JP2013070498A - Manufacturing method of stator using distributed winding coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a stator using a distributed winding coil, which can correct loose winding caused by springback.SOLUTION: A manufacturing method of a stator 100 using a distributed winding coil in which a zigzag component C is formed by machining a flat conductor D in edgewise bending into a zigzag shape, a coil subassembly CSa is formed by stacking a plurality of the zigzag components C, and a coil assembly Sa is formed by spirally winding the coil subassembly CSa, comprises the steps for shaping the coil assembly Sa of: regulating an inner diameter of the coil assembly Sa with an inner diameter guide part m541 to be a specified dimension of the inner diameter; inserting an inner arrow m532 from an inner peripheral side of the coil assembly Sa into a tooth insertion hole 121 of the coil assembly Sa; moving an outer periphery of the coil assembly Sa in a circumferential direction using a first outer diameter seamer M51 and a first outer arrow device M52 arranged at the outer periphery of the coil assembly Sa; and inserting and positioning an outer arrow m511 and an outer arrow m513 from the outer peripheral side of the coil assembly Sa into the tooth insertion hole 121.

Description

  The present invention relates to a method of manufacturing a stator using distributed winding coils, and more specifically, corrects a positional deviation of a coil that is rounded into a spiral shape by overlapping flat conductor wires bent into a 99-fold shape. The present invention relates to a technique for shaping a child core into a state that allows insertion.

  In recent years, in view of environmental problems, there are an increasing number of cases in which a driving motor is mounted on an automobile. It is desirable that the drive motor mounted on the vehicle has a large output for moving the vehicle and is space-saving for being mounted on the vehicle. In particular, there is a strong demand for miniaturization of hybrid vehicles because the engine and motor need to be housed in the engine room. In order to improve the output of the motor, a method for increasing the sectional area of the coil used for the motor and increasing the space factor of the stator is being sought. On the other hand, with respect to miniaturization of motors, miniaturization has been studied by various approaches. However, it is considered that the difficulty of manufacturing the stator will increase due to the miniaturization and high output of the stator and motor.

  Patent Document 1 discloses a method for assembling a split core type stator of an inner rotor type rotating electrical machine. The teeth of the split core are radially arranged on the outer periphery of the distributed winding coil arranged in an annular shape, and the split core is held in a predetermined position in the circumferential direction by the conductor guide arrow blades. Move in centripetal direction. At the same time, the slot accommodating conductor is moved in the centripetal direction. Thereby, when inserting a division | segmentation core from the distributed winding coil outer peripheral side, it can prevent that the division | segmentation core contacts and damages the insulation coating of a slot accommodation conductor part.

JP 2009-254137 A

  However, in forming a distributed winding coil by applying the technique of Patent Document 1, it is considered that there are problems described below.

  In the technique described in Patent Document 1, after the distributed winding coil is formed in a cylindrical shape, when the divided core is inserted in the centripetal direction, the conductor guide arrow blades are used to suppress variations in the slot accommodating conductor portion. However, as far as the applicant has confirmed, in order to insert the conductor guide arrow blade into the tooth insertion hole, it is necessary that the center is aligned at least so that the center can be seen through the teeth insertion hole from the outer peripheral side of the cylindrical distributed winding coil. is there. However, when the distributed winding coil is formed in a cylindrical shape, it is affected by the spring back of the flat rectangular conductor used in the coil, so it is considered that a process for adjusting the distributed winding coil is necessary to insert the conductor guiding arrow blades. It is done.

  In particular, when it is necessary to increase the number of distributed winding coils and increase the number of turns of the coils with the aim of improving the output of the stator, it is considered difficult to insert the conductor guide arrow blades. In addition, workability deteriorates even when the stator is downsized, and it is expected that it will become more difficult to align the teeth insertion holes of the distributed winding coils with the conductor guide arrow blades. In fact, at the time of the applicant's trial production stage, when inserting the stator core, it was manually assembled to align the distributed winding coils, and it was assembled by work that relied on the intuition of inserting something similar to the conductor guide arrow blade into the teeth insertion hole. It was. However, in mass production, it is eagerly desired to automate the work of inserting the stator core into the cylindrically distributed coil.

  Accordingly, an object of the present invention is to provide a method for manufacturing a stator using a distributed winding coil that can correct loosening due to springback in order to solve such problems.

  In order to achieve the above object, a method of manufacturing a stator using a distributed winding coil according to an aspect of the present invention has the following characteristics.

(1) A flat conductor is edgewise bent into a ninety-nine fold to form a ninety-nine fold member, a plurality of the ninety-nine fold members are stacked to form a coil sub-assembly, and the coil sub-assembly is spirally formed In the method of manufacturing a stator using a distributed winding coil that is wound around a coil assembly, the inner diameter of the coil assembly is regulated to an inner diameter regulation dimension by an inner diameter guide, and the inside of the coil assembly is inserted into the tooth insertion hole of the coil assembly. An inner arrow is inserted from the peripheral side, and the outer periphery of the coil assembly is moved in the circumferential direction by an outer diameter winding and drawing device arranged on the outer periphery of the coil assembly, and an outer arrow is inserted into the teeth insertion hole from the outer peripheral side of the coil assembly. And positioning and shaping the coil assembly.

(2) In the method for manufacturing a stator using the distributed winding coil according to (1), the inner arrow is inserted into the teeth insertion hole into which the outer arrow is inserted.

(3) In the method for manufacturing a stator using the distributed winding coil according to (1) or (2), two outer diameter drawing devices are provided so as to be positioned diagonally.

  The following operations and effects can be obtained by the method for manufacturing a stator using the distributed winding coil according to an aspect of the present invention having such characteristics.

  According to the aspect described in (1) above, a rectangular conductor is edgewise bent into a ninety-nine fold to form a ninety-nine fold member, and a plurality of ninety-nine fold members are stacked to form a coil sub-assembly, In a method of manufacturing a stator using a distributed winding coil in which a coil assembly is formed by winding a sub assembly in a spiral shape, the inner diameter of the coil assembly is regulated to an inner diameter regulation dimension by an inner diameter guide, and the coil assembly is inserted into the tooth insertion hole of the coil assembly. Insert the inner arrow from the inner circumference side of the coil assembly, move the outer circumference of the coil assembly in the circumferential direction by the outer diameter winding and drawing device placed on the outer circumference of the coil assembly, and insert the outer arrow from the outer circumference side of the coil assembly to the teeth insertion hole. Position and shape the coil assembly.

  A coil sub-assembly using a ninety-nine fold member obtained by edgewise bending a flat rectangular conductor into a ninety-nine fold shape, when the coil sub-assembly is wound in a spiral shape, winding misalignment occurs and the inner diameter side is It is smaller than the prescribed dimension, and the outer diameter side tends to be larger than the prescribed dimension. This is considered to be due to the influence of springback and the like because the flat conductor is formed by bending. As a result, as shown in the problem, it becomes difficult to insert the outer arrow into the teeth insertion hole. For this reason, first press the inner diameter with the inner diameter guide and then insert the inner arrow to prevent the inner diameter side from shifting, and then use the outer diameter drawing device to squeeze and squeeze out the teeth insertion hole. to correct.

  Then, in the situation where the insertion portions in the slots of the coil assembly arranged on the left and right sides of the teeth insertion hole are suppressed to a predetermined variation, the outer core is inserted to prevent the coil assembly from being unraveled. By inserting from the side, the stator core can be inserted smoothly. As a result, it is possible to provide a method for manufacturing a stator using a distributed winding coil that can correct winding looseness due to springback, and automatic stator core assembly in the stator manufacturing process can be realized.

  Further, according to the aspect described in (2) above, in the stator manufacturing method using the distributed winding coil described in (1), the inner arrow is inserted into the tooth insertion hole into which the outer arrow is inserted. is there. It has been confirmed by the applicant's experiment that the tooth insertion hole into which the inner arrow is inserted has less misalignment than the other teeth insertion hole because the inner arrow is inserted first. For this reason, by inserting the outer arrow into the teeth insertion hole, it is possible to rationally correct the deviation, and as a result, it is possible to reduce the risk of peeling off the insulating coating of the coil with the stator core.

  Further, according to the aspect described in (3) above, in the method for manufacturing a stator using the distributed winding coil described in (1) or (2), two outer diameter drawing devices are provided so as to be positioned diagonally. It is what was done. Applicant's experiment has revealed that two outer diameter drawing devices can be appropriately drawn in a state where two outer diameter drawing devices are arranged diagonally, and also when inserting the outer arrow into the teeth insertion hole, It is desirable that the number of diameter winding drawing devices is small. Moreover, it can be expected that the coil assembly is uniformly wound and squeezed by arranging the outer diameter squeezing device diagonally. As a result, it is possible to contribute to automation of the production process with respect to the manufacture of the stator using the distributed winding coil.

It is a perspective view of the stator of this embodiment. It is a perspective view of a coil cage of this embodiment. It is a perspective view of a mode that a split core is inserted in a coil cage of this embodiment. It is a perspective view of a member bundle of this embodiment. It is a top view of a coil subassembly of this embodiment. It is a side view of a coil subassembly of this embodiment. It is a top view of the coil sub assembly shaping machine of this embodiment. It is a side view of the coil sub assembly shaping machine of this embodiment. It is a perspective view of the coil assembly shaping machine of this embodiment. It is a top view of the coil assembly shaping machine of this embodiment. It is a schematic plan view of the inner arrow drive mechanism of the coil assembly shaping machine of this embodiment. It is a schematic plan view of the inner diameter holding mechanism of the coil assembly shaping machine of the present embodiment. It is sectional drawing of the coil assembly of the state of this embodiment in the state where the teeth insertion hole was arranged. It is sectional drawing of the coil assembly of the state of this embodiment in the state where the teeth insertion hole is not aligned. It is an enlarged view of a section of a coil assembly of this embodiment. It is sectional drawing of a mode that the inner arrow was inserted in the coil assembly of this embodiment. It is sectional drawing of a mode that an outer arrow is inserted in a coil assembly of this embodiment. It is a flow regarding the formation process of the stator of this embodiment. It is an operation | movement flow of the coil assembly shaping machine of this embodiment.

  First, an embodiment of the present invention will be described with reference to the drawings.

  In FIG. 1, the perspective view of the stator 100 of this embodiment is shown. In FIG. 2, the perspective view of the coil cage | basket 120 is shown. FIG. 3 is a perspective view showing how the split core 111 is inserted into the coil cage 120. The stator 100 and the coil cage 120 are depicted partially simplified. As shown in FIG. 1, the stator 100 includes a stator core 110 and a coil rod 120, and an outer ring 130 around the stator core 110. The stator core 110 has a substantially cylindrical shape composed of a plurality of divided cores 111, and the divided cores 111 are formed by laminating electromagnetic steel sheets formed in a predetermined shape by press working or the like. As shown in FIG. 3, the split core 111 is provided with teeth 115, and a slot 116 is formed between adjacent teeth 115.

  The stator core 110 formed by arranging the split cores 111 in a cylindrical shape has a state in which the teeth 115 protrude on the inner peripheral side. Forty-eight teeth 115 are prepared, and the same number of slots 116 as the teeth 115 are prepared. Therefore, 24 divided cores 111 are prepared. As shown in FIG. 2, the coil rod 120 inserted into the split core 111 is provided with teeth insertion holes 121 radially in the outer peripheral direction. The teeth insertion hole 121 is a portion into which the teeth 115 provided in the split core 111 are inserted, and is disposed between the adjacent in-slot conductor portions 122.

  FIG. 4 shows a perspective view of the member bundle CS. The member bundle CS is formed by stacking six ninety-nine folded members C. Each of the first 99th folding member C1 to the sixth 99th folding member C6 has the same shape and is formed by edgewise bending the flat conductor D. The flat conductor D is made of a highly conductive metal such as a copper material having a rectangular cross section, and the periphery thereof is insulated and coated with a highly insulating resin such as enamel. The ninety-nine folded member C is formed by edgewise bending the flat conductor D in a ninety-nine fold shape as shown in FIG.

  As shown in FIG. 4, the ninety-nine folded member C is simply overlapped with the first ninety-nine folded member C1 to the sixth ninety-nine folded member C6 to form a member bundle CS. FIG. 5 shows a plan view of the coil sub-assembly CSa. FIG. 6 shows a side view of the coil sub-assembly CSa. The coil sub-assembly CSa is a member bundle CS that is formed by winding in a spiral shape as shown in FIGS. 5 and 6. The member bundle CS is rolled up into a spiral shape, and then shaped into a coil sub-assembly shaping machine M10, which will be described later, so as to have the shape of the coil sub-assembly CSa shown in FIGS. 5 and 6. Therefore, the inner peripheral end CS1 and the outer peripheral end Has CS2.

  Eight coil sub-assies CSa formed in a spiral shape are prepared and stacked to form a coil assembly Sa. Then, the coil end of the coil assembly Sa is processed to form the coil rod 120 in the state shown in FIG. Thereafter, the split core 111 is inserted from the outer periphery of the coil rod 120, and the outer ring 130 is fitted on the outer periphery to form the stator 100.

  Next, the coil sub assembly shaping machine M10 will be described. FIG. 7 is a plan view of the coil sub-assembly shaping machine M10. FIG. 8 shows a side view of the coil sub-assembly shaping machine M10. Although the coil sub-assembly shaping machine M10 shown in FIGS. 7 and 8 is a test jig, the configuration is the same as that used in the production line, and therefore, description will be made using a simple test jig having a structure. The coil sub-assembly shaping machine M10 has two inner diameter fixed guides M11 and two slide guides M12 on a base M17, an inner diameter guide cylinder M13, a link shaft M14 connected to the cylinder, an end pressing guide cylinder M15, an end A partial pressing guide M16 and a displacement stopping projection M18 are provided.

  The base M17 includes an upper base M17a and a lower base M17b connected by a plurality of posts M17c. The upper base M17a is provided with a coil sub-assembly CSa, and the lower base M17b is used for an inner diameter guide as a driving mechanism. A cylinder M13 and an end pressing guide cylinder M15 are disposed. The inner diameter fixed guide M11 is a guide that supports the inner diameter near the inner peripheral end of the coil sub-assembly CSa, and has a function of holding the coil sub-assembly CSa on the outer peripheral surface of the inner diameter fixed guide M11 so as not to be deformed to the inner diameter side. ing.

  The slide guide M12 is a guide that supports the inner diameter around the center of the coil sub-assembly CSa. The slide guide M12 has an inner-diameter guide cylinder M13 linked by a link shaft M14. The slide guide M12 is outside the coil sub-assembly CSa. It has a function of moving to the radial side. The slide guide M12 moves backward toward the inner diameter side at the forward end of the inner diameter guide cylinder M13, and the slide guide M12 moves forward toward the outer diameter side at the backward end of the inner diameter guide cylinder M13. The inner peripheral surface of the coil sub-assembly CSa is supported by the outer peripheral surface of the slide guide M12.

  The end pressing guide M16 is connected to the end pressing guide cylinder M15, and is disposed at a position where the outer end of the coil sub-assembly CSa is pressed at the forward end of the end pressing guide cylinder M15. The misalignment stop projection M18 is provided with a projection portion M18a, which restricts the movement of the coil sub-assembly CSa. As shown in FIG. 6, the coil sub-assembly CSa has a lower surface side recess CSa <b> 1, and the lower surface side recess CSa <b> 1 is equal to the width of the tooth insertion hole 121. By inserting the protrusion portion M18a of the shift stop projection M18 into the lower surface side recess CSa1, it functions as a shift stop.

  Next, the coil assembly shaping machine M50 will be described. FIG. 9 shows a perspective view of the coil assembly shaping machine M50. FIG. 10 is a plan view of the coil assembly shaping machine M50. The coil assembly shaping machine M50 will be described using a test machine with a simple structure, but an apparatus having the same configuration is used in an actual production line. The coil assembly shaping machine M50 includes a first outer diameter drawing device M51, a first outer arrow mechanism M52, a second outer arrow mechanism M53, a third outer arrow mechanism M54, a second outer diameter winding device M55, The fourth outer arrow mechanism M56, the fifth outer arrow mechanism M57, the sixth outer arrow mechanism M58, the first inner arrow mechanism M59, and the second inner arrow mechanism M60 are provided on the base M65. The elevator M63 is a member that arranges the coil assembly Sa on the upper surface and is arranged on the base M65. M63 also has a function of assembling the coil sub-assembly CSa, but the description is omitted. A first inner arrow mechanism M59, a second inner arrow mechanism M60, a first inner diameter guide M61, and a second inner diameter guide M62 are arranged in the center of the elevator M63.

  The first outer diameter winding and drawing device M51 and the second outer diameter winding and drawing device M55 are devices having the same configuration, which are diagonally positioned. The cylinder m501, the bracket m502, the tensioner bracket m503, and the pressing pulley m504. And a sub pulley m505, a main pulley m506, and a timing belt m507. A main pulley m506 and a sub pulley m505 are attached to a tensioner bracket m503, and a timing pulley m504 is supported by a pressing pulley m504 attached to the bracket m502, and the timing belt m507 is moved by moving the tensioner bracket m503. Adjust the tension. Specifically, the tension is adjusted slightly slightly along the outer periphery of the coil assembly Sa.

  A bracket m502 is attached to the cylinder m501, the timing belt m507 is pressed against the outer surface of the coil assembly Sa at the forward end of the cylinder m501, and the timing belt m507 is disposed at the retracted position at the backward end of the cylinder m501.

  The first outer arrow mechanism M52 and the fourth outer arrow mechanism M56 are devices having the same configuration arranged diagonally, and include a cylinder m512 and an outer arrow m511. The second outer arrow mechanism M53 and the fifth outer arrow mechanism M57, the third outer arrow mechanism M54, and the sixth outer arrow mechanism M58 are also arranged diagonally, and include an outer arrow m513 and a cylinder m512. At the forward end of the cylinder m512, the outer arrow m511 and the outer arrow m513 move to a position to be inserted into the tooth insertion hole 121 of the coil assembly Sa, and at the backward end of the cylinder m512, the outer arrow m511 and the outer arrow m513 are the outer circumference of the coil assembly Sa. Move to a position to retreat outside the surface.

  FIG. 11 shows a schematic plan view of the inner arrow drive mechanism of the coil assembly shaping machine M50. A first inner arrow mechanism M59 and a second inner arrow mechanism M60 are arranged inside the coil assembly Sa arranged in the coil assembly shaping machine M50. The first inner arrow mechanism M59 and the second inner arrow mechanism M60 are arranged adjacent to each other with the same structure, and have a cylinder m531 and an inner arrow m532, respectively. A cylinder m531 is provided so as to protrude in the opposite direction to the inner arrow m532 of the first inner arrow mechanism M59 and the inner arrow m532 of the second inner arrow mechanism M60, and the inner arrow m532 is attached to the cylinder m531. Yes.

  FIG. 12 is a schematic plan view of the inner diameter holding mechanism of the coil assembly shaping machine M50. A first inner diameter guide M61 and a second inner diameter guide M62 are disposed below the first inner arrow mechanism M59 and the second inner arrow mechanism M60. The first inner diameter guide M61 and the second inner diameter guide M62 are provided with an inner diameter guide part m541 and a protrusion part m542, respectively. The inner diameter guide portion m541 is attached to a chuck cylinder (not shown), and moves forward and retracts so that the first inner diameter guide M61 and the second inner diameter guide M62 are separated from each other. At the forward end of the inner diameter guide portion m541, the outer peripheral surface of the inner diameter guide portion m541 moves to a position where the inner diameter of the coil assembly Sa is defined, that is, a position that becomes the inner diameter of the coil rod 120. The retracted end of the inner diameter guide part m541 can be retracted to a position that does not interfere with the inner diameter of the coil assembly Sa.

  The protrusion m542 provided so as to protrude from the outer peripheral surface of the inner diameter guide part m541 is inserted into the tooth insertion hole 121 from the inner peripheral side of the coil assembly Sa. When the protrusion m542 is inserted into the tooth insertion hole 121, it is formed into a straight line having a width corresponding to two layers of the in-slot conductor portion 122, that is, two flat conductors D, and its tip is chamfered. Is formed. This is intended to make the insertion of the protrusion m542 into the teeth insertion hole 121 smooth because the tip is caught by a part of the in-slot conductor portion 122.

  Next, a method for assembling the coil rod 120 used in the stator 100 of this embodiment will be described.

  First, the formation process of the stator 100 will be briefly described using a flow. FIG. 18 shows a flow relating to the formation process of the stator 100. First, in S1, “form of ninety-nine folded members” is performed. The ninety-nine folded member C is formed using the flat rectangular conductor D. The flat rectangular conductor D is bent into a ninety-nine fold by an edgewise bending machine. In S2, “formation of member bundle” is performed. Specifically, ninety-nine folded members C are shifted one by one and stacked as shown in FIG. The shift amount is determined to be a width in which the teeth 115 of the stator core 110 are sandwiched. In S3, “form coil sub-assembly” is performed. The coil sub-assembly CSa is bent by a forming machine (not shown) so as to be spirally wound. Thereafter, the shape of the coil sub-assembly CSa is shaped by the coil sub-assembly shaping machine M10. The shaping by the coil sub-assembly shaping machine M10 will be described later.

  In S4, “assembly of coil sub-assembly” is performed. A coil assembly Sa is formed by stacking eight sets of coil sub-assies CSa. In S5, “coil assembly alignment” is performed. The coil assembly Sa is aligned using the coil assembly shaping machine M50, and the ninety-nine folded members C are aligned so that the teeth 115 of the split core 111 can be inserted into the teeth insertion holes 121 of the coil assembly Sa. In S6, “insert the stator core into the coil cage”. The coil rod 120 referred to here is an aligned coil assembly Sa, and the coil end processing is slightly different from the coil rod 120 shown in FIG. In S7, “the outer cylinder is fitted to the outer periphery of the stator core”. After the split core 111 is inserted from the periphery of the coil cage 120 so as to be substantially cylindrical, the outer ring 130 is baked to hold it.

  Thus, the stator 100 is formed. Strictly speaking, in order to make the shape of the coil rod 120 from the coil assembly Sa, the lead portion protruding from the coil end of the coil assembly Sa is bent outward and welded, and powder coating is applied to protect the welded portion. Etc., and a process of attaching an external output terminal (not shown) to the lead portion of the coil end. However, since it is not directly related to the essence of the present invention, the description is omitted here.

  Next, the process for forming the coil sub-assembly CSa in the coil sub-assembly shaping machine M10 will be described. The coil sub-assembly CSa is a member bundle CS formed by shifting and stacking ninety-nine folded members C shown in FIG. 4 into a spiral shape as shown in FIGS. 5 and 6. However, when the member bundle CS is simply rolled into a spiral shape, it is not neatly organized due to variations in formation and springback. For this reason, it is possible to obtain a coil sub-assembly CSa having a predetermined shape by attaching a ridge using the coil sub-assembly shaping machine M10 shown in FIG.

  First, using a robot or the like, the coil sub-assembly CSa is temporarily placed on the coil sub-assembly shaping machine M10 as shown in FIG. At this time, the lower surface side concave portion CSa1 of the coil sub-assembly CSa is arranged to be inserted into the shift stop protrusion M18 fixed on the coil sub-assembly shaping machine M10. As a result, the lower surface side concave portion CSa1 formed near the inner peripheral end and the outer peripheral end of the coil sub-assembly CSa is engaged with the convex portion of the misalignment projection M18. In this state, the coil sub-assembly CSa is arranged at the approximate position on the coil sub-assembly shaping machine M10.

  Then, by moving the inner diameter guide cylinder M13, the inner periphery of the coil sub-assembly CSa is spread by the slide guide M12, and the coil sub-assembly CSa is moved to the slide guide M12 in a state where the slide guide M12 is stopped at a predetermined position. As a result, the coil sub-assembly CSa is held at a predetermined position at a predetermined size. Then, by moving the end pressing guide cylinder M15, the outer end of the coil sub-assembly CSa is pressed by the end pressing guide M16, and the shape of the coil sub-assembly CSa is adjusted.

  Next, the shaping process of the coil assembly Sa in the coil assembly shaping machine M50 will be described. FIG. 19 shows an operation flow of the coil assembly shaping machine M50. First, in S10, “placement of coil assembly” is performed. The coil assembly Sa is disposed on the elevator M63 of the coil assembly shaping machine M50. The eight coil assemblies Sa to be arranged are assembled as shown in FIG. 5, and 48 sets of ninety-nine folded members C are used. In this case, the coil assembly Sa does not have the teeth insertion holes 121 of the coil assembly Sa, the inner diameter of the coil assembly Sa is smaller than the prescribed dimension, and the outer diameter of the coil assembly Sa is larger than the prescribed dimension.

  Next, in S11, “inner arrow insertion” is performed. As shown in FIG. 11, the inner arrow m532 of the first inner arrow mechanism M59 and the second inner arrow mechanism M60 is inserted into the coil insertion hole 121 from the inner peripheral side of the coil assembly Sa to the coil assembly Sa arranged on the elevator M63. To do. At this time, the insertion depth of the inner arrow m532 is up to the middle of the in-slot conductor portion 122. In S12, “inner diameter expansion” is performed. As the inner diameter guide part m541 of the first inner diameter guide M61 and the second inner diameter guide M62 moves to a predetermined position as shown in FIG. 12, the outer peripheral surface of the inner diameter guide part m541 enlarges the inner diameter of the coil assembly Sa, and the coil assembly Sa. The inner diameter is defined as the inner diameter regulation dimension.

  Next, in S13, “advance of outer diameter drawing device” is performed. The first outer diameter winding / squeezing device M51 and the second outer diameter winding / squeezing device M55 shown in FIG. 10 are advanced in the central direction of the coil assembly Sa. The first outer diameter winding / squeezing device M51 and the second outer diameter winding / squeezing device M55 have a timing belt m507 at the front end in the traveling direction, and the timing belt m507 is brought into close contact with the outer peripheral surface of the coil assembly Sa. The advancement of the first outer diameter winding and drawing device M51 and the second outer diameter winding and drawing device M55 also has an object of reducing the outer dimensions of the coil assembly Sa to a specified size.

  Next, in S14, “coil winding drawing” is performed. The main pulley m506 included in the first outer diameter winding / squeezing device M51 and the second outer diameter winding / squeezing device M55 is rotated to move the timing belt m507, so that the outer diameter of the coil assembly Sa is started. Then, when the main pulley m506 rotates by a predetermined angle, the coil assembly Sa is wound and squeezed, and as a result, the outer dimension of the coil assembly Sa becomes the outer diameter regulation dimension.

  Next, in S15, "first and fourth outer arrows are inserted". In a situation in which the coil assembly Sa is wound and squeezed by the first outer diameter squeezing device M51 and the second outer diameter squeezing device M55, the teeth insertion hole 121 of the coil assembly Sa is inserted into the outer arrow m511 and the outer arrow m513. Is complete. For this reason, the 1st outer arrow mechanism M52 and the 4th outer arrow mechanism M56 can be advanced, and the outer arrow m511 which each has can be inserted in the teeth insertion hole 121 which the coil assembly Sa has. The outer arrow m511 is inserted at the same position as the inner arrow m532 and at the 0-degree phase position of the coil assembly Sa, but the outer arrow m511 and the inner arrow m532 do not interfere with each other because they dodge in the height direction.

  Next, in S16, “the outer diameter winding and drawing device is retracted”. By retracting the first outer diameter winding / squeezing device M51 and the second outer diameter winding / squeezing device M55, the outer surface of the coil assembly Sa becomes free. However, since the outer arrow m511 has already been inserted, the coil assembly Sa does not loosen. Next, in S17, “insertion of second and fifth outer arrows” is performed. The second outer arrow mechanism M53 and the fifth outer arrow mechanism M57 are advanced to insert the outer arrow m513 into the tooth insertion hole 121 at the 45-degree phase position of the coil assembly Sa.

  Next, in S18, “third and sixth outer arrow insertion” is performed. The third outer arrow mechanism M54 and the sixth outer arrow mechanism M58 are advanced, and the outer arrow m513 is inserted into the tooth insertion hole 121 at the 90-degree phase position of the coil assembly Sa. The outer arrow m513 is also designed so as not to interfere with the inner diameter guide part m541. Thus, the tooth insertion holes 121 of the coil assembly Sa are aligned, and the coil assembly Sa is conveyed to the next process. Then, after the guide is inserted into the coil assembly Sa, the split core 111 is inserted into the coil assembly Sa to form the stator 100.

  Since the present embodiment is configured as described above, the following operations and effects are achieved.

  First, as an effect, the production process can be automated with respect to the manufacture of the stator 100 using distributed winding coils. As shown in the problem, the ninety-nine folded member C formed by edgewise bending the flat conductor D is easily affected by the spring back due to the processing characteristic of bending, and it is difficult to obtain the shape accuracy. Accordingly, in the present invention, the rectangular conductor D is edgewise bent into a 99-fold shape to form a 99-fold member C, and a plurality of the 99-fold members C are stacked to form a coil sub-assembly CSa. In the manufacturing method of the stator 100 using the distributed winding coil, in which the coil assembly Sa is formed by winding the sub-assembly CSa in a spiral shape, the inner diameter of the coil assembly Sa is regulated to the inner diameter regulation dimension by the inner diameter guide part m541. An inner arrow m532 is inserted into the teeth insertion hole 121 from the inner circumference side of the coil assembly Sa, and the outer circumference of the coil assembly Sa is moved by the first outer diameter winding / squeezing device M51 and the first outer arrow mechanism M52 arranged on the outer circumference of the coil assembly Sa. The outer arrow m511 and the outer arrow m513 are inserted into the teeth insertion hole 121 from the outer peripheral side of the coil assembly Sa, and positioned. It has adopted a technique called shaping the Ruashi Sa.

  FIG. 13 shows a cross-sectional view of the coil assembly Sa with the teeth insertion holes 121 aligned. FIG. 14 is a cross-sectional view of the coil assembly Sa in a state where the teeth insertion holes 121 are not aligned. FIG. 15 shows an enlarged view of a cross section of the coil assembly Sa. FIG. 14 schematically shows the coil assembly Sa in a free state due to the influence of springback, and the rectangular conductor D spreads in the outer diameter direction and the inner diameter direction. However, for the sake of explanation, the inner diameter of the coil assembly Sa is shown. The outer diameter side and the outer diameter side are depicted as being pressed by the inner diameter guide portion m541 and the timing belt m507, respectively. This springback is obtained when the flat conductor D is edgewise bent into the ninety-nine folded member C, or when the ninety-nine folded member C is formed into a member bundle CS and bent into a spiral shape to form the coil sub-assembly CSa. In addition, it is considered that this is due to strain accumulated in the material.

  As shown in FIG. 9, even when the coil assembly Sa is held by the inner diameter guide part m541 and the timing belt m507 on the coil assembly shaping machine M50 as shown in FIG. The state is shifted. This is presumably because the above-described springback occurs in the coil assembly Sa. In this state, it is difficult to insert the outer arrow m513 as pointed out in the problem.

  The reason why it is difficult to insert the outer arrow m513 into the teeth insertion hole 121 is that the allowable dimension for inserting the outer arrow m513 is about the dimension a as shown in FIG. The dimension a is experimentally confirmed to be about ¼ to ３ of the width of the tooth insertion hole 121. The outer arrow m511 has a narrower tip than the outer arrow m513, so that the allowable width of the dimension a tends to increase slightly. However, it is difficult to insert the outer arrow m511 in a state like the coil assembly Sa shown in FIG.

  FIG. 16 shows a cross-sectional view of the state in which the inner arrow m532 is inserted into the coil assembly Sa. In FIG. 17, sectional drawing of a mode that the outer arrow m511 or the outer arrow m513 is inserted in the coil assembly Sa is shown. In the present invention, the inner diameter m532 is inserted to a predetermined position after the inner diameter guide portion m541 provided in the coil assembly shaping machine M50 is enlarged so that the inner diameter becomes a specified dimension. After that, the rectangular conductor D on the outer side of the coil assembly Sa moves by winding the outer diameter with the timing belt m507 of the first outer diameter winding and drawing device M51 and the second outer diameter winding and drawing device M55, and the state shown in FIG. 17 is obtained. Can do. The displacement of the flat conductor D in the tooth insertion hole 121 of the coil assembly Sa in the state of FIG. 17 is accommodated within the range of the dimension a shown in FIG. 15, so the outer arrow m511 and the outer arrow m513 are inserted from the outer peripheral side of the coil assembly Sa. can do.

  After the outer arrow m511 is first inserted into the same tooth insertion hole 121 as the inner arrow m532 to align the in-slot conductor portion 122 of the coil assembly Sa, the outer arrow m513 is sequentially inserted. By doing so, it is possible to align all the teeth insertion holes 121 of the coil assembly Sa. The coil assemblies Sa arranged in this way are carried to the next process to insert and guide the outer arrow (not shown) in order to insert the split core 111, and the stator 100 can be formed by inserting the split core 111. It becomes possible.

  The total number of outer arrows m511 and outer arrows m513 to be inserted is related to the fact that the member bundle CS is formed by stacking sixty nine folded members C. When the ninety-nine folded members C are stacked in the member bundle CS and one pitch corresponds to the width of one slot, the shape of the first ninety-nine folded member C1 is as follows. If it rises before the slot, the pattern that falls after the sixth slot and rises after the 12th slot is repeated. That is, by inserting the outer arrow m511 or the outer arrow m513 every six slots, the in-slot conductor 122 of the first ninety-nine folded member C1 is always supported in contact with the outer arrow m511 or the outer arrow m513. Become.

  If the outer arrow m511 and the outer arrow m513 are described with reference to FIG. 16, the outer arrow m511 of the first outer arrow mechanism M52 is inserted into the first slot of the coil assembly Sa, and this position is at phase 0 degree. Next, the outer arrow m513 of the second outer arrow mechanism M53 is inserted into the seventh slot of 45 degrees phase, and the outer arrow m513 of the third outer arrow mechanism M54 is inserted into the thirteenth slot of phase 90 degrees. The outer arrow m511 of the fourth outer arrow mechanism M56 is inserted into the 25th slot of the phase 180 degrees, the outer arrow m513 of the fifth outer arrow mechanism M57 is inserted into the 31st slot of the phase 225 degrees, and the sixth outer arrow mechanism M58. The outer arrow m513 is inserted into the 37th slot of phase 270 degrees. By defining the position of the first 99th folding member C1, the second 99th folding member C2 to the sixth 99th folding member C6 are also in contact with the first 99th folding member C1. This defines the position.

  The applicant applies a case where the outer arrow m513 is inserted into all 24 slots excluding a portion where the first outer diameter winding / squeezing device M51 and the second outer diameter winding / squeezing device M55 are in contact, and a total of six outer arrows m511 and outer arrows m513. Compared to the case of using a book, almost the same effect was obtained. This is considered to be because the position is determined by the reason described above, and when the number is reduced from six, the positional deviation amount does not fall within the specified range. Therefore, it was confirmed that the coil assembly Sa can be shaped within the specified range by using a total of six outer arrows m511 and outer arrows m513 as shown in the present embodiment.

  As shown in the problem, the operation of aligning the in-slot conductor portion 122 of the coil assembly Sa on the radiation using the coil assembly shaping machine M50 has been conventionally performed manually depending on the experience and intuition of the operator. For this reason, the work efficiency is very poor, and there is a possibility that the finish may vary depending on the skill of the operator or that the insulation coating covering the outer periphery of the flat conductor D may be damaged. However, by obtaining an automated method for shaping the coil assembly Sa according to the present invention, it is possible to automate the production of the stator 100 and consequently contribute to reducing the manufacturing cost of the stator 100.

  Further, the reason why the first outer diameter winding and drawing device M51 and the second outer diameter winding and drawing device M55 are provided diagonally as shown in FIG. 9 and the like is that there is an appropriate force when the coil assembly Sa is drawn and drawn. The reason is that it is necessary to secure a space on the outer peripheral surface because of the added arrangement and the relationship of inserting the outer arrow m511 and the outer arrow m513. In the experiment conducted by the applicant, compared with the case where four equivalents of the first outer diameter winding / squeezing device M51 were prepared and wound and squeezed, it was confirmed that the windings were not excessively squeezed and fit within the dimension a shown in FIG. Yes.

  Further, when the device such as the first outer diameter winding / squeezing device M51 and the outer arrow m511 such as the first outer arrow mechanism M52 interfere with each other, the first outer diameter winding / squeezing device M51 etc. Since it is necessary to insert the outer arrow m511 or the outer arrow m513 by retracting the outer diameter winding / squeezing device M51 or the like, the lead time becomes longer. If the first outer diameter winding / squeezing device M51 and the second outer diameter winding / squeezing device M55 are prepared diagonally and the coil assembly Sa can be wound only by this, the first outer diameter winding / squeezing device M51 and the second outer diameter winding device will be provided. Since the outer diameter m511 of the first outer diameter winding and squeezing device M51 and the fourth outer arrow mechanism M56 can be inserted without retracting the squeezing device M55, the lead time can also be reduced.

  Next, description will be made on the point that by using the coil sub-assembly shaping machine M10, the influence of the springback of the member bundle CS can be suppressed and the formation of the coil sub-assembly CSa can be assisted. The coil sub-assembly shaping machine M10 performs shaping of the ninety-nine folded member C by pressing with the end portion pressing guide M16 using the shape characteristic of the member bundle CS. Conventionally, the shaping operation of the member bundle CS has been performed over several seconds using an expensive device as compared with the coil sub-assembly shaping machine M10. However, by using the coil sub assembly shaping machine M10, the cost of the apparatus can be reduced and the cycle time can be shortened to about 1/4. Therefore, the cost of the stator 100 can be reduced.

  Specifically, the shape characteristic of the member bundle CS will be mentioned. First, as shown in FIG. 4, the shape of the member bundle CS is obtained by stacking ninety nine folded members C while shifting six pieces. For this reason, as shown in FIG. 7, the power is obtained by pushing the coil sub-assembly CSa to the outer peripheral side with the slide guide M12, and the ninety-nine folded members C constituting the member bundle CS are pressed against each other. The shape of the coil sub-assembly CSa is stabilized in a spiral shape on the upper base M17a of the coil sub-assembly shaping machine M10. In addition, at the inner peripheral end CS1 of the member bundle CS, the inward protrusion of the first ninety-nine folded member C1 is guided by the inner diameter fixed guide M11, so that the coil sub-assembly CSa is deformed on the inner side. It is preventing.

  Further, at the outer peripheral end CS2 of the member bundle CS, the end pressure guide M16 presses the first ninety-nine folded member C1 to the sixth ninety-fold folded member C6 in the circumferential direction, thereby forming the shape of the coil sub-assembly CSa. Will be stable. The force generated from the end pressing guide M16 can be used for the alignment of the coil sub-assembly CSa by being inserted into the lower surface side recess CSa1 at the protrusion M18a of the misalignment protrusion M18.

  With such a configuration, in addition to shortening the cycle time, the portion where the surface of the coil sub-assembly CSa and the components of the coil sub-assembly shaping machine M10 are in direct contact with each other is minimized, so the insulation coating of the flat conductor D is damaged. There is a merit that fear can be reduced.

  Further, in the coil assembly shaping machine M50, the protrusion m542 is provided on the outer surface of the inner diameter guide section m541, so that the inner teeth insertion hole 121 is shifted when the outer diameter winding is performed on the coil assembly Sa. Can be prevented. The winding diaphragm is directly applied to the outer peripheral side of the coil assembly Sa. However, the ninety-nine folded members C contacting the outermost periphery of the coil assembly Sa are not only pulled directly from the circumferential direction, but are also arranged on the outer peripheral side. The friction with the nineteen-fold member C is also affected by the winding drawing.

  As a result, the innermost ninety-nine folded member C receives a force that moves in the radial direction. While the inner arrow m532 is inserted, it receives the force of the winding diaphragm, but it is not preferable that the innermost peripheral side be displaced because it needs to be a reference. However, since the protrusion m542 is provided on the inner diameter guide part m541, the movement is restricted by the protrusion m542 in addition to the friction between the inner diameter guide part m541 and the flat conductor D, so that deformation on the inner peripheral side is prevented. I can do it. By providing the inner diameter guide portion m541 and the projection portion m542 in the coil assembly shaping machine M50, the in-slot conductor portion 122 is neatly arranged on the radiation in the coil assembly Sa, and the teeth 115 of the divided core 111 are included. It is possible to prevent the insertion into the tooth insertion hole 121 from being hindered.

  Although the invention has been described according to the present embodiment, the invention is not limited to the embodiment, and by appropriately changing a part of the configuration without departing from the spirit of the invention. It can also be implemented.

  For example, in the present embodiment, the stator 100 employs a 48-slot object, but this does not prevent changing this by design thinking. Further, along with this, it is not hindered to change the number and arrangement position of the outer arrows m513. In addition, regarding the device configuration of the coil sub-assembly shaping machine M10, the coil assembly shaping machine M50, etc., changes within a range that does not deviate from the gist thereof are not hindered.

100 Stator 120 Coil cage 121 Teeth insertion hole 122 In-slot lead wire part 130 Outer ring C Ninety-fold fold member CS Member bundle CS1 Inner peripheral edge part CS2 Outer peripheral edge part CSa Coil sub-assembly CSa1 Lower surface side concave part D Flat conductor M10 Coil sub Assy shaping machine M11 Inner diameter fixed guide M12 Slide guide M16 End pressing guide M18 Misalignment stop projection M50 Coil assembly shaping machine M51 First outer diameter winding and contracting device M52 First outer arrow mechanism M53 Second outer arrow mechanism M54 Third outer arrow mechanism M55 Second outer diameter coiling device M56 Fourth outer arrow mechanism M57 Fifth outer arrow mechanism M58 Sixth outer arrow mechanism M59 First inner arrow mechanism M60 Second inner arrow mechanism M61 First inner diameter guide M62 Second inner diameter guide Sa Coil assembly

Claims (3)

A flat conductor is edgewise bent into ninety-nine folds to form a ninety-nine fold member, a plurality of the ninety-nine fold members are stacked to form a coil sub-assembly, and the coil sub-assembly is wound in a spiral shape In the manufacturing method of the stator using the distributed winding coil that forms the coil assembly,
The inner diameter of the coil assembly is regulated to an inner diameter regulation dimension by an inner diameter guide,
Inserting an inner arrow into the teeth insertion hole of the coil assembly from the inner peripheral side of the coil assembly,
The outer periphery of the coil assembly is moved in the circumferential direction by an outer diameter winding and drawing device disposed on the outer periphery of the coil assembly,
Inserting and positioning an outer arrow from the outer peripheral side of the coil assembly into the teeth insertion hole, and shaping the coil assembly;
The manufacturing method of the stator using the distributed winding coil characterized by these. In the manufacturing method of the stator using the distributed winding coil according to claim 1,
The inner arrow is inserted into the teeth insertion hole into which the outer arrow is inserted;
The manufacturing method of the stator using the distributed winding coil characterized by these. In the manufacturing method of the stator using the distributed winding coil of Claim 1 or Claim 2,
The outer diameter winding drawing device is provided in two so as to be diagonally located;
The manufacturing method of the stator using the distributed winding coil characterized by these.

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