Stator manufacturing method and motor manufacturing method

Abstract

The manufacturing method of the stator (220) includes a main guide preparation process in which a pair of main guides (51) that guide the wire rod (2) into the opening (31) are arranged opposite each other with a first guide gap (CL1) in between, on the stator core (30); a subguide preparation process in which a pair of subguides (61) that guide the wire rod (2) at positions shifted from the opening (31) in the rotational direction of the rotating shaft (22) are arranged opposite each other with a second guide gap (CL2) in between, on the stator core (30); and a winding process in which the positions of the first guide gap (CL1) and the second guide gap (CL2) are moved relatively along the axial direction of the rotating shaft (22) to wind the wire rod (2) inserted into the slot (33) through the first and second guide gaps (CL1, CL2) around the bottom (32) while adjusting the winding position in the slot (33).

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a stator and a method for manufacturing a motor. [Background technology]

[0002] Japanese Patent No. 4771137 discloses a method for manufacturing a motor in which windings are pushed radially outward beyond an imaginary line connecting both ends of the circumferential direction of the inner peripheral surface of an outer core. Summary of the Invention

[0003] In the above method, when the winding is pushed radially outward from the imaginary straight line, the nozzle is stopped or moved slowly near the teeth, which hinders high-speed winding.

[0004] An object of the present invention is to increase the speed of the winding.

[0005] According to one aspect of the present invention, there is provided a method for manufacturing a stator, in which a stator core having a slot formed therein, the width of the opening of which is narrower than the width of the opposing bottom, is held on the axis of a rotating shaft, and a wire fed from a nozzle is guided into the slot and wound around the bottom. The method includes: a main guide preparation process for arranging a pair of main guides facing each other across a first guide gap with respect to the stator core held on the axis of the rotating shaft, the pair of main guides guiding the wire into the opening; a subguide preparation process for arranging a pair of subguides facing each other across a second guide gap with respect to the stator core held on the axis of the rotating shaft, the pair of subguides guiding the wire at a position offset from the opening in the rotational direction of the rotating shaft; and a winding process for winding the wire around the bottom while adjusting the winding position within the slot of the wire inserted into the slot through the first guide gap and the second guide gap by moving the position of the first guide gap and the position of the second guide gap relatively along the axial direction of the rotating shaft. [Effects of the Invention]

[0006] According to this aspect, the winding position within the slot of the wire inserted into the slot through the gap between the pair of main guides is adjusted according to the relative positions of the first guide gap and the second guide gap. This eliminates the need to reduce the winding speed when winding around the corners of the slot bottom where the width of the opening is narrower than the width of the opposing bottom, making it possible to increase the winding speed. [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a schematic configuration diagram of a winding device according to an embodiment of the present invention; [Figure 2] FIG. 2 is a cross-sectional view showing a stator core according to the embodiment of the present invention. [Figure 3] 1 is a cross-sectional view showing a motor according to an embodiment of the present invention. [Figure 4] 1 is a first side view of a rotation device according to an embodiment of the present invention. FIG. [Figure 5] FIG. 2 is a second side view of the rotation device according to the embodiment of the present invention. [Figure 6] 1 is a perspective view of a pallet according to an embodiment of the present invention. FIG. [Figure 7] 10A to 10C are explanatory diagrams of a main guide preparation step and a sub-guide preparation step according to the embodiment of the present invention. [Figure 8] FIG. 3 is a first explanatory view of a winding step according to an embodiment of the present invention. [Figure 9] FIG. 6 is a second explanatory view of the winding step according to the embodiment of the present invention. [Figure 10] FIG. 10 is a third explanatory view of the winding step according to the embodiment of the present invention. [Figure 11] FIG. 10 is an explanatory diagram of aligned winding performed by adjusting the winding position within the slot. [Figure 12] 5 is a diagram showing a first setting example of the rotation speed of the stator core when winding in regular winding according to the embodiment of the present invention. FIG. [Figure 13] 10 is a diagram showing a second example of setting the rotation speed of the stator core when winding in regular winding according to the embodiment of the present invention. FIG. [Figure 14]10 is a diagram showing a first setting example of the rotation speed of the stator core during a winding process incorporating a stripping process according to an embodiment of the present invention. FIG. [Figure 15] FIG. 10 is a diagram showing a second setting example of the rotation speed of the stator core during the winding process in which the stripping process is incorporated according to the embodiment of the present invention. [Figure 16] 10A to 10C are explanatory diagrams of a stator core carrying-in / out process according to the embodiment of the present invention. [Figure 17] 5 is a flowchart illustrating a method for manufacturing a motor according to an embodiment of the present invention. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0008] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

[0009] The winding device 1 is a device for manufacturing an aligned wound coil by winding the wire 2 unwound from a nozzle 3 in an aligned manner around a stator core 30. As shown in FIG. 1, the winding device 1 includes a nozzle 3 that unwound the wire 2 from its tip 3a, a nozzle moving device 10 that moves the nozzle 3, a rotation device 20 that rotates the stator core 30 around a spindle 22 as a rotation axis, a stripping device 70 that strips the insulating coating of the wire 2, and a wire unwinding device 80 that unwound the wire 2 while applying tension to the wire 2.

[0010] The nozzle 3 is a cylindrical member having a through-hole (not shown) penetrating in the axial direction. The nozzle 3 is attached to the nozzle moving device 10 so that a tip end 3a where one end of the through-hole opens faces the stator core 30. The nozzle 3 pays out the wire rod 2 supplied from the wire rod pay-out device 80 from the tip end 3a and guides it to the stator core 30.

[0011] The nozzle moving device 10 is an electric slider that can reciprocate a movable base 11 along the axial direction AX of the spindle 22, and the nozzle 3 and the peeling device 70 are attached to the movable base 11. The nozzle moving device 10 is supported on a base 5 via a support 6.

[0012] The rotation device 20 is a spindle unit and includes an electric motor 21, a spindle 22 that also serves as the rotation shaft of the electric motor 21, a spindle flange 23 attached to the tip of the spindle 22, an actuator unit 24 that is provided on the spindle flange 23 and drives a rotor 64 of a sub-guide mechanism 60 (described later) in the axial direction AX of the spindle 22, and a cover 25 that houses the electric motor 21, the spindle 22, the spindle flange 23, and the actuator unit 24. The electric motor 21 may be provided with a rotation shaft separate from the spindle 22 and rotate the spindle 22.

[0013] The winding device 1 is provided with a pair of rotation devices 20, namely, rotation devices 20A and 20B, in which spindles 22 are arranged facing each other with a common axis. The rotation device 20A is supported on the base 5 via a support base 7, and the rotation device 20B is supported on the base 5 via a support base 8. The pair of rotation devices 20 are rotated synchronously. One of the pair of rotation devices 20 (20A, 20B) may be a rotation device that does not have an electric motor 21 as a drive source.

[0014] As shown in Figures 1 and 2, the wire 2 fed from a nozzle 3 is wound around the stator core 30. Figure 2 is a view of the stator core 30 as viewed from the cross-sectional direction. The stator core 30 is a divided core, and as shown in Figure 2, when the stator core 30 is viewed from the cross-sectional direction, slots 33 are formed in which the width W1 of the openings 31 is narrower than the width W2 of the opposing bottom portions 32. The cross-sectional direction is defined as the cross-sectional direction of a cross section intersecting (orthogonal to) the openings 31 and the bottom portions 32. The cross-sectional direction is defined as the cross-sectional direction of a cross section intersecting (orthogonal to) the longitudinal direction of the stator core 30 (the vertical direction in Figure 1).

[0015] The opening 31 of the slot 33 communicates with the inside of the slot 33, and the bottom 32 of the slot 33 faces the opening 31 on the front side, with the opening 31 side (upper side in FIG. 2) being the front side. The opening 31 has a width W1 and extends to both ends in the longitudinal direction of the stator core 30 (up and down direction in FIG. 1), and is located at the center of the bottom 32 in the axial direction AX of the spindle 22.

[0016] The stator core 30 has flanges 34, 35 extending from the bottom portion 32. The flanges 34, 35 extend from the front side of the bottom portion 32 (upper side in FIG. 2 ) at an angle inward of the slot 33 in the axial direction AX of the spindle 22, forming an opening 31 between their tip ends. The flanges 34, 35, together with the bottom portion 32, form a trapezoidal slot 33 that opens at the opening 31 when viewed in the longitudinal direction of the stator core 30 (i.e., when viewed in the cross-sectional direction of the stator core 30). The slot 33 extends in the longitudinal direction of the stator core 30 and is open at both ends of the stator core 30 in the longitudinal direction.

[0017] The stator core 30 further has flanges 36, 37 extending substantially perpendicularly from the back side (lower side in FIG. 2 ) of the bottom portion 32. The flanges 36, 37, together with the bottom portion 32, form a slot 38 on the back side of the bottom portion 32, and an opening 39 of the slot 38 is formed between the tip ends of the flanges 36, 37.

[0018] When viewed in the longitudinal direction of the stator core 30, the slots 38 are formed in a rectangular shape that opens at openings 39, and the openings 39 have a width W3 that is the same as the width W2 of the bottom 32 and extend to both ends in the longitudinal direction of the stator core 30. The slots 38 extend in the longitudinal direction of the stator core 30 and are open at both ends of the stator core 30 in the longitudinal direction.

[0019] The wire 2 is wound around the bottom portion 32. The wire 2 is inserted into the slot 33 through the opening 31 and folded back to the back side of the bottom portion 32 (the lower side in FIG. 2) at one longitudinal end of the stator core 30. The wire 2 folded back to the back side of the bottom portion 32 is inserted into the slot 38 through the opening 39, folded back to the front side of the bottom portion 32 (the upper side in FIG. 2) at the other longitudinal end of the stator core 30, and inserted into the slot 33 again. By repeating this process, the wire 2 is wound around the bottom portion 32 multiple times.

[0020] 3, stator core 30 is assembled into motor 200 after winding. Motor 200 is an electric motor, and includes rotor 210, stator 220 that houses rotor 210, shaft 230 that rotates integrally with rotor 210, and cylindrical housing 240 that covers the outer periphery of stator 220.

[0021] Stator 220 has a holder 221 that houses stator cores 30 as multiple split cores, and multiple wound stator cores 30 housed in holder 221. Holder 221 is provided with multiple core housing portions 221a that house stator cores 30, arranged radially, and each core housing portion 221a houses a wound stator core 30.

[0022] Core accommodating portion 221a is formed to fit the outer shape of stator core 30, and is narrower on the radially inner side of motor 200 than on the radially outer side. Stator 220 is assembled into housing 240 with stator core 30 after multiple windings housed in multiple core accommodating portions 221a of holder 221. Stator core 30 after multiple windings is installed in motor 200 with its position in the circumferential, radial, and axial directions on motor 200 restricted.

[0023] As shown in FIGS. 4 and 5, the rotating device 20 includes a holding mechanism 40 (see FIG. 5) that holds the stator core 30, and a main guide mechanism 50 and a sub-guide mechanism 60 that guide the wire 2 into the slot 33 of the stator core 30.

[0024] As shown in Figure 5, the holding mechanism 40 has a clamping portion 41 that clamps the stator core 30 (see Figure 1), an arm 42 that supports the clamping portion 41 at the tip end and is attached to the spindle flange 23 (see Figure 1) at the base end, and an actuator portion 43 that moves the clamping portion 41 in the axial direction AX of the spindle 22 relative to the arm 42.

[0025] The clamping unit 41 is supported by an arm 42 via an actuator unit 43. The arm 42 is disposed beside the rotor 64 of the sub-guide mechanism 60 and extends in the axial direction AX of the spindle 22. The arm 42 is bent in a crank shape on the tip side of the rotor 64 and is offset radially inward of the spindle 22. The actuator unit 43 is fixed to the arm 42 and drives the clamping unit 41 in the axial direction AX of the spindle 22.

[0026] The winding device 1 is provided with a pair of holding mechanisms 40, including a holding mechanism 40A that is provided in the rotating device 20A and a holding mechanism 40B that is provided in the rotating device 20B, and the stator core 30 (see FIG. 1) is clamped by a pair of clamping portions 41 of the pair of holding mechanisms 40. The stator core 30 is clamped by the pair of clamping portions 41 from both sides in the axial direction AX of the spindle 22 with the opening 31 facing the radial direction of the spindle 22. Note that FIG. 1 shows a state in which the opening 31 is clamped in this position and is visible to the front.

[0027] As shown in Figure 4, the main guide mechanism 50 includes a main guide 51, an arm 52 that supports the main guide 51 at its tip end and is attached to the spindle flange 23 (see Figure 1) at its base end, and an actuator unit (not shown) that moves the main guide 51 relative to the arm 52 in the axial direction AX of the spindle 22.

[0028] The main guide 51 guides the wire 2 into the opening 31 of the stator core 30 (see FIG. 1). The main guide 51 has a tip guide portion 51a that slopes toward the spindle 22 as it approaches the tip. The tip guide portion 51a is formed in a tapered shape that narrows toward the tip, and the main guide 51 guides the wire 2 into the opening 31 of the stator core 30 by the tip guide portion 51a while rotating around the spindle 22 as the rotation axis.

[0029] The main guide 51 is supported by an arm 52 via an actuator unit. The arm 52 is disposed beside the rotor 64 of the sub-guide mechanism 60 and extends in the axial direction AX of the spindle 22. The arm 52 is bent in a crank shape on the tip side of the rotor 64 and is offset radially inward of the spindle 22. The actuator unit is fixed to the arm 52 and drives the main guide 51 in the axial direction AX of the spindle 22.

[0030] The winding device 1 is provided with a pair of main guide mechanisms 50, namely, a main guide mechanism 50A which is a main guide mechanism 50 provided on the rotating device 20A, and a main guide mechanism 50B which is a main guide mechanism 50 provided on the rotating device 20B, and the wire 2 is guided into the opening 31 of the stator core 30 (see Figure 1) by a pair of main guides 51 of the pair of main guide mechanisms 50.

[0031] As shown in Figures 4 and 5, the sub-guide mechanism 60 includes a rotating body 64 that is mounted on the spindle flange 23 (see Figure 1) via the actuator section 24 (see Figure 1), a sub-guide 61, and an arm 62 that is attached to a slide block (not shown) that supports the sub-guide 61 at the tip end and supports the arm 62 at the base end so that it can slide freely in the radial direction of the spindle 22 relative to the rotating body 64.

[0032] The sub-guide 61 has a guide surface 61a that guides the wire rod 2, and a guide claw 61b that is formed at the tip of the sub-guide 61 and is continuous with the guide surface 61a. The guide surface 61a is formed as the outer surface of the tapered portion of the sub-guide 61 that guides the wire rod 2 toward the tip side while rotating around the spindle 22 as the rotation axis, and the guide claw 61b extends at the tip of the sub-guide 61 in the radial direction of the spindle 22 (see FIG. 1) toward the axial side of the spindle 22.

[0033] The arm 62 extends in the axial direction AX of the spindle 22 and is fixed at its base end to a slide block. The slide block is housed in a rotating body 64 so as to be slidable in the radial direction of the spindle 22.

[0034] The rotating body 64 holds the slide block so that it can slide freely in the radial direction of the spindle 22, and rotates integrally with the sub-guide 61 via the slide block and arm 62. The actuator unit 24 (see FIG. 1) drives the rotating body 64 in the axial direction AX of the spindle 22, whereby the sub-guide 61, which is attached to the rotating body 64 via the slide block and arm 62, moves in the axial direction AX of the spindle 22.

[0035] The actuator unit 24 is further configured to be able to drive the slide block in the radial direction of the spindle 22, and when the actuator unit 24 drives the slide block in the radial direction of the spindle 22, the sub-guide 61 attached to the slide block via the arm 62 moves in the same direction.

[0036] The sub-guide 61 is provided at a position shifted in the rotation direction of the spindle 22 (see FIG. 1) from the main guide 51. The sub-guide 61 is provided at a position shifted by 90 degrees from the main guide 51 in the rotation direction of the spindle 22.

[0037] The winding device 1 is provided with a pair of sub-guide mechanisms 60, consisting of a sub-guide mechanism 60A which is a sub-guide mechanism 60 provided in the rotating device 20A and a sub-guide mechanism 60B which is a sub-guide mechanism 60 provided in the rotating device 20B, and the wire 2 is guided into the slot 33 of the stator core 30 (see Figure 2) by a pair of sub-guides 61 of the pair of sub-guide mechanisms 60.

[0038] The sub-guide mechanisms 60 are provided at positions offset from the main guide mechanism 50 in the forward and reverse directions in the rotation direction of the spindle 22 (see FIG. 1). Therefore, the winding device 1 is provided with a total of four sub-guide mechanisms 60 (two pairs in total), namely, sub-guide mechanisms 60A, 60B, 60C, and 60D. The sub-guide mechanisms 60 are provided at positions offset by 90 degrees from the main guide mechanism 50 in the forward and reverse directions in the rotation direction of the spindle 22. The rotating body 64 is shared between the sub-guide mechanisms 60A and 60C on the rotating device 20A side and between the sub-guide mechanisms 60B and 60D on the rotating device 20B side.

[0039] 1, the stripping device 70 is mounted on a movable base 11 and moves together with the nozzle 3. The stripping device 70 includes a cutter 71 pressed against the periphery of the wire 2, a rotation mechanism 72 that rotates the cutter 71 around the wire 2 and presses the cutter 71 against the wire 2 by using centrifugal force generated during the rotation, a motor 73 that rotates the cutter 71 via the rotation mechanism 72, and an electric slider 74 that moves the cutter 71 along the wire 2 via the rotation mechanism 72. The cutter 71 pressed against the periphery of the wire 2 is moved along the wire 2 while being rotated around the wire 2, thereby stripping the insulating coating of the wire 2.

[0040] The wire rod feeding device 80 includes a spool 81 that is rotated by an electric motor (not shown) and feeds out the wound wire rod 2, and a tensioning device 82 that applies tension to the wire rod 2 unwound from the spool 81, and feeds out the wire rod 2 toward the peeling device 70. The wire rod feeding device 80 is supported on the base 5 via a support table 9, and the tensioning device 82 applies tension to the wire rod 2 between the spool 81 and the peeling device 70. The wire rod 2 fed out from the wire rod feeding device 80 is fed out from the nozzle 3 through the peeling device 70. The tip of the wire rod 2 fed out from the nozzle 3 is gripped by a chuck device (not shown).

[0041] The winding device 1 is provided with a transport device 90 that transports stator cores 30 in and out of the winding device 1, a lifting device 100 as an advancing / retracting device that moves a holding portion 123 of a pallet 110 transported by the transport device 90 toward and away from a pair of clamping portions 41 of the winding device 1, and a controller 150 that controls the winding device 1, the transport device 90, and the lifting device 100. The transport device 90 and the lifting device 100 may be controlled by a controller separate from the controller 150, and may be connected to the controller 150 so as to be able to communicate with each other.

[0042] The conveying device 90 conveys the pallet 110 in a conveying direction that crosses between the pair of clamping portions 41 of the rotating devices 20A and 20B. The conveying device 90 is disposed opposite the nozzle 3 with the axis of the spindle 22 sandwiched therebetween. The conveying device 90 is supported by the base 5 and disposed below the axis of the spindle 22.

[0043] The conveying device 90 includes a conveying belt 91 that conveys a pallet 110, a driving device 92 that supports the conveying belt 91 via pulleys (not shown) at both ends installed at a distance in the conveying direction and rotates the conveying belt 91 around the pulleys, and a linear guide 93 that guides the pallet 110 in the conveying direction. When the driving device 92 rotates the conveying belt 91, the pallet 110, which is fixed to a movable block of the linear guide 93 and engaged with the conveying belt 91, moves in the conveying direction. The driving device 92 can rotate the conveying belt 91 in both forward and reverse directions, and the pallet 110 reciprocates along the conveying direction. The conveying belt 91 may be a toothed belt with concave and convex portions as shown in the example, or alternatively, a chain belt or a ball screw may be used.

[0044] 1 and 6, the pallet 110 has a holding unit 120 that holds the stator core 30. The holding unit 120 is provided on one end side (left side in FIGS. 1 and 6) of the pallet 110 in the axial direction AX of the spindle 22, and a movable block of the linear guide 93 (see FIG. 1) is fixed to the back side (lower side in FIGS. 1 and 6) of the other end side (right side in FIGS. 1 and 6) of the pallet 110 in the axial direction AX of the spindle 22.

[0045] As shown in Figure 6, the holding unit 120 has a cylindrical base 121 with a flange that is attached by penetrating the pallet 110, a shaft 122 that is inserted into the base 121, a holding portion 123 that is provided at the tip of the shaft 122 and holds the stator core 30, a flange 124 that is provided between the base 121 and the holding portion 123 and abuts against the base 121, a roller unit 125 that is provided at the base end of the shaft 122, and a return spring 126 that is provided between the base 121 and the roller unit 125.

[0046] Base 121 is a linear ball bearing that supports shaft 122 for linear motion. Base 121 has a cylindrical portion 121a that penetrates pallet 110, and a flange portion 121b that is housed in and fixed to recessed mounting portion 110a of pallet 110 with its surface exposed on the front side of pallet 110 (upper side in FIG. 6).

[0047] The holding portion 123 and the flange 124 are provided on the front side of the pallet 110 and fixed to the tip side of the shaft 122. The holding portion 123 holds an end portion of the stator core 30 in the longitudinal direction (the vertical direction in FIG. 1 ), thereby holding the stator core 30 in an upright state, and the flange 124 abuts against the flange portion 121b of the base 121.

[0048] The roller unit 125 has a roller 125a that rotates in the conveying direction of the conveying device 90 (see FIG. 1), and a holding member 125b that rotatably holds the roller 125a. The return spring 126 is provided between the cylindrical portion 121a of the base 121 and the holding member 125b of the roller unit 125, and generates a spring force in a direction that moves the roller unit 125 away from the pallet 110.

[0049] 1, the lifting device 100 is disposed facing the pair of clamping parts 41 in the radial direction of the spindle 22. The lifting device 100 is supported by a base 5 and disposed below the pair of clamping parts 41. The lifting device 100 has a cylinder 101 and a pushing jig 102 attached to the tip of the rod of the cylinder 101.

[0050] The pallet 110 has a fixed position in the conveying direction of the conveying device 90 where the holding unit 120 is aligned with the spindle 22, and when the cylinder 101 extends relative to the pallet 110 at the fixed position, the pushing jig 102 comes into contact with the roller 125a of the holding unit 120 and pushes the holding portion 123. Therefore, the lifting device 100 moves the holding portion 123 in the forward / backward direction between the pair of clamping portions 41 by extending and retracting relative to the pallet 110 at the fixed position.

[0051] As shown in FIG. 6, the pallet 110 is provided with a pair of holding units 120, namely, a first holding unit 120A that holds the stator core 30 before winding, and a second holding unit 120B that holds the stator core 30 after winding.

[0052] Of the pair of holding units 120, first, the second holding unit 120B receives the wound stator core 30 from the pair of clamping sections 41 (see FIG. 1), and then the first holding unit 120A supplies the unwound stator core 30 to the pair of clamping sections 41. For this reason, the first holding unit 120A is installed on the front side in the transfer direction of the transfer device 90 relative to the second holding unit 120B.

[0053] 1 is formed in a flange shape that simultaneously contacts the rollers 125a (see FIG. 6) of the first and second holding units 120A and 120B. Therefore, the lifting device 100 simultaneously advances and retreats the holding portions 123 (see FIG. 6) of the first and second holding units 120A and 120B between the pair of clamping portions 41.

[0054] As shown in Fig. 1, a controller 150 controls the operation of each device 10, 20, 70, 80, such as the nozzle moving device 10, of the winding device 1, as well as the transport device 90 and the lifting device 100. The controller 150 is composed of a microcomputer equipped with a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), and an I / O interface (Input / Output Interface). The RAM stores data for CPU processing, and the ROM stores the CPU control program and the like in advance. The I / O interface is used for inputting and outputting information to and from each device 10, 20, 70, 80, 90, and 100 connected to the controller 150.

[0055] Next, a description will be given of a method for manufacturing the stator 220 according to this embodiment. The method for manufacturing the stator 220 is used in the winding device 1, and the operation of the winding device 1 is automatically controlled by the controller 150.

[0056] The manufacturing method of the stator 220 is a method in which a stator core 30 (see Figure 2) having a slot 33 formed therein, where the width W1 of the opening 31 is narrower than the width W2 of the opposing bottom 32, is held on the axis of a spindle 22 (see Figure 1) serving as a rotation axis, and the wire 2 fed from the nozzle 3 is guided into the slot 33 and wound around the bottom 32, and includes a main guide preparation process and a sub-guide preparation process shown in Figure 7, and a winding process shown in Figures 8 to 10.

[0057] The manufacturing method of the stator 220 further includes a clamping process shown in FIG. 7(a), in which the stator core 30 before winding, supplied by the first holding unit 120A (see FIG. 6), is clamped between a pair of clamping portions 41, thereby holding the stator core 30 on the axis of the spindle 22 (see FIG. 1).

[0058] In the main guide preparation process shown in Figure 7(b), a pair of main guides 51 that guide the wire 2 into the opening 31 are arranged opposite each other with a first guide gap CL1 between them, with the stator core 30 held on the axis of the spindle 22.

[0059] The main guide 51 is arranged to guide the wire 2 toward the opening 31 by being driven by an actuator unit (not shown), and a first guide gap CL1 is formed between a pair of tip guide portions 51a of the pair of main guides 51.

[0060] 2, the first guide gap CL1 formed by the pair of main guides 51 is larger than the outer diameter of the wire 2 and smaller than the width W1 of the opening 31. This prevents the insulating coating of the wire 2 guided into the opening 31 by the pair of main guides 51 from being damaged by the edges of the flanges 34, 35.

[0061] In the sub-guide preparation process shown in Figure 7(c), a pair of sub-guides 61 (here, a pair of sub-guides 61 of sub-guide mechanisms 60A and 60B, and a pair of sub-guides 61 of sub-guide mechanisms 60C and 60D) that guide the wire 2 at a position shifted from the opening 31 in the rotational direction of the spindle 22 are arranged opposite each other with a second guide gap CL2 between them, for the stator core 30 held on the axis of the spindle 22.

[0062] The sub-guides 61 are arranged so as to be driven by the actuator unit 24 (see FIG. 1) to guide the wire 2 to the slots 33 (see FIG. 2) of the stator core 30. The second guide gap CL2 is formed between a pair of guide claws 61b of the pair of sub-guides 61, and is set to the same size as the first guide gap CL1.

[0063] The main guide preparation step and the sub-guide preparation step may be performed simultaneously, or the sub-guide preparation step may be performed before the main guide preparation step.

[0064] In the winding process shown in FIGS. 8 to 10, the position of the first guide gap CL1 of the main guide 51 and the position of the second guide gap CL2 of the sub-guide 61 are moved relative to each other along the axial direction AX of the spindle 22, thereby adjusting the winding position of the wire 2 inserted into the slot 33 through the first and second guide gaps CL1 and CL2 within the slot 33 (see FIG. 2), and winding is performed around the bottom portion 32. In FIGS. 8 to 10, the rotation direction of the stator core 30 is clockwise when viewing the stator core 30 from the left side in the drawings. In the winding process shown in FIGS. 8 to 10, the center position of the nozzle 3 is aligned with the center position L1 of the opening 31 of the stator core 30 in the axial direction AX of the spindle 22. In other words, the center position L1 of the opening 31 of the stator core 30 is the center position of the bottom portion 32 of the stator core 30. The pair of sub-guides 61 forming the second guide gap CL2 are provided at an interval of 180 degrees in the rotation direction of the spindle 22, as shown in FIGS.

[0065] Figure 8 shows the arrangement of the main guide 51 and sub-guide 61 when winding the wire 2 on the bottom 32 of the stator core 30 at a winding position L2 to the left of the center position L1 of the opening 31 in the axial direction AX of the spindle 22.

[0066] A pair of main guides 51 that guide the wire 2 into the opening 31 are arranged relative to the opening 31 with a first guide gap CL1, and the center position of the first guide gap CL1 is aligned with the center position L1 of the opening 31 in the axial direction AX of the spindle 22. The pair of main guides 51 are fixedly arranged relative to the opening 31 of the stator core 30 during winding.

[0067] The pair of sub-guides 61 are aligned with the winding position L2 with the second guide gap CL2, and the center position of the second guide gap CL2 is aligned with the winding position L2 in the axial direction AX of the spindle 22. The pair of sub-guides 61 are aligned with the winding position L2 while maintaining the second guide gap CL2.

[0068] In the guide arrangement shown in Figure 8, compared to the state shown in Figure 7(c), for example, the position of the second guide gap CL2 of the sub-guide 61 is moved relatively to the left in the figure with respect to the position of the first guide gap CL1 of the main guide 51.

[0069] In this state, when the spindle 22 (see FIG. 1) rotates as indicated by the arrow in FIG. 8, the stator core 30 clamped by the clamping portion 41 rotates together with the main guide 51 and the sub-guide 61 around the spindle 22 as the rotation axis. That is, the stator core 30, the main guide 51, and the sub-guide 61 rotate relative to the nozzle 3. As the stator core 30 rotates, the wire 2 is unwound from the nozzle 3 and wound around the bottom portion 32 of the stator core 30. The actions of the main guide 51 and the sub-guide 61 during winding will be described below.

[0070] The wire 2 fed from the nozzle 3 is guided by the main guide 51 and inserted into the slot 33 through the first guide gap CL1 and the opening 31 (the wire 2 is shown by the solid line in FIG. 8 ). Furthermore, as the stator core 30 rotates, the wire 2 fed from the nozzle 3 is sequentially guided by the sub-guides 61 provided at 180-degree intervals, and the winding position of the wire 2 in the slot 33 is adjusted to the winding position L2 shown by the dashed line in FIG. 8 . In FIG. 8 , as the stator core 30 rotates approximately one time, the winding position of the wire 2 fed from the nozzle 3 and inserted into the slot 33 is adjusted from the position shown by the solid line to the position shown by the dashed line. Specifically, as shown in FIG. 8 , the wire 2 fed from the nozzle 3 abuts against the guide surface 61 a of the sub-guide 61, changing its traveling direction. As the sub-guide 61 continues to rotate, the wire 2 slides on the guide surface 61 a and is guided into the second guide gap CL2 between the guide claws 61 b. The guide surface 61a is formed as a three-dimensional outer surface that rotates and guides the abutting wire 2 toward the second guide gap CL2. Note that Fig. 8 shows only the wire 2 whose winding position in the slot 33 has been adjusted, and the other wires 2 are not shown.

[0071] As described above, in the axial direction AX of the spindle 22, the winding position of the wire 2 inserted into the slot 33 through the opening 31 is adjusted to the winding position L2 within the slot 33 as shown by the dashed line in FIG. 8. Furthermore, by adjusting the winding position in this manner, it is not necessary to reduce the rotational speed of the spindle 22 when winding the wire around the corner of the slot 33 (see FIG. 2), and therefore high-speed winding is possible. In this way, by adjusting the two second guide gaps CL2 of the pair of upper and lower sub-guides 61 in FIG. 8 to the left in FIG. 8 relative to the first guide gap CL1, the wire 2 can be positioned at the winding position "S" in FIG. 11.

[0072] When winding the wire 2 on the back side of the stator core 30, i.e., on the side of the opening 39 (see FIG. 2), the slots 38 (see FIG. 2) are rectangular, so there is no need to guide the wire 2 by a guide similar to the main guide 51. When winding the wire 2 on the back side of the stator core 30, the position of the nozzle 3 in the axial direction AX of the spindle 22 may be adjusted to the winding position L2, and in this case, the pair of sub-guides 61 of the lower sub-guide mechanisms 60C and 60D in FIG. 8 can be omitted.

[0073] 9 shows the arrangement of the main guide 51 and the sub-guides 61 when the wire 2 is wound around the bottom 32 of the stator core 30 at a winding position L3 that is to the right of the center position L1 of the opening 31 in the axial direction AX of the spindle 22. In this case, the pair of sub-guides 61 are aligned with the winding position L3, and first and second guide gaps CL1, CL2 are formed between the pair of main guides 51 and between the pair of sub-guides 61, similar to the case of FIG.

[0074] In this case, for example, compared to the state shown in FIG. 7(c), the position of the second guide gap CL2 of the sub-guide 61 is moved rightward in the drawing relative to the position of the first guide gap CL1 of the main guide 51, and the winding position of the wire 2 in the slot 33 in the axial direction AX of the spindle 22 is adjusted in the same manner as in FIG. 8, thereby being adjusted to winding position L3 as shown by the dashed line. In FIG. 9, as the stator core 30 rotates approximately one revolution, the winding position of the wire 2 unwound from the nozzle 3 and inserted into the slot 33 is adjusted from the position shown by the solid line to the position shown by the dashed line. Note that FIG. 9 illustrates only the wire 2 whose winding position in the slot 33 has been adjusted; the other wires 2 are not illustrated. In this way, by adjusting the two second guide gaps CL2 of each pair of upper and lower sub-guides 61 in FIG. 9 to the rightward in FIG. 9 with respect to the first guide gap CL1, the wire 2 can be arranged at winding position "5" in FIG. 11.

[0075] 10 shows the arrangement of the main guide 51 and the sub-guides 61 when the wire 2 is wound around the bottom 32 of the stator core 30 at the center position L1 of the opening 31 in the axial direction AX of the spindle 22. In this case, the center position L1 of the opening 31 is the winding position, so the pair of sub-guides 61 are aligned with the center position L1 of the opening 31 in the axial direction AX of the spindle 22.

[0076] In this case, for example, compared to the state shown in FIG. 8, the position of the second guide gap CL2 of the sub-guide 61 is moved to the right in the figure, thereby causing the main guide 51 and the sub-guide 61 to move relatively.

[0077] In this case, when the stator core 30 is rotated, the wire 2 fed from the nozzle 3 is wound around the bottom portion 32 at the center position L1 of the opening 31 in the axial direction AX of the spindle 22, and the winding position of the wire 2 in the slot 33 is not particularly adjusted by the sub-guide 61. However, even in this case, compared to the state shown in Fig. 8, for example, the winding position of the wire 2 in the slot 33 is adjusted by the relative movement of the main guide 51 and the sub-guide 61.

[0078] In this way, in the winding process, the first guide gap CL1 is fixed relative to the opening 31 of the stator core 30, and the second guide gap CL2 is moved along the axial direction AX of the spindle 22 relative to the first guide gap CL1, thereby adjusting the winding position of the wire 2 inserted into the slot 33 through the first and second guide gaps CL1 and CL2 within the slot 33.

[0079] Fig. 11 is an explanatory diagram of the aligned winding that is performed by adjusting the winding position within the slot 33. In Fig. 11, the winding order of the aligned winding is indicated by adding symbols "S" indicating the start of winding, "2 to 13" indicating intermediate winding orders, and "F" indicating the end of winding to the wire 2 wound around the bottom portion 32 of the stator core 30.

[0080] For example, the winding position of the wire 2 at the start of winding in winding order "S" is at a corner of the slot 33, and is covered by the flange 34 from the opening 31 side. Therefore, for this winding position, by winding using the guide arrangement shown in FIG. 8, the winding position of the wire 2 inserted into the slot 33 is adjusted, and the wire 2 is placed at the corner of the slot 33.

[0081] In this example, the wire rods 2 with winding orders "S", "2", "8", "9", "10" and "F" are wound in the guide arrangement shown in FIG. 8, the wire rods 2 with winding orders "4", "5", "6", "7", "12" and "13" are wound in the guide arrangement shown in FIG. 9, and the wire rods 2 with winding orders "3" and "11" are wound in the guide arrangement shown in FIG. 10.

[0082] In the winding process, the wire 2 is wound around the bottom 32 of the stator core 30, which rotates around the spindle 22 (see Figure 1) as a rotation axis, to form a layer 130 in which the wire 2 is aligned in the axial direction AX of the spindle 22, and multiple layers 130 are formed by stacking the next layer 130 on top of the formed layer 130.

[0083] When forming each layer 130, the position of the sub-guide 61 is shifted by one pitch equivalent to the outer diameter of the wire 2 in the axial direction AX of the spindle 22 each time the wire 2 is wound, thereby adjusting the winding position of the wire 2 within the slot 33, and thereby arranging the wire 2 side by side in the axial direction AX of the spindle 22.

[0084] When forming the next layer 130 on top of the previously formed layer 130, the position of the sub-guide 61 is shifted by half a pitch in the axial direction AX of the spindle 22, so that the winding position of the wire 2 in the slot 33 is adjusted to the midpoint between the two wires 2 of the previously formed layer 130.

[0085] In this example, a total of four layers 130, from the first layer 131 to the fourth layer 134, are formed by stacking them on top of each other, and the number of turns of wire 2 forming each layer 130 is less on the opening 31 side than on the bottom 32 side, depending on the width of the slot 33, which is narrower on the opening 31 side than on the bottom 32 side.

[0086] If the position of the wire rod 2 at the start of winding in the winding order "S" is shifted, the positions of the subsequent wire rods 2 will also be shifted. Furthermore, depending on how the wire rod 2 at the end of winding in the winding order "F" is wound, the aligned wound wire rod 2 may become unbalanced. For this reason, in the winding device 1, the rotational speed of the stator core 30 during aligned winding (in other words, the rotational speed of the spindle 22) is set as follows:

[0087] 12 and 13 are diagrams showing examples of setting the rotation speed of the stator core 30 during aligned winding. As shown in Fig. 12 and 13, the rotation speed of the stator core 30 is reduced during winding the wire 2 at the start and end of the winding (periods of winding orders "S" and "F") across the multiple layers 130 compared to during winding between the start and end of the winding (periods of winding orders "2 to 13").

[0088] In the first setting example shown in FIG. 12, the rotation speed of the stator core 30 is gradually increased during the initial winding of winding order "S." The rotation speed of the stator core 30 is gradually increased from zero to the rotation speed during intermediate winding of winding order "2 to 13." The rotation speed during intermediate winding is set to a steady rotation speed. The rotation speed during intermediate winding does not have to be constant.

[0089] In the first setting example, the rotation speed of the stator core 30 is gradually reduced at the end of the winding of the winding order "F." The rotation speed of the stator core 30 is gradually reduced from the rotation speed at the time of the intermediate winding to zero.

[0090] Therefore, in the first setting example, when winding at the beginning and end of winding orders "S" and "F", the rotational speed of the stator core 30 is transiently increased or decreased relative to the rotational speed at the intermediate winding (for example, when winding order "2", i.e., the winding next to the beginning of winding, or when winding order "13", i.e., the winding one before the end of winding).

[0091] In the second setting example shown in Fig. 13, the rotational speed of the stator core 30 is increased in a stepwise manner at the start of winding in the winding order "S". The rotational speed of the stator core 30 is increased in a stepwise manner from zero to a rotational speed lower than the rotational speed at the time of intermediate winding. The rotational speed at the time of intermediate winding is increased in a stepwise manner from the rotational speed at the start of winding in the winding order "S".

[0092] In the second setting example, at the end of winding of winding order "F", the rotational speed of the stator core 30 is reduced in a stepwise manner. The rotational speed of the stator core 30 is reduced in a stepwise manner from the rotational speed during intermediate winding to a rotational speed higher than zero, and then reduced in a stepwise manner to zero at the end of winding.

[0093] Therefore, in the second setting example, when winding at the beginning and end of winding orders "S" and "F", the rotational speed of the stator core 30 is increased or decreased in a stepwise manner relative to the rotational speed during intermediate winding (for example, when winding with winding order "2" or winding with winding order "13").

[0094] In both the first setting example shown in Fig. 12 and the second setting example shown in Fig. 13, the wire 2 is wound more slowly at the start of winding in the winding order "S" than at the intermediate winding, making it easier to wind the wire 2 more accurately with respect to the start of winding in the winding order "S". Also, the wire 2 is wound more slowly at the end of winding in the winding order "F" than at the intermediate winding, making it less likely that the wire 2 will collapse when wound at the end of winding in the winding order "F".

[0095] After the final winding of winding order "F" is completed, the wire 2 is cut by a cutter (not shown) between the nozzle 3 and the stator core 30 (see FIG. 1), thereby forming the terminal end of the wire 2 wound around the stator core 30. The terminal end of the wire 2 will be connected to a terminal or the like when the stator core 30 is mounted, so the insulating coating needs to be stripped off.

[0096] For this reason, in the winding device 1, the insulating coating peeling process is incorporated into the winding process in such a way that the winding is interrupted, and the rotation speed of the stator core 30 during winding is set as follows.

[0097] 14 and 15 are diagrams showing examples of setting the rotational speed of the stator core 30 during the winding process in which the stripping process is incorporated. The first setting example shown in Fig. 14 corresponds to the first setting example in Fig. 12, and the second setting example shown in Fig. 15 corresponds to the second setting example in Fig. 13.

[0098] In these examples, before the winding of the wire 2 is completed across the entire plurality of layers 130, the rotation of the stator core 30 is stopped, and the insulating coating of the wire 2 is stripped off from a portion including the termination position of the wire 2 according to the remaining winding length of the wire 2.

[0099] In this embodiment, when the winding of the wire rod 2 in the winding order "9" is completed, the terminal position of the wire rod 2 according to the remaining winding length of the wire rod 2 reaches a position where the stripping device 70 (see FIG. 1) can strip the insulating coating of the wire rod 2. Therefore, in these setting examples, when the winding of the wire rod 2 in the winding order "9" is completed, the timing for stopping the rotation of the stator core 30 to strip the insulating coating of the terminal end of the wire rod 2 arrives, and the rotation of the stator core 30 is stopped.

[0100] The timing to stop the rotation of the stator core 30 can be determined by previously determining the length of the wire 2 between the stator core 30 and the stripping device 70 and the remaining length of the wire 2 up to the end position according to the number of windings around the stator core 30. When stopping the rotation of the stator core 30 for the stripping process, the rotation speed of the stator core 30 is transiently reduced in the first setting example shown in Fig. 14, and the rotation speed of the stator core 30 is reduced in a stepwise manner in the second setting example shown in Fig. 15.

[0101] In the stripping step, a stripping device 70 (see FIG. 1) strips the insulating coating from the portion of the wire 2 including the terminal end position of the wire 2. Then, when the stripping step is completed, the interrupted winding is resumed, and winding from winding order "10" onwards is performed. Then, when all windings are completed, the wire 2 is cut by a cutter (not shown), and the terminal end of the wire 2 is formed in a state where the insulating coating has been stripped and the conductor is exposed.

[0102] Peeling off the insulating coating in this manner eliminates the need to peel off the insulating coating during assembly of the stator core 30, simplifying the assembly procedure of the stator core 30. When resuming winding, the rotation speed of the stator core 30 is increased transiently in the first setting example shown in Fig. 14, and the rotation speed of the stator core 30 is increased in a stepwise manner in the second setting example shown in Fig. 15.

[0103] As shown in FIG. 1, the winding process is performed by a winding device 1 that rotates around a spindle 22 as a rotation axis and has a pair of clamping parts 41 that are arranged opposite each other on both sides of the spindle 22 in the axial direction AX and clamp the stator core 30.

[0104] The manufacturing method of the stator 220 further includes a stator core carrying-in / out step of carrying the pallet 110, which has the holding portions 123 of the first and second holding units 120A and 120B (see FIG. 6) as first and second holding portions that respectively hold the stator core 30 before and after winding, in a carrying direction that crosses between the pair of clamping portions 41, thereby carrying the stator core 30 into and out of the winding device 1. The pallet 110 is carried out using a carrying device 90.

[0105] Figure 16 is an explanatory diagram of the stator core loading / unloading process, and Figure 16 shows the rotating device 20A and pallet 110 so that the horizontal direction in the figure is the transport direction, and also shows the state of the pair of clamping portions 41 of the rotating devices 20A and 20B and the stator core 30 as viewed from the transport direction.

[0106] In the stator core carrying-in / out process, first, the pallet 110 is transported into the winding device 1 with the stator core 30 before winding held by the holding portion 123 (first holding portion) of the first holding unit 120A, and then the holding portion 123 (second holding portion) of the second holding unit 120B is positioned between the pair of clamping portions 41 in the transport direction (arrow P1). At this time, the stator core 30 after winding is clamped between the pair of clamping portions 41.

[0107] Next, each of the holding portions 123 of the first and second holding units 120A, 120B is moved in the approach direction (upward in Figure 16) between the pair of clamping portions 41, and the wound stator core 30 clamped between the pair of clamping portions 41 is held by the holding portion 123 of the second holding unit 120B (arrow P2).

[0108] Next, the pair of clamping parts 41 are moved back to release the clamping of the wound stator core 30 (arrow P3), whereby the wound stator core 30 is placed on the holding parts 123 of the second holding unit 120B.

[0109] Next, the stator core 30 sandwiched between the pair of sandwiching portions 41 is replaced from the wound stator core 30 to the unwound stator core 30 (arrows P4 to P6).

[0110] Next, with the wound stator core 30 held by the holding portion 123 of the second holding unit 120B, the pallet 110 is transported outside the winding device 1 (arrow P7), and the wound stator core 30 is sent to the next process by the pallet 110.

[0111] According to this stator core loading / unloading process, as shown in FIG. 1, the conveying device 90 can be positioned opposite the nozzle 3 with the axis of the spindle 22 in between, so that the stator core 30 can be loaded / unloaded while avoiding interference with the nozzle 3, the nozzle moving device 10, a cutter (not shown) that cuts the wire 2 at the terminal position, etc.

[0112] Figure 17 is a flowchart showing a method for manufacturing motor 200 (see Figure 3). The method for manufacturing motor 200 includes a first step 141 in which stator core 30 before winding is carried into winding device 1 and winding is performed, a second step 142 in which stator core 30 after winding is carried out from winding device 1, a third step 143 in which stator core 30 after winding is placed in holder 221 (see Figure 3) and stator 220 is assembled, and a fourth step 144 in which rotor 210 and stator 220 are incorporated into housing 240 to assemble motor 200.

[0113] In the first step 141, winding is performed using the manufacturing method of the stator 220 described above, and the first step 141 to the third step 143 correspond to the manufacturing method of the stator 220.

[0114] According to this method for manufacturing the motor 200, the motor 200 is manufactured using the same method for manufacturing the stator 220, and therefore, by increasing the speed of the winding, it is possible to increase the manufacturing capacity of the motor 200 and reduce the manufacturing cost.

[0115] In this embodiment, the motor 200 has been described as having a stator 220 configured by incorporating a plurality of stator cores 30 as divided cores, but the motor 200 may also be, for example, a shaded motor. A shaded motor also has an iron core (stator core) structured such that the portion around which the stator coil is wound is the bottom and a space (slot) is formed in which the width of the opening is narrower than the width of the opposing bottom.

[0116] The main effects of the method for manufacturing the stator 220 and the method for manufacturing the motor 200 according to the embodiments of the present invention will be summarized below.

[0117] The method for manufacturing the stator 220 includes holding the stator core 30, which has a slot 33 formed therein, and which has a width W1 of the opening 31 narrower than a width W2 of the opposing bottom 32, on the axis of the spindle 22 as a rotation shaft, and guiding the wire 2 fed from the nozzle 3 into the slot 33 and winding it around the bottom 32. The method includes a main guide preparation step of arranging a pair of main guides 51, which guide the wire 2 into the opening 31, facing each other with a first guide gap CL1 between them, for the stator core 30 held on the axis of the spindle 22; The method includes a subguide preparation process in which a pair of subguides 61 that guide the wire 2 at positions shifted from the opening 31 in the rotational direction of the spindle 22 are arranged opposite each other with a second guide gap CL2 therebetween on the stator core 30 in this state; and a winding process in which the position of the first guide gap CL1 of the main guide 51 and the position of the second guide gap CL2 of the subguide 61 are moved relatively along the axial direction AX of the spindle 22, thereby winding the wire 2 around the bottom portion 32 while adjusting the winding position within the slot 33 of the wire 2 inserted into the slot 33 through the first and second guide gaps CL1, CL2.

[0118] According to this method, the winding position within the slot 33 of the wire 2 inserted into the slot 33 through the gap between the pair of main guides 51 is adjusted according to the relative positions of the first guide gap CL1 and the second guide gap CL2. Therefore, when winding at a corner of the bottom 32 of the slot 33 where the width W1 of the opening 31 is narrower than the width W2 of the opposing bottom 32, the winding speed does not need to be reduced, and high-speed winding becomes possible.

[0119] In the winding process, while the first guide gap CL1 is fixed relative to the opening 31 of the stator core 30, the second guide gap CL2 is moved along the axial direction AX of the spindle 22 relative to the first guide gap CL1, thereby adjusting the winding position within the slot 33 of the wire 2 inserted into the slot 33 through the first and second guide gaps CL1 and CL2.

[0120] According to this method, the winding position of the wire 2 within the slot 33 can be adjusted simply by adjusting the position of the sub-guide 61 in the axial direction AX of the spindle 22, making it easy to increase the speed of aligned winding.

[0121] In the winding process, the wire 2 is wound around the bottom 32 of the stator core 30, which rotates around the spindle 22, to form layers 130 in which the wire 2 is aligned in the axial direction AX of the spindle 22, and the next layer 130 is formed on top of the formed layer 130, thereby forming multiple layers 130.When winding the wire 2 at the start and end of the winding across the multiple layers 130, the rotational speed of the stator core 30 is reduced compared to when winding between the start and end of the winding, i.e., when winding intermediate layers.

[0122] According to this method, the wire 2 is wound more slowly at the start of winding than at the intermediate winding, making it easier to wind the wire 2 more accurately with respect to the start of winding. Also, the wire 2 is wound more slowly at the end of winding than at the intermediate winding, making it less likely that the wire 2 wound at the end of winding will collapse.

[0123] In the winding process, the wire 2 is wound around the bottom 32 of the stator core 30, which is rotated around the spindle 22, to form layers 130 in which the wire 2 is aligned in the axial direction AX of the spindle 22, and the next layer 130 is formed on top of the formed layer 130, thereby forming multiple layers 130.Before the winding of the wire 2 is completed across all of the multiple layers 130, the rotation of the stator core 30 is stopped, and the insulating coating of the wire 2 is peeled off from a portion including the termination position of the wire 2 according to the remaining winding length of the wire 2.

[0124] According to this method, the insulating coating does not need to be peeled off during the mounting of the stator core 30, and the mounting procedure for the stator core 30 is simplified.

[0125] The winding step is performed by winding device 1 that rotates around spindle 22 and has a pair of clamping parts 41 that are arranged opposite each other on both sides of spindle 22 in axial direction AX and that clamp stator core 30. The manufacturing method of stator 220 further includes a stator core carrying-in / out step of carrying stator core 30 into / out of winding device 1 by transporting pallet 110 that has holding parts 123 of first and second holding units 120A and 120B as first and second holding parts that respectively hold stator core 30 before and after winding, in a transport direction that crosses between the pair of clamping parts 41. In the stator core carrying-in / out process, the pallet 110 is transported into the winding device 1 with the stator core 30 before winding held by the holding portion 123 of the first holding unit 120A as the first holding portion, and the holding portion 123 of the second holding unit 120B as the second holding portion is positioned between the pair of clamping portions 41 in the transport direction. The winding process includes the following operations: holding the wound stator core 30 in the holding portion 123 of the second holding unit 120B; retracting the pair of clamping portions 41 to release the clamped stator core 30; replacing the stator core 30 clamped by the pair of clamping portions 41 from the wound stator core 30 to the unwind stator core 30; and transporting the pallet 110 out of the winding device 1 while the wound stator core 30 is held by the holding portion 123 of the second holding unit 120B.

[0126] According to this method, the conveying device 90 can be positioned opposite the nozzle 3 with the axis of the spindle 22 in between, so that the stator core 30 can be loaded and unloaded while avoiding interference with the nozzle 3, the nozzle moving device 10, a cutter (not shown) that cuts the wire 2 at the terminal position, and the like.

[0127] In the method for manufacturing the motor 200 having the stator 220, the stator 220 is manufactured using the method for manufacturing the stator 220 described above.

[0128] This method allows for increased production capacity and reduced manufacturing costs for the motor 200 through faster winding speeds achieved by the manufacturing method for the stator 220.

[0129] Although an embodiment of the present invention has been described above, the above embodiment merely shows one application example of the present invention, and is not intended to limit the technical scope of the present invention to the specific configuration of the above embodiment.

[0130] This application claims priority based on Japanese Patent Application No. 2025-4220, filed with the Japan Patent Office on January 10, 2025, the entire contents of which are incorporated herein by reference.

Claims

1. A method for manufacturing a stator, comprising: holding a stator core on an axis of a rotary shaft, the stator core having slots each having an opening narrower than a bottom portion thereof; and guiding a wire fed from a nozzle into the slots and winding the wire around the bottom portion, a main guide preparation process in which a pair of main guides are arranged opposite to each other across a first guide gap, with the pair of main guides guiding the wire rod into the opening, with respect to the stator core held on the axis of the rotary shaft; a subguide preparation process in which a pair of subguides are arranged opposite to each other across a second guide gap, the subguides guiding the wire rod at positions shifted from the opening in the rotational direction of the rotary shaft, with respect to the stator core held on the axis of the rotary shaft; a winding process in which the position of the first guide gap and the position of the second guide gap are moved relatively along the axial direction of the rotation shaft, thereby winding the wire inserted into the slot through the first guide gap and the second guide gap onto the bottom while adjusting the winding position within the slot.

2. A method for manufacturing a stator according to claim 1, In the winding process, the first guide gap is fixed relative to the opening of the stator core, and the second guide gap is moved relative to the first guide gap along the axial direction of the rotation shaft, thereby adjusting the winding position within the slot of the wire inserted into the slot through the first guide gap and the second guide gap.

3. A method for manufacturing a stator according to claim 1 or 2, In the winding step, the wire is wound around the bottom of the stator core that is rotated around the rotation shaft, thereby forming a layer in which the wire is aligned in the axial direction of the rotation shaft, and a next layer is formed on top of the formed layer, thereby forming a plurality of layers; A method for manufacturing a stator, wherein the rotation speed of the stator core is reduced when winding the wire at the start and end of the winding across all of the multiple layers compared to when winding between the start and end of the winding.

4. A method for manufacturing a stator according to any one of claims 1 to 3, In the winding step, The wire is wound around the bottom of the stator core, which rotates around the rotation shaft, to form a layer in which the wire is aligned in the axial direction of the rotation shaft, and a next layer is formed on top of the formed layer, thereby forming a plurality of layers; A method for manufacturing a stator, comprising stopping the rotation of the stator core before the winding of the wire is completed in all of the multiple layers, and peeling off the insulating coating of the wire from a portion including the termination position of the wire according to the remaining winding length of the wire.

5. A method for manufacturing a stator according to any one of claims 1 to 4, comprising the steps of: the winding step is performed by a winding device that rotates around the rotation shaft and has a pair of clamping parts that are arranged opposite to each other on both axial sides of the rotation shaft and clamp the stator core, a stator core carrying-in / out step of carrying the stator core into / out of the winding device by transporting a pallet having first and second holding parts that hold the stator core before and after winding, respectively, in a transport direction that crosses between the pair of clamping parts, The stator core carrying-in / out process includes: the pallet is transported into the winding device in a state in which the first holding portion holds the stator core before winding, and the second holding portion is positioned between the pair of clamping portions in the transport direction; The first and second holding portions are moved in an approaching direction relative to the pair of clamping portions, and the wound stator core sandwiched by the pair of clamping portions is held by the second holding portion. The pair of clamping parts are retracted to release the clamping of the stator core after winding, The stator core sandwiched between the pair of sandwiching portions is replaced from the stator core after winding to the stator core before winding, the pallet is transported outside the winding device while the second holding portion holds the stator core after winding.

6. A method for manufacturing a motor having a stator, comprising: A method for manufacturing a motor, wherein the stator is manufactured using the method for manufacturing a stator according to any one of claims 1 to 5.

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