 the second state, i.e. in the wide state, contact with the inner periphery of all of the first turn portion 15D and the second turn portion 15C of each winding member _{15 TN,} each turn portion 15D, holds 15C.

Note that the winding assembly _10TN shown in FIG. 8B has drawer end portions 18a to 18d at both left and right end portions and twelve lead wires 17 at the center portion. The lead wire 17 is formed simultaneously with the winding assembly 10 _TN by the method disclosed in FIGS. 21 and 22 of Patent Document 2 and the description thereof.

  In FIG. 8B, the support member 120 of the holding jig 110 is shown at the right end of the holding jig 110. The support member 120 includes a support bar 121, a pair of support blocks 122 and 123, and a guide pin 124. The support bar 121 is connected to the right end portion of the center bar 111 and extends in the extending direction of the center bar 111. The support blocks 122 and 123 are disposed on both upper and lower sides of the support bar 121. The support block 122 is connected to the right end portion of the holding bar 112 via the connecting member 125, and the support block 123 is connected to the right end portion of the holding bar 113 via the connecting member 126. The guide pin 124 is arranged in a direction orthogonal to the support bar 121 without being fitted into the support bar 121, and both upper and lower ends thereof are fitted into the support blocks 122 and 123. The movement of the support blocks 122 and 123 is guided along the guide pins 124 and is movable in a direction orthogonal to the support bar 121. When the holding bars 122, 123 are parallel to the center bar 111 and move between the first state, that is, the narrow state, and the second state, that is, the wide state, the movement of the holding bars 122, 123 is Guided by the guide pin 124, the holding bars 122 and 123 move in a direction approaching or separating from each other by the guide pin 124.

  The support member 120 is connected to the first and second drive mechanisms 130 and 131. The first drive mechanism 130 is connected to the support blocks 122 and 123, and feeds the holding jig 110 into the winding assembly 10TN in the direction of the arrow H along the extension direction in parallel with the center bar 111. The first drive mechanism 130 drives the support blocks 122 and 123 in the direction of arrow H when the holding bars 112 and 113 of the holding jig 110 are in the first state shown in FIG. To do. By driving the support blocks 122 and 123 in the direction of arrow H, the holding bars 112 and 113 are driven in the direction of arrow H, and the center bar 111 is also driven in the direction of arrow H through the link 125. The second drive mechanism 131 is connected to the support bar 121 without being connected to the support blocks 122 and 123, and drives the support bar 121 and the center bar 111 in the directions of arrows h1 and h2 along the extending direction thereof. The second drive mechanism 131 drives the center bar 111 in the directions of the arrows h1 and h2 relative to the holding bars 122 and 123, and moves the holding bars 122 and 123 in the first state, that is, in the narrow state, The state is changed between the wide state.

When the rotating body 31 of the winding machine 20 is driven forward in the arrow A1 direction, the holding jig 110 is internal to the winding assembly _{10 TN,} with the winding assembly _{10 TN,} driven forward. When the rotating body 31 of the winding machine 20 is reversed driven in the arrow A2 direction, the holding jig 110 with the winding assembly _{10 TN} is left on the second surface 42 of the fixed block 20. When the center bar 111 is driven in the direction of the arrow h1 or h2 along the rotation axis LL, only the center bar 111 moves relative to the holding bars 112 and 113 in the direction of the arrow h1 or h2. As the center bar 111 moves in the direction of the arrow h1 or h2, each link 115 rotates, and the holding bars 112 and 113 move between the first state, that is, the narrow state, and the second state, that is, the wide state.

  9A to 9E are explanatory views showing a holding operation using the holding jig 110 in the winding process TN. 9A to 9E, (a) is a plan view, and (b) is a side view. 9A to 9E divide the wire rod feeding step S2 from the end stage of the wire rod feeding step S1 of a certain unit cycle into the following first wire rod feeding step S1 into five first step A to fifth step E. The winding operation and the operation of the holding jig 110 are shown. The first step A to the fifth step are executed in this order.

First, the first step A in FIG. 9A shows a state in which the wire rod feeding step S1 is completed. In the first step A, the holding bars 112, 113 of the holding jig 110 has a first state, that is in the narrow state, the holding bars 112, 113 are present in the interior of the winding member _{15 TN,} each winding It does not contact the wire member _15TN . In the second step B in Fig. 9B, the holding jig 110 is further inserted in the arrow H direction to the inside of the winding member _{15 TN.} Insertion of the holding jig 110, the support member 120 the first drive mechanism 130 is performed by feeding toward the winding member _{15 TN.} The feed of the support member 120, retaining bar 112, 113 and central bar 111 is inserted into the interior of the winding member _{15 TN.} Holding jig 110 continues the first state to the first step A, i.e. because the narrow state, without contacting the winding member 15 _TN, is inserted into the interior of the winding member 15 _TN.

9C, the center bar 111 is driven in the direction of the arrow h1 by the second drive mechanism 131, and the holding bars 112 and 113 are changed from the first state, that is, the narrow state, to the second state, that is, the wide state. To migrate. The holding bars 112, 113 on the basis of migrating the second state, i.e. the wide state, the holding bars 112, 113 to hold the winding member _{15 TN.} In the third step C, the movement of the center bar 111 in the direction of the arrow h1 rotates each link 115 to a position orthogonal to the center bar 111, and the holding bars 112 and 113 are in the second state, that is, the wide state. . In this state, the outer end surfaces of the holding bars 112 and 113 are pressed against the inner circumferences of the first turn portions 15D and the second turn portions 15C of the winding members _15TN , respectively, and the pin-like protrusions 112a and 113a The first turn part 15D and the second turn part 15C are held.

After the completion of the third step C, the fourth step D is executed. This fourth step D is a winding turn step S2, and in this fourth step D, the rotary block 33 is driven to rotate in the direction of the arrow A1 around the rotation axis LL, as shown in FIG. 9D. Then, the winding member 15 _TN is pressed against the second surface 42 of the fixed block 40. In the fourth step D, the rotary block 33 is driven to rotate forward, and each winding member _15TN is bent along the molding surface 44 to form the first turn portion 15D or the second turn portion 15C. The fourth step D, the winding member _{15 TN} is rotated by the rotation block 33, the holding jig 110 is also rotated together with the winding member _{15 TN.} Rotation of the winding member _{15 TN,} each turn portion 15D by the retention bars 112 and 113 of the holding jig 110, so carried out while holding the 15C, unnecessary deformation does not occur in the winding member _{15 TN.}

At the end of the fourth step D, the rotary block 33 is driven in reverse in the direction of the arrow A2, and the rotary block 33 returns to the original position as shown in FIG. 9D, but the winding member _15TN is the first of the fixed block 140. stops the second surface 42, the holding jig 110 in a state where the holding bar 112 holds the second state, it remains in the interior of the winding member _{15 TN.} In the fourth step D, when the rotary block 33 is driven to rotate forward, the axis drive mechanism 39 drives the rotary block 33 by a small dimension in the arrow B1 direction, and the rotary block 33 is driven in reverse. Sometimes, the rotary block 33 is driven by a slight dimension in the direction of the arrow B2. The shape of the first turn part 15D or the second turn part 15D is adjusted by driving the rotary block 33 to a small dimension in the directions of the arrows B1 and B2.

The fifth step E shown in FIG. 9E is the next wire feeding step S1. In the fifth step E, each wire is supplied to the rotating surface 36 of the rotating block 33 by a wire feeding mechanism (not shown) in the arrow direction along the feeding line SL. Even in the fifth step E, the holding bars 112 and 113 move together with the winding member _15TN while maintaining the second state, that is, the wide state. In this fifth step E, the holding bars 112, 113, each turn portion 15D of each winding member _{15 TN,} to press the inner periphery of 15C, so to retain the winding member _{15 TN,} unnecessary winding member _{15 TN} No significant deformation occurs.

  The process proceeds from the fifth process E to the first process A. In the first step A, the center bar 111 is driven in the direction of the arrow h2 by the second drive mechanism 131, and the holding bars 112 and 113 return to the first state, that is, the narrow state.

As described above, in the manufacturing method of the second embodiment, in addition to the same effects as those of the first embodiment, in the winding process TN, the fourth process D in which each winding member _15TN is rotated, and prevention in a fifth step E which each winding member _{15 TN} is sent, each turn portion 15D of the winding member _{15 TN} by the holding jig 110, so holding the 15C, unnecessary deformation from occurring in the winding member _{15 TN} There is an effect that can be done. Further, the winding assembly 10 _TN completing the winding process TN also, since it is held by the holding jig 110, in the course of transition to the next displacement step RM, can prevent unnecessary deformation for each winding member 15 _TN.

In the second embodiment, in the first step A and the second step B, the holding bars 112 and 113 are in the second state, that is, the narrow state, and the respective winding members _15TN cannot be held. However, in the first state A and the second state B, by using a pair of aids for pressing the respective first linear portions 15A and the second linear portion 15B of each winding member 15 _TN to the other sides, each winding The wire member _15TN can be held and unnecessary deformation thereof can be prevented.

In the second embodiment, the holding jig 110 having a plurality of links 115 and capable of taking either the first state or the second state is used. However, the holding jig 110 having no link 115 is used. It is also possible to use a holding jig. The holding plate, the interior of each winding member 15 _TN, each turn portion 15D, the inner periphery of 15C through a small distance is configured to have two outer end surfaces facing in the winding step TN, forming Unnecessary deformation of each winding member 15 _TN can be prevented by always arranging the winding member 10 _TN inside.

  The method for manufacturing a winding assembly of a rotating electrical machine according to the present invention can be used for manufacturing a winding assembly of various rotating electrical machines such as a vehicle AC generator.

FIG. 1 is a sectional view showing an automotive alternator using a winding assembly of a rotating electrical machine manufactured according to the present invention. FIG. 2 is a perspective view showing a stator assembly of the AC generator of FIG. FIG. 3 is a plan view showing an example of the winding assembly at the end stage of the winding process according to the present invention. FIG. 4 is an explanatory diagram of a displacement process in the first embodiment of the method for manufacturing a winding assembly of a rotating electrical machine according to the present invention. FIG. 5 is a plan view showing a blade and its drive bar used in the displacement step of FIG. 6 shows a blade used in the displacement process of FIG. 4, FIG. 6 (a) is a plan view, FIG. 6 (b) is a front view, and FIG. 6 (c) is a side view. FIG. 7 is a plan view of a winding machine used in the winding process in Embodiment 2 of the method for manufacturing a winding assembly of a rotating electrical machine according to the present invention. FIG. 8 shows a holding jig used in the winding process of the second embodiment, FIG. 8 (a) is a plan view showing the first state, and FIG. 8 (b) is a plan view showing the second state. FIG. FIG. 9A shows a first step of the winding step according to the second embodiment, where FIG. 9A is a plan view and FIG. 9B is a side view. FIG. 9B shows a second step of the winding step according to the second embodiment, in which FIG. 9A is a plan view and FIG. 9B is a side view. FIG. 9C shows a third step of the winding step according to the second embodiment, in which FIG. 9A is a plan view and FIG. 9B is a side view. FIG. 9D shows a fourth step of the winding step according to the second embodiment, in which FIG. 9A is a plan view and FIG. 9B is a side view. FIG. 9E shows a fifth step of the winding step according to the second embodiment, in which FIG. 9A is a plan view and FIG. 9B is a side view.

Explanation of symbols

10, 10 _TN : winding assembly, 15, 15 _TN , 15 _FM : winding member, 15A: first straight part, 15B: second straight part, 15D: first turn part, 15C: second turn part,
15a, 15b: intermediate part, 15a1: first parallel straight line part, 15b1: second parallel straight line part, 15a2, 15a3, 15b2, 15b3: inclined part, 101A, 101B: blade, 102C, 102D: regulating jig,
103A1, 103A2, 103B1, 103B2: driving bar,
20: winding machine, 33: rotating block, 40: fixed block, 110: holding jig.
111: Center bar, 112, 113: Holding bar.

Claims (8)

Including a winding step of winding a plurality of winding members constituting the winding assembly of the rotating electrical machine, and a displacement step after the winding step,
In the winding step, each of the plurality of winding members includes a first turn portion, a second turn portion, and a first turn portion that extends obliquely from the first turn portion toward the second turn portion and connects them. Wound so as to have one straight portion and a second straight portion extending obliquely from the second turn toward the first turn portion and connecting them,
In the deforming step, the first straight portion of each winding member has a first parallel straight portion at an intermediate portion thereof, and the second straight portion of each winding member has a second parallel straight portion at an intermediate portion thereof. A method of manufacturing a winding assembly for a rotating electrical machine, wherein the first and second straight line portions are displaced so that the first and second straight line portions are substantially parallel to each other. ,
In the displacement step, a first blade that holds the intermediate portion of the first straight portion over substantially the entire length thereof and a second blade that holds the intermediate portion of the second straight portion over the substantially entire length thereof are used. And rotating the first blade and the second blade in opposite directions to form the first and second parallel straight portions.   2. The method of manufacturing a winding assembly for a rotating electrical machine according to claim 1, wherein the first blade is centered at an intermediate point of an intermediate portion of the first straight portion, and the second blade is the second straight line. A method of manufacturing a winding assembly of a rotating electrical machine, wherein the winding assembly is rotated about an intermediate point of an intermediate part of each part.   2. The method of manufacturing a winding assembly of a rotating electrical machine according to claim 1, wherein in the displacement step, a restriction jig that contacts the outer periphery of the first turn part and the outer periphery of the second turn part is further used. When the first and second blades are rotated in opposite directions, the jig moves so as to approach each other and regulates the first and second turn portions of each winding member. A method for manufacturing a winding assembly of a rotating electrical machine.   2. The method for manufacturing a winding assembly of a rotating electrical machine according to claim 1, further comprising: holding each winding member using a holding jig in the winding step. Manufacturing method of wire member.   5. The method of manufacturing a winding assembly for a rotating electrical machine according to claim 4, wherein the winding member is held using the holding jig even at the end of the winding step. Manufacturing method for winding assembly.   6. The method of manufacturing a winding assembly for a rotating electrical machine according to claim 4 or 5, wherein the holding jig holds each first turn portion and each second turn portion of each winding member. Manufacturing method for electrical wire winding assembly.   7. The method of manufacturing a winding assembly for a rotating electrical machine according to claim 6, wherein the holding jig includes a first holding bar facing the first turn portion of each winding member, and a second holding member for each winding member. It has the 2nd holding bar which counters a turn part, and these 1st and 2nd holding bars can take the 1st state in which they approached, and the 2nd state which mutually separated from this 1st state A method for manufacturing a winding assembly of a rotating electrical machine, wherein the first turn portion and the second turn portion of each winding member are held in the second state.   8. The method of manufacturing a winding assembly for a rotating electrical machine according to claim 7, wherein the first and second holding bars are connected to a central bar via a plurality of links. Manufacturing method of assembly.

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