Method for manufacturing stator, device for manufacturing stator, and method for manufacturing motor

Abstract

This method for manufacturing a stator involves: providing, radially around the center axis of a stator core (13) of a stator, wire guides (31) having provided on one sides thereof notches (31a) which allow entry of the end portions (12a) of coil segments; arranging the wire guides (31) between the continuous end portions spaced apart from each other in the circumferential direction to cause the notches (31a) of the wire guides (31) to face the end portions (12a) in the circumferential direction; and moving the wire guides (31) in the circumferential direction, thereby allowing the end portions (12a) to enter the notches (31a) of the wire guides (31) and align the same.

Description

Stator manufacturing method, stator manufacturing device, and motor manufacturing method

[0001] The present invention relates to a stator manufacturing method, a stator manufacturing apparatus, and a motor manufacturing method.

[0002] Conventionally, for example, in the stator of a rotating electric machine, coil segments formed by bending a rectangular wire with a rectangular cross section into a U-shape are inserted into slots in a core, and the ends of the coil segments protruding from the end face of the core are bent in opposite circumferential directions for each layer adjacent to each other in the radial direction of the core, and the ends facing each other in the radial direction are electrically connected to form a coil in which multiple coil segments are connected in series.

[0003] As an apparatus for bending the end portions of such coil segments protruding from the end face of the core, one has been proposed which includes a cylindrical bending jig having a groove into which the end portion of the segment coil protruding to one axial side of the stator core can be inserted, and a drive unit for moving the bending jig axially while rotating it axially (see, for example, Patent Publication No. 2023-37860).

[0004] The ends of the segment coils are arranged in multiple rows in the radial direction of the stator core. For this reason, it is proposed that this device further include a coil segment end alignment device that includes an alignment jig having a pair of regulating surfaces that face each other in the circumferential direction of the stator core and can regulate the circumferential position of the tip ends of the segment coils, and a moving device that can move the alignment jig along the radial direction of the stator core.

[0005] In this alignment device, the alignment jig is moved radially to insert a plurality of radially arranged rows of end portions between a pair of regulating surfaces formed on the alignment jig, thereby aligning the circumferential positions of the plurality of end portions in each row, thereby facilitating the subsequent bending process of the plurality of end portions.

[0006] However, while aligning the ends by moving the alignment jig radially and inserting a plurality of ends arranged in a row radially between a pair of regulating surfaces formed on the alignment jig is suitable for positioning the ends of the segments circumferentially around the core, there are limitations to positioning the ends of the segments radially around the core.

[0007] In other words, when the alignment jig is moved radially and multiple ends arranged in a row radially are inserted between a pair of regulating surfaces formed on the alignment jig, the ends of the segments also move circumferentially and are positioned during the insertion process, making it suitable for positioning the ends of the segments circumferentially around the core.

[0008] On the other hand, the ends of the segments may be misaligned in the radial direction of the core, but the alignment jig that moves radially does not move the ends in the radial direction, and there are limitations to the positioning of the ends of the segments in the radial direction of the core.

[0009] An object of the present invention is to provide a stator manufacturing method, a stator manufacturing apparatus, and a motor manufacturing method that are capable of positioning the ends of coil segments in both the radial and circumferential directions.

[0010] According to one aspect of the present invention, there is provided a method for manufacturing a stator that aligns the ends of coil segments protruding from the end face of the stator core of the stator, by providing a plurality of wire guides radially around the central axis of the stator core, each having a notch on one side through which the ends can enter, and arranging the wire guides between successive ends at circumferential intervals so that the notches in the plurality of wire guides face the ends from the circumferential direction, and moving the plurality of wire guides circumferentially to allow the ends to enter the notches in the plurality of wire guides and align them.

[0011] According to another aspect of the present invention, there is provided a stator manufacturing apparatus for aligning ends of coil segments protruding from an end face of a stator core of a stator, the stator manufacturing apparatus comprising: an annular base plate arranged around the axis of the stator core; a plurality of wire guides arranged radially from the center of the base plate; and a base rotation unit that rotates the base plate together with the plurality of wire guides, the plurality of wire guides having notches that allow the ends to enter and align when rotated together with the base plate.

[0012] According to another aspect of the present invention, there is provided a rotating electric machine having a stator manufactured using the above-described method for manufacturing a stator.

[0013] 13 is a diagram showing a state in which the end portions of the coil segments are inserted into and aligned with the notches formed in the wire guide according to an embodiment of the present invention. It is a diagram showing a state in which the notches formed in the wire guide face the end portions, and corresponds to FIG. 1. It is a diagram showing a state in which the wire guide surrounds the end portions of the coil segments, and is an enlarged view of part A in FIG. 12. It is a diagram showing a state in which multiple wire guides are radially arranged on an annular base plate, and is a cross-sectional view taken along line B-B in FIG. 13. It is a diagram showing a state in which a cam ring is superimposed on the base plate, and is a cross-sectional view taken along line CC in FIG. 13. It is a cross-sectional view showing a state in which the cam ring is rotated relative to the base plate to move multiple wire guides toward the center, and is a cross-sectional view corresponding to FIG. 5. It is a bottom view showing a state in which the cam ring is further rotated together with the base plate to insert the end portions of the coil segments into the notches formed in the wire guides. It is a diagram showing a state in which the wire guides are in the outer radial direction, and is a cross-sectional view taken along line D-D in FIG. 5. It is a diagram showing a state in which the wire guides have been moved to the center, and is a cross-sectional view taken along line E-E in FIG. Fig. 12 is a cross-sectional view showing a state in which the cam ring is locked to the base plate, and is a cross-sectional view corresponding to Fig. 9. Fig. 13 is a view showing a state in which the wire guide is attached to the base plate, and is a view seen from direction G in Fig. 8. Fig. 14 is a top view of an alignment device for coil segment ends. Fig. 15 is a cross-sectional view taken along line H-H in Fig. 12.

[0014] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0015] 12 and 13 show a coil segment end alignment device 10 as a stator manufacturing device according to an embodiment of the present invention. The coil segment end alignment device 10 aligns the ends 12a of the coil segments housed in slots (not shown) of a stator core 13 (FIG. 13) of the stator, the ends 12a protruding from the end face of the stator core 13. The coil segments are coils used in a motor and constitute the coils of the motor's stator.

[0016] The motor is mounted, for example, on a vehicle (not shown). The motor can operate as an electric motor that receives power from a battery (not shown) to rotate. When the rotor of the motor receives rotational energy from drive wheels (not shown), the motor can function as a generator and charge the battery. The motor may be used as either an electric motor or a generator. The motor can also be mounted on various devices other than vehicles.

[0017] Vehicles equipped with motors include, for example, BEVs (Battery Electric Vehicles), HEVs (Hybrid Electric Vehicles), and PHEVs (Plug-in Hybrid Electric Vehicles).

[0018] In this embodiment, as shown in Figure 13, as an example, the stator core 13 is arranged with its central axis vertical so that, when multiple coil segments are installed in the slots, the ends 12a of the multiple coil segments are downward.

[0019] 12, a plurality of coil segments are arranged in the circumferential direction and housed in a state in which a plurality of coil segments overlap each other in the radial direction on the stator core 13. Therefore, the end portions 12a of the coil segments are arranged in a continuous manner with a gap in the radial direction, and the plurality of coil segments arranged in a continuous manner with a gap in the radial direction are also arranged in a continuous manner with a gap in the circumferential direction.

[0020] As shown in Figure 13, the coil segment end alignment device 10 in this embodiment, as an example, can be moved and positioned below the stator core 13 by a moving device not shown, and includes a base substrate 21 having a round hole 21a formed therein that is coaxial with the stator core 13, i.e., is arranged coaxially with the stator core 13.

[0021] The base substrate 21 is a plate material, and the round hole 21 a is moved and positioned below the stator core 13 by a moving device (not shown), for example, and has an inner diameter larger than the outer diameter of the stator core 13 .

[0022] An annular base plate 22 is provided on the base substrate 21 so as to be rotatable around a circular hole 21a that is coaxial with the axis of the stator core 13. In this embodiment, the annular base plate 22 is formed with an annular step portion 22a into which the circular hole 21a of the base substrate 21 is fitted, and with the step portion 22a inserted into the circular hole 21a, the base plate 22 is superimposed on the base substrate 21 so as to be coaxial with the circular hole 21a.

[0023] 4, a plurality of spacers 23 are arranged on the base substrate 21 so as to surround the annular base plate 22, and the annular base plate 22 is superimposed on the base substrate 21 while being surrounded by the plurality of spacers 23. As shown in FIGS. 7 and 13, a support 24 that supports the periphery of the annular base plate 22 is screwed to the lower end of the spacer 23.

[0024] The height of the spacer 23 is formed slightly higher than the thickness of the base plate 22. As a result, the base plate 22, which is superimposed on the base substrate 21 so as to be coaxial with the round hole 21a of the base substrate 21, is configured to be able to rotate relative to the base substrate 21 while remaining coaxial with the round hole 21a.

[0025] 4 and 8 , the base substrate 21 is provided with a fixing portion 26 that locks and unlocks the rotation of the base plate 22 relative to the base substrate 21, thereby limiting the allowable range of rotation of the base plate 22 relative to the base substrate 21. The fixing portion 26 in this embodiment includes a recess 22b formed on the outer periphery of the ring-shaped base plate 22, a stopper piece 27 that can enter the recess 22b from the radial direction, and a fixing actuator 28 that is provided on the base substrate 21 and moves the stopper piece 27 in the radial direction of the base plate 22.

[0026] The fixing actuator 28 in this embodiment is a fluid pressure cylinder, and has a retractable rod 28a and a main body 28b that is fixed to the base substrate 21 with the retractable rod 28a facing in the radial direction of the base plate 22. The stopper piece 27 is attached to the tip of the retractable rod 28a, and when the retractable rod 28a is caused to protrude from the main body 28b and the stopper piece 27 enters the recess 22b of the base plate 22, rotation of the base plate 22 relative to the fixing actuator 28 provided on the base substrate 21 is prohibited, and when the fixing actuator 28 moves the stopper piece 27 radially outward of the base plate 22 to remove it from the recess 22b, as shown in Figures 7 and 10, rotation of the base plate 22 relative to the base substrate 21 is permitted.

[0027] 12 and 13, a plurality of wire guides 31 are provided on the base plate 22 so as to be movable in the radial direction of the base plate 22, which forms an annular shape radiating from the center of the base plate 22. As shown in Figures 1 to 3, the wire guides 31 in this embodiment are formed so that their widths narrow toward the central axis of the stator core 13, and are thereby formed so as to be able to enter between the ends 12a of consecutive coil segments spaced apart in the circumferential direction from the radially outer side.

[0028] 12 , the wire guides 31 directly align the end portions 12 a of the coil segments, and the end portions 12 a are formed in a series with gaps in the radial direction of the stator core 13 and in a series with gaps in the circumferential direction as well. For this reason, the number of wire guides 31 provided is the same as the number of end portions 12 a of the coil segments that are continuous with gaps in the radial direction in the circumferential direction, and therefore the number of slots (not shown) in the stator core 13, so that the wire guides 31 can simultaneously enter between all of the end portions 12 a that are continuous with gaps in the circumferential direction.

[0029] 4 and 8 to 11, grooves 22c are formed radially on the underside of the annular base plate 22, and the grooves 22c accommodate the moving piece 32 for moving the wire guide 31 in the radial direction so as to be movable in the radial direction of the base plate 22. The depth of the grooves 22c is formed slightly deeper than the thickness of the moving piece 32, and thus the grooves 22c of the base plate 22 are configured to restrict the movement of the moving piece 32 in the circumferential direction of the annular base plate 22, while allowing the moving piece 32 to move in the radial direction.

[0030] 11, in this embodiment, two wire guides 31 are attached to a single moving piece 32 via guide spacers 33. As shown in Fig. 12, the number of wire guides 31 prepared is the same as the number of circumferential ends 12a of the coil segments, i.e., the number of slots (not shown) in the stator core 13, and since the two wire guides 31 are attached to the single moving piece 32 via guide spacers 33, the number of moving pieces 32 and the recessed grooves 22c that movably house the moving pieces 32 are each provided in half the number of wire guides 31.

[0031] As shown in Figures 8 to 11, in this embodiment, the guide spacer 33 is erected at the end of the inner diameter side of the moving piece 32 so that its upper surface reaches above the upper surface of the base plate 22, and a pair of wire guides 31 are attached to the upper surface of the guide spacer 33 so as to be parallel to the moving piece 32 with a predetermined gap between them in the circumferential direction.

[0032] 5 and 8 to 10, a cam ring 36 for moving wire guides 31 is further provided on base plate 22 so as to overlap coaxially with base plate 22 and close radial grooves 22c. Cam ring 36 thus overlapped coaxially with base plate 22 is also provided to be rotatable independently of base plate 22 around the axis of stator core 13.

[0033] As shown in Figures 7 to 10 and 13, in this embodiment, a ring-shaped cam holder 37 that rotatably supports a cam ring 36 is attached to the base plate 22, and the cam ring 36 is sandwiched between the base plate 22 and the cam holder 37 and is rotatable relative to the base plate 22 and the cam holder 37.

[0034] 13, the cam holder 37 in this embodiment is annular, and has an annular stepped portion 37a formed therein into which the cam ring 36 is fitted. The cam holder 37 is attached to the base plate 22 with the cam ring 36 inserted into the stepped portion 37a.

[0035] As a result, the ring-shaped cam ring 36, base plate 22, and cam holder 37 are each coaxially mounted on the base substrate 21 and are rotatable about their axes. The base plate 22 and cam holder 37 are fastened together with screws and rotate together, while the cam ring 36 is sandwiched between the base plate 22 and cam holder 37 and is rotatable separately and independently from the base plate 22 and cam holder 37.

[0036] 12 and 13, coil segment end alignment device 10 is provided with rotating unit 41 that rotates cam ring 36. Cam ring 36 is formed with bulging portion 36b that bulges outward in the radial direction from a portion of cam ring 36, and cam holder 37, base plate 22, and base substrate 21, which are arranged to sandwich cam ring 36, are each formed with notches 21b, 22d, and 37b that release bulging portion 36b outward in the radial direction.

[0037] Meanwhile, a rotation actuator 42 that moves the bulge portion 36b is provided on the base substrate 21. In this embodiment, the rotation actuator 42 is an electric motor, and has a rotation shaft 42a and a main body 42b that is attached to the base substrate 21 via a mounting fixture 42c with the rotation shaft 42a facing in the circumferential direction of the cam ring 36. A male threaded member 43 is coaxially attached to the rotation shaft 42a, and a locking member 44 that locks onto the bulge portion 36b of the cam ring 36 is threadedly engaged with the male threaded member 43.

[0038] As an example, the locking member 44 has a female threaded portion 44a into which the male threaded member 43 screws, and a clamping portion 44b that protrudes from the female threaded portion 44a to sandwich the bulge portion 36b, and as an example, a recess 44c is formed in the clamping portion 44b into which the locking pin 36d that is provided to penetrate the bulge portion 36b enters.

[0039] Such a rotating portion 41 is configured such that when a rotary actuator 42 consisting of an electric motor is driven to rotate the rotating shaft 42a together with the male screw member 43, the locking member 44 threadedly engaged with the male screw member 43 moves the bulge portion 36b in the circumferential direction of the cam ring 36, thereby rotating the cam ring 36 a predetermined amount.

[0040] 5 and 6, the cam ring 36 is provided coaxially overlapping the base plate 22 so as to close the radial grooves 22c formed in the base plate 22. Therefore, the cam ring 36 is provided so as to overlap the moving pieces 32 housed in the grooves 22c so as to be movable in the longitudinal direction, and the moving pieces 32 to which the wire guides 31 are attached are each provided with a cam pin 32a.

[0041] The cam ring 36 is a donut-shaped ring member concentrically centered on the central axis of the stator core 13, and overlaps successive moving pieces 32 at intervals in the circumferential direction. Therefore, the cam ring 36 has a plurality of cam holes 36a formed in succession at intervals in the circumferential direction opposite the plurality of moving pieces 32, through which the cam pins 32a provided on the moving pieces 32 can move.

[0042] As shown in Fig. 5, the multiple cam holes 36a formed in the cam ring 36 are formed with the same inclination angle (the inclination of the cam holes 36a relative to the radial direction). The multiple cam holes 36a formed at an angle in this manner move in the circumferential direction when the cam ring 36 rotates relative to the base plate 22, and the cam pins 32a are guided along these multiple cam holes 36a. As shown in Figs. 6 and 9, the multiple cam holes 36a are configured so that all of the moving pieces 32 formed radially move simultaneously in the radial direction of the base plate 22 along the recessed grooves 22c of the base plate 22.

[0043] As shown in Figures 7 and 10, the coil segment end alignment device 10 is provided with a locking portion 45 that locks the cam ring 36 to the base plate 22 and rotates the base plate 22 together with the cam ring 36 when the stopper piece 27 in the fixing portion 26 moves away from the recess 22b of the base plate 22, allowing the base plate 22 to rotate relative to the base substrate 21.

[0044] As an example, the locking portion 45 in this embodiment includes a locking piece 46 pivotally supported in a recess 22b formed on the outer periphery of the base plate 22, a vertical groove 36c extending in the thickness direction on the outer periphery of the cam ring 36 opposite the locking piece 46 so that the locking piece 46 can enter, and a spring 47 as an elastic body that biases the locking piece 46 in the direction of entering the vertical groove 36c.

[0045] The recess 22b is formed on the outer periphery of the base plate 22, continuing from the recess groove 22c that accommodates the moving piece 32 to which the wire guide 31 is attached, and the locking piece 46 is pivotally supported via a holder 48 attached to the recess 22b.

[0046] The locking piece 46 shown in the figure is crank-shaped, and as an example, has a swinging piece 46a whose base end is pivoted so that its tip, facing the center of the base plate 22, can enter the vertical groove 36c while being arranged parallel to the groove 22c, a rising portion 46b that rises from the pivoted base end of the swinging piece 46a while being arranged parallel to the groove 22c so as to be parallel to the axis of the base plate 22, and an operating piece 46c that is formed by extending outward from the upper end of the rising portion 46b and facing the stopper piece 27 of the fixed portion 26.

[0047] Vertical groove 36c is formed on the outer periphery of cam ring 36 facing stopper piece 27 of fixed portion 26 when multiple wire guides 31 are in the inner circumferential position as shown in Figure 6. Holder 48 that pivots the connection between swing piece 46a and rising portion 46b is attached to recess 22b, and the tip of swing piece 46a that moves by rotating is configured to be able to enter vertical groove 36c formed on the outer periphery of cam ring 36 when multiple wire guides 31 are in the inner circumferential position as shown in Figure 6.

[0048] A support plate 49 facing the rising portion 46b is provided in the recess 22b, and a spring 47, which is an elastic body, is interposed between the rising portion 46b and the support plate 49. As an example, the spring 47, which is an elastic body, urges the rising portion 46b in a direction that widens the gap between the support plate 49 and the rising portion 46b, thereby urging the rising portion 46b so that the tip of the swinging piece 46a is inserted into the vertical groove 36c formed in the cam ring 36.

[0049] The stopper piece 27 of the fixed portion 26 is formed with an entry piece 27a that enters the recess 22b to prevent the base plate 22 from rotating relative to the base substrate 21, and an abutment portion 27b that abuts against the tip of the operating piece 46c of the locking piece 46.

[0050] The locking portion 45 is configured so that, when the stopper piece 27 of the fixed portion 26 moves and the entering piece 27a attempts to enter the recess 22b, the operation piece 46c comes into contact with the contact portion 27b of the stopper piece 27. The locking portion 45 is configured so that, when the entering piece 27a further enters the recess 22b, as shown in Fig. 8, the locking piece 46, whose operation piece 46c abuts against the contact portion 27b, rotates against the biasing force of the spring 47, and the swinging piece 46a of the locking piece 46 disengages from the vertical groove 36c formed in the cam ring 36, prohibiting rotation of the base plate 22 relative to the base substrate 21. This allows rotation of the cam ring 36 relative to the base plate 22, and the cam ring 36 is configured to allow all of the wire guides 31 to move simultaneously.

[0051] In this embodiment, as shown in Figure 5, the cam ring 36 is rotated to position the radially arranged multiple wire guides 31 radially outward, so that the multiple wire guides 31 can move between an outer peripheral position where they surround all of the ends 12a of the coil segment, and an inner peripheral position where the notches 31a of the wire guides 31, described later, circumferentially face the ends 12a of the wire segments, as shown in Figure 6, so that the cam ring 36 is rotated to move the multiple wire guides 31 toward the center of the round holes 21a of the base substrate 21.

[0052] The wire guides 31 are prepared in the same number as the number of slots (not shown) in the stator core 13, so that, as shown in Figure 6, when the wire guides 31 move toward the inner periphery of the base plate 22, all of the multiple wire guides 31 are configured to enter from the radially outer side between the ends 12a of the coil segments that are spaced apart in the circumferential direction.

[0053] As shown in Figure 2, the wire guides 31 are arranged radially and inserted between the ends 12a of consecutive coil segments spaced apart in the circumferential direction, and have notches 31a that circumferentially face the ends 12a protruding from the end face of the stator core 13, and the notches 31a are formed on one side of each of the multiple wire guides 31.

[0054] The notch 31a has an opening as an open end facing the end 12a, a bottom formed so as to have the same width as the radial width of the end 12a, and side walls as both sides that slope so that the width increases toward the opening as the open end, and is formed so as to gradually narrow from the opening toward the bottom in the circumferential direction. In other words, both side walls extending from the opening to the bottom are formed so as to slope, and such notches 31a are formed for each consecutive end 12a at intervals in the radial direction, so that a plurality of such notches 31a are formed consecutively at intervals in the radial direction on one side of the wire guide 31.

[0055] The vertical grooves 36c of the locking portion 45 are formed on the outer periphery of the cam ring 36, which faces the stopper pieces 27 of the fixed portion 26, when the plurality of wire guides 31 are in the inner peripheral position as shown in Fig. 6. Therefore, when the plurality of radially arranged wire guides 31 have entered between the ends 12a of the coil segments (that is, when they are in the inner peripheral position as shown in Fig. 6), and the stopper pieces 27 of the fixed portion 26 are moved away from the recesses 22b of the base plate 22 as shown in Fig. 10, and the base plate 22 is allowed to rotate relative to the base substrate 21, the cam ring 36 is locked to the base plate 22.

[0056] 7, the rotating portion 41 that rotates the cam ring 36 can be said to be both the rotating portion 41 serving as a ring rotating portion that rotates the cam ring 36 and the rotating portion 41 serving as a base rotating portion that also rotates the base plate 22. Therefore, the rotating portion 41 serves both as the rotating portion 41 serving as a ring rotating portion and as the rotating portion 41 serving as a base rotating portion.

[0057] As shown in Figure 1, when the base plate 22 rotates due to the rotating part 41 and the plurality of wire guides 31 rotate together with it, the coil segment end alignment device 10 is configured so that the end parts 12a enter and align into the notches 31a of the plurality of wire guides 31 that move circumferentially.

[0058] Next, a coil segment end alignment method will be described as a stator manufacturing method using the coil segment end alignment device configured as described above. By manufacturing a motor having a stator manufactured using the coil segment end alignment method (i.e., the stator manufacturing method), it is possible to manufacture an advantageous motor with improved stator manufacturing.

[0059] The coil segment end alignment device 10 described above is used in a preliminary step of bending the ends 12 a of the coil segments inserted into slots (not shown) arranged radially in the circumferential direction of the stator core 13 .

[0060] Since the multiple coil segments are inserted into multiple slots (not shown) of the stator core 13, the end portions 12a of the multiple coil segments are aligned in both the radial direction and the circumferential direction of the stator core 13 (FIG. 13), as shown in Fig. 12. These end portions 12a are then twisted in the circumferential direction for each adjacent layer, and the end portions 12a that face each other in the radial direction are electrically connected to each other, but for this twisting process, it is necessary to align the end portions 12a.

[0061] Therefore, the method for aligning the coil segment ends of this embodiment includes a guide arrangement process in which a plurality of wire guides 31, each having notches 31a on one side through which the ends 12a can enter, are arranged radially around the central axis of the stator core 13, as shown in Figure 3; a guide entry process in which the wire guides 31 are arranged between consecutive ends 12a spaced apart in the circumferential direction so that the notches 31a of the plurality of wire guides 31 face the ends 12a from the circumferential direction, as shown in Figure 2; and a guide rotation process in which the plurality of wire guides 31 are moved in the circumferential direction to insert the ends 12a into the notches 31a of the plurality of wire guides 31 and align them, as shown in Figure 1.

[0062] Each step will be explained below.

[0063] <Guide placement process> In this process, as shown in Figure 3, multiple wire guides 31 are arranged radially around the central axis of the stator core 13, each having a notch 31a on one side that can accommodate multiple end portions 12a that protrude from the end face of the stator core 13 and are aligned along both the radial and circumferential directions of the stator core 13.

[0064] As shown in Figures 5 and 8, when using the coil segment end alignment device 10 in which multiple wire guides 31 are arranged radially and movably on the annular base plate 22 toward the center of the circular hole 21a in the base substrate 21, first, the multiple radially arranged wire guides 31 are positioned radially outward from the end 12a, and all of the end 12a of the coil segment are surrounded by the multiple wire guides 31.

[0065] As a result, the plurality of radially arranged wire guides 31 surround the ends 12 a of the coil segments, allowing all of the ends 12 a to be inserted within the inscribed circle of the wire guides 31. The movement of the wire guides 31 is made possible by rotating the cam ring 36 relative to the base plate 22 as shown by the dashed arrow in Figure 5.

[0066] As shown in Figure 12, this coil segment end alignment device 10 is positioned below the stator core 13 so that the round holes 21a in the base substrate 21 are coaxial with the central axis of the stator core 13, and all of the ends 12a protruding downward from the end face of the stator core 13 are surrounded by a plurality of radially arranged wire guides 31.

[0067] The alignment device 10 is positioned by moving the entire alignment device 10 including the base substrate 21 using a moving device not shown, or by moving the stator core 13 in which the coil segments are arranged in slots not shown.

[0068] As a result, multiple wire guides 31, each with a notch 31a on one side through which the end 12a of the coil segment protruding from the end face of the stator core 13 can enter, are arranged radially around the central axis of the stator core 13 (Figures 3 and 12).

[0069] <Guide Entry Process> In this process, as shown in FIG. 2 , each of the multiple wire guides 31 is disposed between successive end portions 12 a spaced apart in the circumferential direction, and the multiple notches 31 a of each wire guide 31 are arranged radially around the central axis of the stator core 13 so as to face the multiple radially arranged end portions 12 a from the circumferential direction.

[0070] As shown in Figures 5 and 8, in the previous process, all of the end portions 12a are surrounded by a plurality of radially arranged wire guides 31. Therefore, by moving the radially arranged wire guides 31 toward their centers, the plurality of wire guides 31 can be inserted between the end portions 12a that protrude from the end face of the stator core 13 and are adjacent in the circumferential direction.

[0071] That is, by shifting the multiple radially arranged wire guides 31 radially, the multiple wire guides 31 are each inserted between successive end portions 12a spaced apart in the circumferential direction of the coil segments protruding from the end face of the stator core 13.

[0072] When using the above-mentioned alignment device 10, the radial movement of the multiple wire guides 31 can be achieved by rotating the cam ring 36 placed on the wire guides 31 relative to the base plate 22, as shown in Figures 6 and 9.

[0073] Specifically, the coil segment end alignment device 10 is provided with a fixed portion 26, a rotating portion 41, and a locking portion 45, and as shown in Fig. 5, the stopper piece 27 of the fixed portion 26 is inserted into the recess 22b of the base plate 22 to prevent the base plate 22 from rotating relative to the base substrate 21. Then, as shown in Fig. 8, the locking portion 45 allows the cam ring 36 to rotate relative to the base plate 22, and as shown in Fig. 6, the cam ring 36 is rotated by the rotating portion 41, thereby making it possible to shift the plurality of wire guides 31 in the radial direction.

[0074] When the cam ring 36 is rotated relative to the base plate 22 on which the wire guide 31 is radially movable, the cam pin 32a moves along the cam hole 36a formed in the cam ring 36, and the wire guide 31 to which the cam pin 32a is attached moves simultaneously at the same speed in the radial direction of the stator core 13.

[0075] 2, the wire guides 31, the number of which is equal to the number of slots, enter from the radially outer side between the ends 12a of the coil segments inserted into the slots of the stator core 13 and spaced apart in the circumferential direction, and in this state, the notches 31a of the plurality of wire guides 31 face the ends 12a in the circumferential direction. In this way, the notches 31a of the plurality of wire guides 31 face all of the ends 12a in the circumferential direction.

[0076] <Rotation process> In this process, as shown in Figure 1, multiple wire guides 31 are moved circumferentially, and all of the ends 12a of the coil segments are aligned by entering them into the opposing notches 31a of the wire guides 31 that move circumferentially.

[0077] The above-mentioned coil segment end alignment device 10 is provided with a fixed portion 26, a rotating portion 41, and an engaging portion 45, so that the fixed portion 26 allows the base plate 22 to rotate relative to the base substrate 21, while the engaging portion 45 engages the cam ring 36 to the base plate 22, and in that state the rotating portion 41 rotates the cam ring 36, thereby making it possible to rotate the base plate 22 together with the cam ring 36.

[0078] Specifically, when the plurality of wire guides 31 are in the inner peripheral position as shown in Fig. 6, the vertical groove 36c formed on the outer periphery of the cam ring 36 faces the stopper piece 27 of the fixed portion 26, so that the stopper piece 27 of the fixed portion 26 is released from the recess 22b of the base plate 22, allowing the base plate 22 to rotate relative to the base substrate 21, as shown in Fig. 7. Then, as shown in Fig. 10, the spring 47, which is an elastic body in the locking portion 45, urges the rising portion 46b in a direction that widens the gap between the support plate 49 and the rising portion 46b, causing the locking piece 46 to rotate and the tip of the swinging piece 46a to be inserted into the vertical groove 36c formed in the cam ring 36.

[0079] 7, when the rotating unit 41 rotates the cam ring 36, the cam ring 36 rotates together with the base plate 22, and the plurality of wire guides 31 radially arranged on the base plate 22 move circumferentially together with the base plate 22. Therefore, in the coil segment end alignment device 10 described above, there is no need for an independent rotating unit that rotates the base plate 22 in addition to the rotating unit 41 that rotates the cam ring 36.

[0080] When the base plate 22 rotates together with the cam ring 36, the wire guides 31, which are allowed to move radially relative to the base plate 22 but are restricted in their circumferential movement, move circumferentially together with the base plate 22, and as a result, as shown in Figure 1, the notches 31a formed in the wire guides 31 enter the opposing ends 12a, aligning all of the ends 12a of the coil segments.

[0081] In other words, when the wire guide 31 moves circumferentially and the end 12a enters the notch 31a of the wire guide 31, even if the end 12a is radially misaligned, the radial misalignment is eliminated by entering the notch 31a.

[0082] The notch 31a of the wire guide 31 has both side walls inclined in the radial direction, so even if the end 12a is misaligned in the radial direction, the misalignment is eliminated by the inclined both side walls as the end 12a enters the notch 31a.

[0083] On the other hand, the ends 12 a of the segments may also be misaligned in the circumferential direction of the core. In this embodiment, the wire guides 31 are moved in the circumferential direction, so that the ends 12 a that have entered the cutouts 31 a eventually reach the bottoms of those cutouts 31 a, and by moving all of the wire guides 31 in the circumferential direction until all of the ends 12 a reach the bottoms of the cutouts 31 a of all of the wire guides 31, the misalignment in the circumferential direction is eliminated.

[0084] Therefore, in this embodiment, it is possible to position the end portions 12 a of the coil segments in both the radial and circumferential directions. Furthermore, by placing a cam ring 36 on a plurality of wire guides 31 arranged radially on the annular base plate 22 and rotating the cam ring 36 relative to the base plate 22 to shift adjacent wire guides 31 in the circumferential direction, it is possible to simultaneously shift the plurality of wire guides 31. Furthermore, by rotating the cam ring 36 together with the base plate 22 to move the plurality of wire guides 31 in the circumferential direction, it is possible to move the plurality of wire guides 31 radially and circumferentially using a single rotation mechanism, thereby avoiding an increase in the device's complexity and height. The end portions 12 a of the coil segments whose positions have been determined are then bent by a forming device (not shown).

[0085] In the above-described embodiment, the cam ring 36 is rotated using the rotating unit 41 having the male thread member 43, but the rotating unit 41 does not need to have the male thread member 43 as long as it can rotate the cam ring 36. For example, the cam ring 36 may be rotated by a fluid pressure cylinder or the like.

[0086] In the above-described embodiment, the end portions 12a of the four coil segments are aligned in the radial direction, and the wire guide 31 has four notches 31a formed on one side thereof to receive the four end portions 12a. However, the number and size of the notches 31a are not limited to this. The number and size of the notches 31a may be adjusted to match the number and shape of the end portions 12a to be aligned, and multiple types of wire guides 31 with different numbers and shapes of notches 31a may be used and arranged radially.

[0087] That is, the number of notches 31a formed in a single wire guide 31 is not limited to four. The number of notches 31a varies depending on the number of end portions 12a corresponding to the wire guides 31 having those notches 31a, and when the numbers of corresponding end portions 12a differ between wire guides 31, the wire guides 31 are arranged radially using multiple types of wire guides 31 having different numbers of notches 31a.

[0088] In the above-described embodiment, two wire guides 31 are attached to a single moving piece 32 via guide spacers 33. However, without being limited to this, three wire guides 31 may be attached to a single moving piece 32 via guide spacers 33, or conversely, a single wire guide 31 may be attached to a single moving piece 32.

[0089] If three wire guides 31 are attached to a single moving piece 32, the number of moving pieces 32 can be further reduced, and a complicated structure such as a reduction in the thickness between the cam holes 36a of the cam ring 36 can be avoided. Conversely, if a single wire guide 31 is attached to a single moving piece 32, the wire guide 31 can be moved more reliably in the radial direction.

[0090] Furthermore, in the above embodiment, the rotating portion 41 as the ring rotating portion also serves as the rotating portion 41 as the base rotating portion. However, the ring rotating portion and the base rotating portion may be provided separately. In this case, the locking portion 45 that locks the cam ring 36 to the base plate 22 can be omitted.

[0091] In the above-described embodiment, the stator is of an inner rotor type, but the stator may be of an outer rotor type.

[0092] According to the above embodiment, the following advantageous effects are achieved.

[0093] The method for aligning coil segment ends in this embodiment constitutes a stator manufacturing method for aligning the ends 12a of coil segments as ends 12a protruding from the end face of the stator core 13 of the stator, and involves providing a plurality of wire guides 31 radially around the central axis of the stator core 13, each having a notch 31a on one side through which the ends 12a can enter, and arranging the wire guides 31 between successive ends 12a at circumferential intervals so that the notches 31a of the plurality of wire guides 31 face the ends 12a from the circumferential direction, and moving the plurality of wire guides 31 circumferentially to allow the ends 12a to enter the notches 31a of the plurality of wire guides 31 and align them.

[0094] According to this method, the wire guides 31 are moved in the circumferential direction, and the end portions 12 a are inserted into the notches 31 a formed in the wire guides 31 to align them, so that radial misalignment is eliminated as the end portions 12 a enter the notches 31 a of the wire guides 31, and circumferential misalignment of the end portions 12 a is also eliminated as all of the end portions 12 a reach the bottoms of the notches 31 a of the wire guides 31. This makes it possible to position the end portions 12 a of the coil segments in both the radial and circumferential directions.

[0095] In this embodiment, a plurality of wire guides 31 are arranged radially on a circular base plate 22 formed to be able to surround the end portion 12a, and are movable toward the center.The circular base plate 22 is then positioned to surround the end portion 12a, and the plurality of wire guides 31 are then moved toward the center, so that the wire guides 31 each enter between consecutive end portions 12a spaced apart circumferentially, causing the notches 31a of the plurality of wire guides 31 to face the end portions 12a from the circumferential direction.

[0096] According to this method, after placing the annular base plate 22 so as to surround the end portion 12a, the wire guides 31 can be inserted between successive end portions 12a spaced apart in the circumferential direction simply by moving the wire guides 31 toward the center.

[0097] In this embodiment, the cam ring 36 for moving the wire guides 31 is stacked coaxially on the base plate 22 and rotated relative to the base plate 22, thereby moving the multiple wire guides 31 toward the center of the base plate 22.

[0098] According to this method, it is possible to simultaneously shift a plurality of wire guides 31 simply by rotating the cam ring 36 relative to the base plate 22.

[0099] In this embodiment, the cam ring 36 is rotated together with the base plate 22 to move the plurality of wire guides 31 in the circumferential direction.

[0100] According to this method, the single rotating part 41 that rotates the cam ring 36 can move the multiple wire guides 31 radially and circumferentially, thereby avoiding the device becoming complicated and its height increasing.

[0101] In a method for manufacturing a motor having a stator, the stator is manufactured using a coil segment end alignment method that constitutes a manufacturing method for the stator.

[0102] This method allows for the production of advantageous motors with improved stator manufacturing.

[0103] The coil segment end alignment device 10 of this embodiment constitutes a stator manufacturing device that aligns the ends 12a of coil segments as the ends 12a protruding from the end face of the stator core 13 of the stator, and is equipped with a circular base plate 22 centered on the axis of the stator core 13, a plurality of wire guides 31 arranged radially from the center of the base plate 22, and a rotating part 41 serving as a base rotating part that rotates the base plate 22 together with the wire guides 31, and the wire guides 31 have notches 31a that can enter and align the ends 12a by rotating together with the base plate 22.

[0104] According to this configuration, by moving the multiple wire guides 31 in the circumferential direction, it is possible to position the ends 12a of the coil segments in both the radial and circumferential directions.

[0105] In this embodiment, the multiple wire guides 31 are arranged to be movable radially around the base plate 22, and are equipped with a cam ring 36 that overlaps the base plate 22 and rotates relative to the base plate 22 to move the multiple wire guides 31 radially.

[0106] According to this configuration, simply by rotating the cam ring 36 relative to the base plate 22, it is possible to simultaneously shift the plurality of wire guides 31 arranged radially.

[0107] In this embodiment, the device further includes a rotating part 41 as a ring rotating part that rotates the cam ring 36 relative to the base plate 22, a base substrate 21 having a round hole 21a in which the annular base plate 22 is rotatably arranged, a fixed part 26 that limits the allowable range of rotation of the base plate 22 relative to the base substrate 21, and a locking part 45 that locks the cam ring 36 to the base plate 22 and rotates the base plate 22 together with the cam ring 36 when the fixed part 26 allows rotation of the base plate 22 relative to the base substrate 21.When the fixed part 26 allows rotation of the base plate 22 relative to the base substrate 21, the rotating part 41 as a ring rotating part can rotate the base plate 22 by rotating the cam ring 36 locked to the base plate 22 by the locking part 45, and also serves as the rotating part 41 as a base rotating part.

[0108] According to this configuration, the radial and circumferential movements of the multiple wire guides 31 can be performed by a single rotating part 41. Therefore, it is possible to avoid the device becoming complicated and its height increasing.

[0109] In this embodiment, one or more wire guides 31 are provided on a moving piece 32 that is provided on the annular base plate 22 so as to be movable in the radial direction.

[0110] According to this configuration, by providing two or more wire guides 31 on a single moving piece 32, the number of moving pieces 32 can be reduced and the structure can be made less complicated, and by providing a single wire guide 31 on a single moving piece 32, the wire guide 31 can be moved radially more reliably.

[0111] In this embodiment, the notch 31a has an opening as an open end facing the end 12a, a bottom formed to have the same width as the radial width of the end 12a, and side walls as both sides that slope so that the width widens toward the opening as the open end.

[0112] With this configuration, as the end 12a enters the notch 31a, the radial misalignment of the end 12a is eliminated by the inclined side walls, and further, by moving the wire guide 31 circumferentially until the end 12a that has entered the notch 31a reaches the bottom of the notch 31a, the circumferential misalignment of the end 12a is also eliminated.

[0113] Although the embodiments of the present invention have been described above, the above embodiments merely illustrate some of the application examples of the present invention, and it is not intended that the technical scope of the present invention be limited to the specific configurations of the above embodiments.

[0114] This application claims priority based on Japanese Patent Application No. 2023-128377, filed with the Japan Patent Office on August 7, 2023, the entire contents of which are incorporated herein by reference.

Claims

1. A method for manufacturing a stator that aligns the ends of coil segments protruding from the end face of a stator core, comprising the steps of: providing a plurality of wire guides radially around the central axis of the stator core, each of which has a notch on one side through which the end portions can enter; arranging the wire guides between successive end portions spaced circumferentially so that the notches of the plurality of wire guides face the end portions from the circumferential direction; and moving the plurality of wire guides circumferentially to allow the end portions to enter the notches of the plurality of wire guides and align them.

2. A method for manufacturing a stator as described in claim 1, comprising providing a plurality of wire guides radially on a circular base plate formed so as to be able to surround the end portions, the circular base plate being positioned so as to surround the end portions, and then moving the plurality of wire guides toward the center, thereby inserting the wire guides respectively between the end portions which are spaced apart in the circumferential direction, so that the notches of the plurality of wire guides face the end portions from the circumferential direction.

3. A method for manufacturing a stator as described in claim 2, in which a cam ring for moving the wire guides is stacked coaxially on the base plate and rotated relative to the base plate, thereby moving the multiple wire guides toward the center of the base plate.

4. A method for manufacturing a stator according to claim 3, wherein the cam ring is rotated together with the base plate to move the plurality of wire guides in the circumferential direction.

5. A method for manufacturing a motor having the stator, wherein the stator is manufactured using the method for manufacturing a stator according to claim 1.

6. A stator manufacturing apparatus for aligning ends of coil segments protruding from an end face of a stator core of a stator, comprising: an annular base plate centered on the axis of the stator core; a plurality of wire guides arranged radially from the center of the base plate; and a base rotation unit that rotates the base plate together with the plurality of wire guides, wherein the plurality of wire guides have notches into which the ends can enter and align them by rotating together with the base plate.

7. A stator manufacturing apparatus as described in claim 6, wherein the plurality of wire guides are arranged to be movable in the radial direction of the base plate, and a cam ring is provided which overlaps with the base plate and rotates relative to the base plate to move the plurality of wire guides in the radial direction.

8. A stator manufacturing apparatus as described in claim 7, further comprising: a ring rotation unit which rotates the cam ring relative to the base plate; a base material having a round hole in which the annular base plate is rotatably mounted; a fixing unit which limits the allowable range of rotation of the base plate relative to the base material; and a locking unit which locks the cam ring to the base plate and rotates the base plate together with the cam ring when the fixing unit allows rotation of the base plate relative to the base material, wherein the ring rotation unit is capable of rotating the base plate by rotating the cam ring locked to the base plate by the locking unit when the fixing unit allows rotation of the base plate relative to the base material, and also serves as the base rotation unit.

9. The stator manufacturing apparatus according to claim 8, wherein one or more of said wire guides are provided on a movable piece which is provided on said annular base plate so as to be movable in the radial direction.

10. A stator manufacturing apparatus as described in claim 8, wherein the notch has an open end facing the end portion, a bottom formed to have the same radial width as the end portion, and both sides sloping so that the width increases toward the open end.

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