Coil Installation Device and Coil Installation Method

Abstract

The problem to be solved by the present invention is to provide a coil mounting device that can simply and reliably insert a strip coil into a slot from the inside of a stator core. To solve the above problems, the present invention includes: a stator core; a coil winding jig having an outer diameter formed to be smaller than the inner diameter of the stator core, and wound into a circular ring by inserting a straight portion of the strip coil from the outside into a comb-shaped groove; a stator core fixing jig that fixes the stator core at a predetermined position and posture; and a coil expanding mechanism portion that expands the strip coil of the coil winding jig. The coil expanding mechanism portion has: a holding portion that holds the coil winding jig inside the stator core in a state where the phase of the comb-shaped groove is aligned with the slot; and a coil expanding portion that presses in an expanding manner against a position closer to the end side than the straight portion of the strip coil on the coil winding jig held by the holding portion, thereby expanding the strip coil and inserting the straight portion into the slot.

Description

Technical Field

[0001] The present invention relates to a coil mounting device and a coil mounting method. Background Art

[0002] Conventionally, the following method has been known: A coil wound in a circular ring shape is inserted into the inside of a stator core, and the slot housing portion of the coil is moved from the inside to the outside with respect to the slot of the stator core, thereby being mounted in the slot of the stator core (for example, refer to Patent Document 1).

[0003] In the above prior art, a coil is wound around a cylindrical insertion jig having grooves on its outer periphery, and after being inserted into the inside of the stator core, the coil wound around the insertion jig is expanded in diameter by an expansion jig.

[0004] [Prior Art Documents]

[0005] (Patent Document)

[0006] Patent Document 1: Japanese Patent No. 3982446 Gazette Summary of the Invention

[0007] [Problems to be Solved by the Invention]

[0008] However, in the above prior art, a specific device and method required for expanding the diameter of a coil inserted into the inside of a stator core and then inserting it into a slot are not disclosed.

[0009] An object of the present invention is to provide a coil mounting device and a coil mounting method that can simply and reliably insert a strip-shaped coil wound in a circular ring shape into a slot from the inside of a stator core.

[0010] [Technical Means for Solving the Problems]

[0011] (1) The coil mounting device of the present invention (for example, the coil mounting device 1 described later) mounts the strip coil (for example, the strip coil 100 described later) along the circumferential direction of the stator core by inserting the straight portion (for example, the straight portion 102 described later) of the strip coil from the inside of the stator core (for example, the stator core 2 described later) into the slot (for example, the slot 22 described later). The coil mounting device includes: the aforementioned stator core; a coil winding jig (for example, the coil winding jig 4 described later), which has comb-shaped grooves (for example, the comb-shaped grooves 43 described later) radially arranged on the outer circumference and an outer diameter formed to be smaller than the inner diameter of the aforementioned stator core. By inserting the straight portion of the aforementioned strip coil from the outside into the aforementioned comb-shaped grooves, the aforementioned strip coil is wound into a circular ring; a stator core fixing jig (for example, the stator core fixing jig 3 described later), which fixes the aforementioned stator core at a specified position and in a specified posture; and a coil expanding mechanism portion (for example, the coil expanding mechanism portion 5), which expands the aforementioned strip coil wound on the aforementioned coil winding jig from the inside to the outside of the aforementioned strip coil. The aforementioned coil expanding mechanism portion has: a holding portion (for example, the holding portion 52 described later), which holds the aforementioned coil winding jig winding the aforementioned strip coil inside the aforementioned stator core fixed to the aforementioned stator core fixing jig in a state where the phase of the aforementioned comb-shaped grooves is aligned with the aforementioned slot; and a coil expanding portion (for example, the coil expanding portion 53 described later), which pushes at a position closer to the end side than the straight portion of the aforementioned strip coil on the aforementioned coil winding jig held by the aforementioned holding portion (for example, the position of the coil end portion 103 described later) in such a manner that it expands from the inside to the outside of the aforementioned strip coil, thereby expanding the aforementioned strip coil and inserting the aforementioned straight portion into the aforementioned slot.

[0012] (2) In the coil mounting device described in the above (1), it is also possible that the coil expanding portion has a plurality of joint members (for example, the joint members 533 described later) arranged in a circular ring shape on the outer circumference of the aforementioned holding portion. The aforementioned plurality of joint members are arranged to be inserted into the inside of a position closer to the end side than the straight portion of the aforementioned strip coil wound on the aforementioned coil winding jig, and can be expanded in diameter by moving in such a manner that the distance between adjacent aforementioned joint members is enlarged.

[0013] (3) In the coil mounting device described in the above (1) or (2), it is also possible that the aforementioned coil expanding mechanism portion is provided on both axial sides of the aforementioned coil winding jig held inside the aforementioned stator core in the directions of abutting against and moving away from the aforementioned coil winding jig, respectively.

[0014] (4) The coil mounting method of the present invention installs the strip-shaped coil (for example, the strip-shaped coil 100 described later) along the circumferential direction of the stator core by inserting the straight portion (for example, the straight portion 102 described later) of the strip-shaped coil from the inside of the stator core (for example, the stator core 2 described later) into the slot (for example, the slot 22 described later). The coil mounting method includes: a coil winding step of winding the strip-shaped coil into a circular ring by inserting the straight portion from the outside into the comb-shaped groove (for example, the comb-shaped groove 43 described later) of the coil winding jig (for example, the coil winding jig 4 described later). The coil winding jig radially arranges the comb-shaped grooves on the outer circumference and has an outer diameter smaller than the inner diameter of the stator core; a coil winding jig holding step of inserting the coil winding jig that has wound the strip-shaped coil into the inside of the stator core and holding it in a state where the phase of the comb-shaped groove is aligned with the slot; and a coil expanding step of pushing at a position closer to the end side than the straight portion of the strip-shaped coil on the coil winding jig being held, in a manner that expands from the inside to the outside of the strip-shaped coil, thereby expanding the strip-shaped coil and inserting the straight portion into the slot of the stator core.

[0015] (5) In the coil mounting method described in the above (4), it may also be that the coil expanding step is performed from both axial sides of the coil winding jig held inside the stator core.

[0016] (6) In the coil mounting method described in the above (4) or (5), it may also be that the coil expanding step inserts a plurality of joint members (for example, the joint member 533 described later) arranged in a circular ring into the inside of a position closer to the end side than the straight portion of the strip-shaped coil wound on the coil winding jig, and moves them in a manner that increases the distance between adjacent joint members, thereby expanding its diameter.

[0017] (Effect of the Invention)

[0018] According to the above (1), by holding the coil winding jig in a state where the position of the comb-shaped groove is aligned with the phase of the slot of the stator core, and pushing at a position closer to the end side than the straight portion of the strip-shaped coil wound into a circular ring, in a manner that expands from the inside to the outside of the strip-shaped coil, using the coil expanding mechanism portion, the comb-shaped groove can be used as a guide to simply and reliably insert the straight portion of the strip-shaped coil into the slot from the inside of the stator core without interference with the stator core.

[0019] According to (2) above, by moving a plurality of joint members arranged in a circular ring shape in an expanding manner, the strip coil can be easily expanded from the inside toward the outside.

[0020] According to (3) above, since the strip coil can be expanded from both sides in the axial direction of the coil winding jig, the straight portion of the strip coil can be efficiently inserted into the slot.

[0021] According to (4) above, by holding the coil winding jig in a state where the position of the comb-shaped groove is aligned with the phase of the slot of the stator core, and pressing at a position closer to the end than the straight portion of the strip coil wound in a circular ring shape so as to expand it from the inside toward the outside of the strip coil, the comb-shaped groove can be used as a guide to simply and reliably insert the straight portion of the strip coil into the slot from the inside of the stator core without interference with the stator core.

[0022] According to (5) above, by moving a plurality of joint members arranged in a circular ring shape in an expanding manner, the strip coil can be easily expanded from the inside toward the outside.

[0023] According to (6) above, since the strip coil can be expanded from both sides in the axial direction of the coil winding jig, the straight portion of the strip coil can be efficiently inserted into the slot. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a perspective view showing a coil mounting device according to an embodiment of the present invention.

[0025] Figure 2 is a perspective view showing the stator core fixing jig and the coil winding jig in the coil mounting device disassembled.

[0026] Figure 3 is a partially enlarged view showing the fixing portion of the stator core in the stator core fixing jig.

[0027] Figure 4 is a perspective view showing the insulating paper installed in the slot of the stator core.

[0028] Figure 5 is a partially enlarged view showing a state where the phase of the slot of the stator core and the comb-shaped groove of the coil winding jig are aligned.

[0029] Figure 6 is a perspective view showing the coil winding jig.

[0030] Figure 7 is a front view showing the strip coil.

[0031] Figure 8It is a plan view showing a situation where a strip coil is wound on a coil winding jig.

[0032] Figure 9 It is a perspective view showing a coil winding jig on which a strip coil has been wound.

[0033] Figure 10 It is a side view showing in section a situation where a coil expanding mechanism part is installed on a coil winding jig inserted into the inner side of a stator core.

[0034] Figure 11 It is a perspective view showing a holding part of a coil winding jig inserted into the inner side of a stator core and a coil expanding mechanism part.

[0035] Figure 12 It is a perspective view showing a coil expanding mechanism part in a reduced diameter state.

[0036] Figure 13 It is a side view showing a coil expanding part of a coil expanding mechanism part in a reduced diameter state.

[0037] Figure 14 It is a front view showing a coil expanding part of a coil expanding mechanism part in a reduced diameter state.

[0038] Figure 15 It is a perspective view showing a coil expanding mechanism part in an expanded diameter state.

[0039] Figure 16 It is a side view showing a coil expanding part of a coil expanding mechanism part in an expanded diameter state.

[0040] Figure 17 It is a front view showing a coil expanding part of a coil expanding mechanism part in an expanded diameter state.

[0041] Figure 18 It is a perspective view showing a state where insulating paper in a slot of a stator core is supported by a cuff guide.

[0042] Figure 19 It is a partially enlarged view showing a state where insulating paper in a slot of a stator core is supported by a cuff guide.

[0043] Figure 20 It is a side view showing in section a situation where a strip coil fixed to a coil winding jig on a stator core fixture is expanded by a coil expanding mechanism part.

[0044] Figure 21 It is a partially enlarged view showing a state where a strip coil pushed by a coil expanding mechanism part is inserted into a slot of a stator core.

[0045] Figure 22It is a partial enlarged view showing the state where the flanging guide has retreated after the strip coil is inserted into the slot.

[0046] Figure 23 It is a perspective view of the stator in which the strip coil is installed circumferentially in the slot. Detailed implementation mode

[0047] Hereinafter, the embodiments of the present invention will be described in detail with reference to the drawings. As Figure 1 shown, the coil installation device 1 includes: a stator core 2; a stator core fixing jig 3 for fixing the stator core 2; a coil winding jig 4 that winds the strip coil 100 in a circular shape and is inserted inside the stator core 2; and a coil expanding mechanism portion 5 that expands the strip coil 100 wound on the coil winding jig 4.

[0048] As Figure 2 and Figure 3 shown, the stator core 2 has a circular ring portion 21 formed of, for example, a laminate of a plurality of thin-walled core plates. The stator core 2 has a plurality of slots 22 penetrating in the axial direction of the stator core 2. The slots 22 are radially arranged at fixed intervals along the circumferential direction of the circular ring portion 21 and have an opening portion 22a opening toward the inner side in the radial direction of the circular ring portion 21. The stator core 2 of the present embodiment has 72 slots 22. On the outer periphery of the circular ring portion 21 of the stator core 2, six ears 23 project at fixed intervals.

[0049] As Figure 1 , Figure 2 and Figure 3 shown, the stator core fixing jig 3 has a hexagonal prism shape, and the hexagonal prism shape has an axial dimension substantially equal to the axial dimension of the stator core 2, and has a stator core insertion hole 31 in the center into which the stator core 2 can be inserted and arranged. In the coil installation device 1 of the present embodiment, the stator core fixing jig 3 is fixed to the central portion of the base 11 of the coil installation device 1 such that the axial direction of the stator core 2 fixed in the stator core insertion hole 31 is the horizontal direction.

[0050] The stator core fixing jig 3 fixes the stator core 2 in the stator core insertion hole 31 to a specified position and posture. Specifically, as Figure 2 and Figure 3 shown, the stator core fixing jig 3 has six core pressing blocks 32, and the six core pressing blocks 32 correspond to the positions of the six ears 23 of the stator core 2 and can move in a manner of protruding and retreating with respect to the inside of the stator core insertion hole 31. After the stator core 2 is inserted into the stator core insertion hole 31, the stator core fixing jig 3 drives the core pressing blocks 32 to protrude toward the inside of the stator core insertion hole 31 respectively by driving an actuator such as a cylinder (not shown). Thus, asFigure 2 As shown, the iron core pressing block 32 holds the ear portions 23 of the stator iron core 2 respectively, and fixes the stator iron core 2 inserted into the hole 31 at a specified position and posture.

[0051] As Figure 2 and Figure 3 shown, insulating papers 24 are respectively pre-installed in the slots 22 of the stator iron core 2. The insulating papers 24 are bent into a substantially U-shaped manner in a way that imitates the inner surface shape of the slots 22 when observing the stator iron core 2 axially. As Figure 4 shown, the insulating paper 24 installed in the slot 22 has a flanging portion 24a that protrudes from the slot 22 to the axial direction of the stator iron core 2 at a specified height. The flanging portions 24a protrude from the slot 22 to both outer sides in the axial direction of the stator iron core 2 respectively.

[0052] As Figure 2 shown, on the axial end faces 3a, 3a at both ends of the stator iron core fixing jig 3 for pre-fixing the stator iron core 2, a plurality of flanging guides 33 are respectively installed in a radially arranged manner at regular intervals along the circumferential direction. The flanging guides 33 are arranged to be able to move along the radial direction of the stator iron core 2 by the driving of an actuator such as a cylinder (not shown). It should be noted that in Figure 3 , for the sake of easily understanding the description of the iron core pressing block 32, the illustration of the flanging guides 33 is omitted.

[0053] The flanging guides 33 are formed into long thin plate shapes along the radial direction of the stator iron core 2. As Figure 5 shown, on the inner end 33a side of the flanging guide 33, a guide groove 331 is provided along the length direction of the flanging guide 33. The guide groove 331 opens towards the inside of the stator iron core fixing jig 3 and supports the flanging portions 24a of the insulating papers 24 from both sides. The guide groove 331 has a cut width slightly narrower than the circumferential width of the slot 22 of the stator iron core 2 and is cut into a U shape. On the outer end 33b side more outside than the guide groove 331 of the flanging guide 33, a long hole 332 is provided, and the long hole 332 limits the radial movement range of the flanging guide 33.

[0054] On the end faces 3a, 3a of the stator iron core fixing jig 3, there are an inner diameter side limiting pin 34a and an outer diameter side limiting pin 34b, and a pair is respectively provided corresponding to the flanging guides 33. The long holes 332 of the flanging guides 33 engage the pair of inner diameter side limiting pins 34a and outer diameter side limiting pins 34b on the inside, and are installed on the end faces 3a, 3a of the stator iron core fixing jig 3.

[0055] When the flanging guide 33 moves towards the radial outside of the stator iron core fixing jig 3, the inner diameter side limiting pin 34a abuts against the inner end portion 332a of the long hole 332. Thus, as Figure 2As shown, the flanging guide 33 is positioned at the outermost non-guiding position in the radial direction. At the non-guiding position, the inner end 33a of the flanging guide 33 is arranged more radially outward than the stator core insertion hole 31.

[0056] When the flanging guide 33 moves radially inward toward the stator core fixing jig 3, the outer diameter side limiting pin 34b abuts against the outer end portion 332b of the long hole 332, thereby positioning the flanging guide 33 at the innermost guiding position in the radial direction. At this time, the inner end 33a of the flanging guide 33 is arranged more radially outward than the coil winding jig 4 (see Figure 18 and Figure 19 ).

[0057] In addition, since the stator core 2 is inserted into the stator core insertion hole 31 of the stator core fixing jig 3 from either side in the axial direction, as Figure 5 shown, the flanging guide 33 arranged on the opposite side of the insertion side of the stator core 2 may also be arranged such that the inner end 33a side interferes with the ring portion 21 of the stator core 2 in a state where the outer diameter side limiting pin 34b abuts against the inner end portion 332a of the long hole 332. However, the inner diameter side limiting pin 34a and the outer diameter side limiting pin 34b may also selectively project and recess with respect to the surface of the stator core fixing jig 3 by means of a retracting and extending mechanism (not shown), which is provided inside the stator core fixing jig 3 and has an actuator such as a cylinder. Thus, when the flanging guide 33 is arranged as Figure 5 shown, the inner diameter side limiting pin 34a and the outer diameter side limiting pin 34b can be recessed with respect to the surface of the stator core fixing jig 3 as needed, thereby moving the flanging guide 33 further radially outward, as Figure 2 shown, so that the flanging guide 33 can be in a state of completely withdrawing from the ring portion 21 of the stator core 2.

[0058] On both end faces 3a, 3a of the stator core fixing jig 3 in the present embodiment, there are 36 flanging guides 33 respectively. The flanging guides 33 are arranged such that when the flanging guides 33 move radially inward to the stator core fixing jig 3 and are positioned at the guiding position, the circumferential interval distance on the inner end 33a side between adjacent flanging guides 33, 33 is the same as the notch width of the guiding groove 331 of the flanging guide 33.

[0059] As Figure 6 shown, the coil winding jig 4 has: a substantially cylindrical jig body 41; a plurality of comb teeth portions 42 projecting radially from the outer periphery of the jig body 41; a plurality of comb tooth-shaped grooves 43 formed between the comb teeth portions 42 adjacent in the circumferential direction; and a shaft hole 44 opening at the center of the jig body 41.

[0060] The comb teeth part 42 and the comb tooth-shaped grooves 43 are respectively arranged at both axial ends of the fixture body 41. The phases of the comb teeth part 42 and the comb tooth-shaped grooves 43 at both ends of the fixture body 41 are aligned along the axial direction. The number of the comb tooth-shaped grooves 43 arranged in the circumferential direction of the fixture body 41 is the same as the number of the slot grooves 22 provided in the stator core 2. Therefore, the coil winding fixture 4 of the present embodiment has 72 comb tooth-shaped grooves 43. The coil winding fixture 4 is formed such that the outer diameter of the coil winding fixture 4 defined by the position of the front end of the comb teeth part 42 is smaller than the inner diameter of the stator core 2 so that it can be inserted into the inner side of the circular ring part 21 of the stator core 2.

[0061] On the coil winding fixture 4, a strip-shaped coil 100 for being mounted on the stator core 2 is wound in a circular shape. The strip-shaped coil 100 is a long strip-shaped coil formed by a flat wire 101 having a substantially rectangular cross-sectional shape. The flat wire 101 is formed of a highly conductive metal such as copper or aluminum, for example.

[0062] As Figure 7 shown, the coil 100 has a plurality of straight portions 102 and a plurality of coil end portions 103. The straight portions 102 are the parts inserted into the slot grooves 22 of the stator core 2, and respectively extend in a substantially straight line shape and are arranged in parallel at a certain interval. The coil end portions 103 are respectively arranged at positions near the side ends of the strip-shaped coil 100 closer than the straight portions 102, and connect one end and the other end of adjacent straight portions 102 to each other in a mountain shape alternately. The coil end portions 103 are the parts configured to protrude from the slot grooves 22 in the axial direction of the stator core 2 respectively when the strip-shaped coil 100 is mounted in the slot grooves 22 of the stator core 2. The strip-shaped coil 100 of the present embodiment bundles six flat wires 101 in such a manner that the straight portions 102 are arranged in parallel at a certain interval, thereby forming a long strip shape. The six flat wires 101 are respectively formed by bending a plurality of straight portions 102 and a plurality of coil end portions 103.

[0063] As Figure 8 shown, before the coil winding fixture 4 is inserted into the inner side of the stator core 2, the straight portions 102 of the strip-shaped coil 100 are sequentially inserted from the outside of the comb tooth-shaped grooves 43, thereby winding the multi-layer strip-shaped coil 100. Thus, as Figure 9 shown, the coil winding fixture 4 (coil winding step) for winding the strip-shaped coil 100 in a circular shape is constituted.

[0064] The groove width of the comb tooth-shaped grooves 43 along the circumferential direction of the coil winding fixture 4 has a width capable of accommodating the straight portions 102 of the strip-shaped coil 100, but is formed slightly narrower than the opening width of the opening portion 22a of the slot groove 22 along the circumferential direction of the stator core 2.

[0065] The distance between the comb-shaped portions 42 in the axial direction of the jig main body 41 corresponds to the length of the straight portion 102 of the strip coil 100. Therefore, the straight portion 102 of the strip coil 100 wound around the coil winding jig 4 is received by the comb-shaped grooves 43, 43 of the same phase at both ends of the jig main body 41. The coil end portions 103 of the multi-layer wound strip coil 100 project cylindrically from the comb-shaped grooves 43 in the axial direction of the jig main body 41. Thus, as Figure 1 , Figure 2 and Figure 3 shown, the coil winding jig 4 for winding the strip coil 100 in a circular shape is inserted into the inside of the stator core 2 by the operation of a robot (not shown), and the stator core 2 is fixed to the stator core fixing jig 3. It should be noted that in Figure 1 , the illustration of the strip coil 100 of the coil winding jig 4 is omitted.

[0066] The coil winding jig 4 inserted into the inside of the stator core 2 is held in a specified position and posture by the coil expanding mechanism portion 5, and the coil inserting device 5 sandwiches the stator core fixing jig 3 and is respectively arranged on both sides thereof. As Figure 1 shown, the coil expanding mechanism portion 5 of the present embodiment has a substantially cylindrical external shape and faces the coil winding jig 4 inserted into the inside of the stator core 2 in the axial direction.

[0067] As Figure 1 and Figure 10 shown, in the coil expanding mechanism portion 5, on the base 11 for fixing the stator core fixing jig 3, a pair of support substrates 12, 12 are erected so as to face each other with the stator core fixing jig 3 interposed therebetween. The coil expanding mechanism portion 5 projects from the support substrate 12 toward the coil winding jig 4 inserted into the inside of the stator core 2 in the horizontal direction respectively. The coil expanding mechanism portion 5 is arranged such that by driving a motor (not shown) or the like, the support substrate 12 linearly moves on the base 11, and thus it can move in the directions of abutting against and separating from the coil winding jig 4 respectively.

[0068] As Figure 10 and Figure 11As shown, the coil expanding mechanism section 5 has a main shaft section 51 at its center, and the main shaft section 51 extends from the support substrate 12 toward the coil winding jig 4 inserted into the inside of the stator core 2. A holding section 52 is provided at the front end of the main shaft section 51, and the holding section 52 holds the coil winding jig 4 at a specified position and posture inside the stator core 2. The holding section 52 has: a shaft protrusion 522 protruding from the center of the circular end plate section 521 disposed at the front end of the main shaft section 51; and a positioning protrusion 523 protruding from the end plate section 521 on the radially outer side of the shaft protrusion 522 in the same direction as the shaft protrusion 522. The shaft protrusion 522 is fitted into the shaft hole 44 of the coil winding jig 4. The positioning protrusion 523 is fitted into one positioning hole 45 provided on the radially outer side of the shaft hole 44 of the coil winding jig 4.

[0069] The positioning hole 45 of the coil winding jig 4 and the positioning protrusion 523 of the holding section 52 are pre-positioned and set in such a manner that when they are fitted to each other, the phase of the slot 22 of the stator core 2 fixed to the stator core fixing jig 3 coincides with the phase of the comb-shaped groove 43 of the coil winding jig 4 inserted into the inside of the stator core 2. Therefore, when the coil expanding mechanism section 5 moves toward the stator core fixing jig 3 and the shaft hole 44 and the positioning hole 45 of the coil winding jig 4 are fitted to the shaft protrusion 522 and the positioning protrusion 523 of the holding section 52, as Figure 5 shown, the coil winding jig 4 is held in a state where the phase of the comb-shaped groove 43 matches the slot 22 of the stator core 2. Thereby, the inside of the slot 22 of the stator core 2 and the inside of the comb-shaped groove 43 of the coil winding jig 4 communicate with each other in the radial direction.

[0070] The coil expanding mechanism section 5 has a coil expanding section 53 on the outer peripheral side of the main shaft section 51. The coil expanding section 53 has: a movable cylinder section 531 fitted to the outer peripheral side of the main shaft section 51; a plurality of movable arm sections 532 disposed on the outer peripheral side more than the movable cylinder section 531; and a plurality of joint members 533 respectively provided at the front ends of the movable arm sections 532.

[0071] The movable cylinder section 531 has a length shorter than that of the main shaft section 51 and is provided so as to be slidable along the axial direction of the main shaft section 51 by the drive of an actuator 54 such as a working cylinder disposed behind the support substrate 12.

[0072] The movable arm portions 532 extend along the axial direction of the main shaft portion 51, and a plurality of them are arranged at regular intervals in the circumferential direction on the outer peripheral side of the movable cylinder portion 531. The coil expansion portion 53 of the present embodiment has twelve movable arm portions 532 arranged in the circumferential direction of the main shaft portion 51. On the surface of the support substrate 12, twelve guide rails 121 are provided, which are radially arranged outwardly in a radial direction with the main shaft portion 51 as the center. The rear ends 532b of the movable arm portions 532 are respectively movably mounted along the guide rails 121. The movable arm portions 532 bend from the guide rails along the axial direction of the movable cylinder portion 531 and extend to the vicinity of the outer periphery of the holding portion 52. The front ends 532a of the movable arm portions 532 are connected to the outer peripheral surface on the front end side of the movable cylinder portion 531 via two link portions 534 that are respectively rotatably mounted.

[0073] The joint member 533 has a substantially fan-shaped shape, and one is provided at the front end of each of the movable arm portions 532. Therefore, the coil expansion portion 53 of the present embodiment has twelve joint members 533. As Figure 13 and Figure 14 shown, the joint member 533 has a pair of engaging tabs 533a at one end portion in the circumferential direction, and a pair of engaging grooves 533b that engage with the pair of engaging tabs 533a at the other end portion in the circumferential direction. The pair of engaging tabs 533a are arranged parallel to the axial direction of the coil expansion portion 53, and respectively project parallel to the circumferential direction of the coil expansion portion 53. The pair of engaging tabs 533a and the pair of engaging grooves 533b of the adjacent joint members 533, 533 in the circumferential direction engage with each other, whereby the twelve joint members 533 are arranged in a circular shape on the outer peripheral side of the holding portion 52.

[0074] Figure 10 、 Figure 11 and Figure 12 The coil expansion portion 53 of the coil expansion mechanism portion 5 shown represents a state where the movable cylinder portion 531 retreats toward the rear end side (support substrate 12 side) of the main shaft portion 51. At this time, the movable arm portions 532 respectively move toward the inner end side of the radial guide rails 121 and are arranged closest to the outer peripheral surface of the movable cylinder portion 531. Thus, as Figure 13 and Figure 14 shown, the coil expansion portion 53 contracts in diameter to the maximum extent so that the twelve joint members 533 are in close contact with each other. The outer diameter when the coil expansion portion 53 contracts in diameter to the maximum extent is slightly smaller than the inner diameter of the coil end portion 103 that protrudes in a cylindrical shape along the axial direction from the coil winding jig 4 for winding the strip coil 100. The coil expansion mechanism portion 5 is inserted into the coil end portion 103 that protrudes in a cylindrical shape along the axial direction of the coil winding jig 4 in a state where the coil expansion portion 53 has contracted in diameter, and the coil winding jig 4 is held by the holding portion 52.

[0075] Next, if the movable cylinder portion 531 advances along the main shaft portion 51 toward the coil winding jig 4 by driving the actuator 54, the link portions 534 connected to the movable cylinder portion 531 rotate so as to project radially outward from the movable cylinder portion 531, causing the movable arm portions 532 to move parallel to the outside along the guide rails. As a result, the twelve movable arm portions 532 are separated from the movable cylinder portion 531 toward the radially outer side. At this time, as Figure 15 , Figure 16 and Figure 17 show, the coil expanding portion 53 expands in diameter by moving the joint members 533 so as to increase the distance between adjacent joint members 533. The outer diameter of the coil expanding portion 53 after expanding in diameter to the maximum extent is slightly larger than the outer diameter of the coil winding jig 4.

[0076] In addition, as Figure 16 and Figure 17 show, when the coil expanding portion 53 expands in diameter to the maximum extent, the adjacent joint members 533, 533 move away from each other, but between the joint members 533, 533, a pair of engaging tabs 533a away from the engaging groove 533b project along the circumferential direction. Therefore, when observing the coil expanding portion 53 along the circumferential direction, the adjacent joint members 533, 533 are connected by a pair of engaging tabs 533a, and no groove portion penetrating the coil expanding portion 53 in the radial direction is formed.

[0077] Next, a method of inserting the strip coil 100 wound around the coil winding jig 4 into the slot 22 from the inside of the stator core 2 fixed to the stator core fixing jig 3 in the coil mounting device 1 will be described.

[0078] Before the coil winding jig 4 is inserted into the inside of the stator core 2, as described above, in the coil winding process, the strip coil 100 is wound into a circular ring shape. After the coil winding jig 4 around which the strip coil 100 is wound in a circular ring shape is inserted into the inside of the stator core 2 fixed to the stator core fixing jig 3, as Figure 18 shows, the flanging guide 33 moves radially inward by driving an actuator (not shown).

[0079] As Figure 19As shown, when the flanging guide 33 moves toward the radially inner side, the guide groove 331 of the flanging guide 33 supports the flanged portion 24a of the insulating paper 24 in the corresponding slot 22 in a manner of clamping the flanged portion 24a of the insulating paper 24 from both sides in the circumferential direction. At this time, the inner ends 33a, 33a of the adjacent flanging guides 33, 33 in the circumferential direction also support the flanged portion 24a of the insulating paper 24 in the slot 22 arranged between the flanging guides 33, 33 in a manner of clamping the flanged portion 24a of the insulating paper 24 from both sides in the circumferential direction, similar to the guide groove 331. Since the cut width of the guide groove 331 and the interval distance between the inner ends 33a, 33a of the adjacent flanging guides 33, 33 are slightly narrower than the circumferential width of the slot 22, the insulating papers 24 supported by the guide groove 331 and between the flanging guides 33, 33 from both sides with the flanged portion 24a are respectively positioned at the specified positions in the slot 22.

[0080] It should be noted that Figure 18 In, the coil expanding mechanism portion 5 of the coil winding jig 4 is not shown in the figure, but after the stator core 2 is fixed to the stator core fixing jig 3 and before the strip coil 100 is inserted into the slot 22 of the stator core 2 by the operation of the coil expanding portion 53 described later at an appropriate timing, the supporting operation of the flanged portion 24a by the flanging guide 33 is performed.

[0081] The coil expanding mechanism portions 5 in the state of being reduced in diameter by the coil expanding portion 53 move toward the coil winding jig 4 respectively, and the coil winding jig 4 inserted into the inner side of the stator core 2 is held by the holding portion 52 of the coil expanding mechanism portion 5 (coil winding jig holding step).

[0082] Furthermore, after the insulating paper 24 in the slot 22 is positioned by the flanging guide 33, as Figure 20 and Figure 21As shown, the coil expanding portions 53 of the coil expanding mechanism portion 5 expand in diameter respectively under the drive of the actuator 54. Thus, the coil expanding portions 53 push against the coil end portions 103 of the strip coil 100 wound around the coil winding jig 4 so as to expand them from the inside of the strip coil 100 toward the outside. The strip coil 100 pushed by the coil expanding portions 53 gradually expands. Along with this, the straight portions 102 are guided to the comb-shaped grooves 43 while moving toward the slots 22 of the stator core 2 communicating with the comb-shaped grooves 43. Thus, the straight portions 102 of the strip coil 100 are inserted into the slots 22 from the opening portions 22a of the slots 22 without interfering with the slots 22 of the stator core 2 (coil expanding step). At this time, the insulating papers 24 in the slots 22 are respectively positioned at prescribed positions by the flanging guides 33, and the groove width of the comb-shaped grooves 43 is formed slightly narrower than the opening width of the opening portions 22a of the slots 22. Therefore, the straight portions 102 of the strip coil 100 can smoothly pass through the opening portions 22a of the slots 22, and the situation of biting into the insulating papers 24 can be suppressed.

[0083] When the coil expanding portions 53 of the two coil expanding mechanism portions 5 expand in diameter to the maximum extent respectively, the straight portions 102 of the strip coil 100 of the coil winding jig 4 are Figure 22 as shown, respectively completely inserted into the slots 22 of the stator core 2, and the strip coil 100 is mounted in the slots 22 of the stator core 2. The coil expanding portions 53 of the two coil expanding mechanism portions 5 can act in a manner of expanding in diameter simultaneously, or can act by setting a time difference to expand in diameter successively in a manner of inserting the straight portions 102 into the opening portions 22a of the slots 22 obliquely in the radial direction.

[0084] Thereafter, the flanging guides 33 move radially outward and completely withdraw from the end faces of the stator core 2, and the coil expanding portions 53 contract in diameter respectively, so that the coil expanding mechanism portions 5 move away from the coil winding jig 4 respectively. Thus, Figure 23 as shown, the stator 200 with the strip coil 100 mounted in the slots 22 of the stator core 2 is obtained.

[0085] As described above, the coil mounting device 1 of the present embodiment mounts the strip coil 100 along the circumferential direction of the stator core 2 by inserting the straight portion 102 of the strip coil 100 from the inside of the stator core 2 into the slot 22. The coil mounting device 1 includes: a stator core 2; a coil winding jig 4 having comb-shaped grooves 43 radially arranged on the outer periphery and an outer diameter formed smaller than the inner diameter of the stator core 2, and winding the strip coil 100 into a circular ring by inserting the straight portion 102 of the strip coil 100 from the outside into the comb-shaped grooves 43; a stator core fixing jig 3 for fixing the stator core 2 in a predetermined position and posture; and a coil expanding mechanism portion 5 for expanding the strip coil 100 wound on the coil winding jig 4 from the inside to the outside of the strip coil 100. The coil expanding mechanism portion 5 has: a holding portion 52 for holding the coil winding jig 4 winding the strip coil 100 inside the stator core 2 fixed to the stator core fixing jig 3 in a state where the phase of the comb-shaped grooves 43 is aligned with the slot 22; and a coil expanding portion 53 for pushing the coil end portion 103, which is a position closer to the side end than the straight portion 102 of the strip coil 100 wound on the coil winding jig 4 held by the holding portion 52, so as to expand it from the inside to the outside of the strip coil 100, thereby expanding the strip coil 100 and inserting the straight portion 102 into the slot 22. Thus, the straight portion 102 of the strip coil 100 can be simply and reliably inserted into the slot 22 from the inside of the stator core 2 without interfering with the stator core 2 by using the comb-shaped grooves 43 as guides.

[0086] In the coil mounting device 1 of the present embodiment, the coil expanding portion 53 has a plurality of joint members 533 arranged in a circular ring on the outer periphery of the holding portion 52. The plurality of joint members 533 are arranged to be inserted into the inside of the coil end portion 103, which is a position closer to the side end than the straight portion 102 of the strip coil 100 wound on the coil winding jig 4, and can be expanded in diameter by moving in such a way that the distance between adjacent joint members 533 is increased. Thus, the strip coil 100 can be easily expanded from the inside to the outside.

[0087] In the coil mounting device 1 of the present embodiment, the coil expanding mechanism portion 5 is arranged to be movable in the directions of abutting against and away from the coil winding jig 4 on both axial sides of the coil winding jig 4 held inside the stator core 2. Thus, since the strip coil 100 can be expanded from both axial sides of the coil winding jig 4, the straight portion 102 of the strip coil 100 can be efficiently inserted into the slot 22.

[0088] The coil mounting method of this embodiment mounts the strip coil 100 along the circumferential direction of the stator core 2 by inserting the straight portion 102 of the strip coil 100 from the inner side of the stator core 2 into the slot 22. The coil mounting method includes: a coil winding step of winding the strip coil 100 into a circular ring by inserting the straight portion 102 from the outside into the comb-shaped groove 43 of the coil winding jig 4, where the coil winding jig 4 has comb-shaped grooves 43 radially arranged on the outer circumference and an outer diameter formed to be smaller than the inner diameter of the stator core 2; a coil winding jig holding step of inserting the coil winding jig 4 winding the strip coil 100 into the inner side of the stator core 2 and holding it in a state where the phase of the comb-shaped groove 43 is aligned with the slot 22; and a coil expanding step of pushing the coil end 103, which is a position closer to the side end than the straight portion 102 of the strip coil 100 wound on the held coil winding jig 4, in a manner that expands it from the inner side to the outer side of the strip coil 100, thereby expanding the strip coil 100 and inserting the straight portion 102 into the slot 22 of the stator core 2. Thus, the comb-shaped groove 43 can be used as a guide to simply and reliably insert the straight portion 102 of the strip coil 100 into the slot 22 from the inner side of the stator core 2 without interference with the stator core 2.

[0089] In the coil mounting method of this embodiment, in the coil expanding step, a plurality of joint members 533 arranged in a circular ring are inserted into the inner side of the coil end 103, which is a position closer to the side end than the straight portion 102 of the strip coil 100 wound on the coil winding jig 4, and are moved in a manner that increases the distance between adjacent joint members 533, thereby expanding the strip coil 100. Thus, the strip coil 100 can be easily expanded from the inner side to the outer side.

[0090] In the coil mounting method of this embodiment, the coil expanding step is performed from both axial sides of the coil winding jig 4 held inside the stator core 2. Thus, since the strip coil 100 can be expanded from both sides respectively, the straight portion 102 of the strip coil 100 can be efficiently inserted into the slot 22.

[0091] The coil mounting device 1 of the embodiment described above is configured such that the axial directions of the stator core 2 and the coil winding jig 4 are arranged along the horizontal direction, but it can also be configured such that the axial directions of the stator core 2 and the coil winding jig 4 are arranged along a non-horizontal direction such as the vertical direction.

[0092] The coil winding jig 4 that winds the strip coil 100 into a circular ring can also be inserted into the inner side of the stator core 2 fixed to the stator core fixing jig 3 while being mounted and held by the holding portion 52 of any one of the coil expanding mechanism portions 5.

[0093] Reference numerals

[0094] 1: Coil mounting device

[0095] 2: Stator core

[0096] 22: Slot

[0097] 3: Stator core fixing jig

[0098] 4: Coil winding jig

[0099] 43: Comb-shaped groove

[0100] 5: Coil expanding mechanism part

[0101] 52: Holding part

[0102] 53: Coil expanding part

[0103] 533: Section component

[0104] 100: Strip coil

[0105] 102: Straight part

[0106] 103: Coil end

Claims

1. A coil mounting device for mounting a strip coil along the circumferential direction of a stator core by inserting a straight portion of the strip coil into a slot from the inside of the stator core, the coil mounting device comprising: The stator core; A coil winding jig having comb-shaped grooves radially arranged on the outer periphery and an outer diameter formed to be smaller than the inner diameter of the stator core, and winding the strip coil into a circular ring by inserting the straight portion of the strip coil into the comb-shaped grooves from the outside; A stator core fixing jig for fixing the stator core at a prescribed position and fixing it in a prescribed posture; and A coil expanding mechanism portion for expanding the strip coil wound on the coil winding jig from the inside of the strip coil toward the outside; The coil expanding mechanism portion has: A holding portion for holding the coil winding jig winding the strip coil inside the stator core fixed to the stator core fixing jig in a state where the phase of the comb-shaped grooves is aligned with the slot; and A coil expanding portion for pressing the coil end portion of the strip coil on the coil winding jig held by the holding portion so as to contact along the circumferential direction of the coil end portion and expand it from the inside of the strip coil toward the outside, thereby expanding the strip coil and inserting the straight portion into the slot, The coil expanding portion has a plurality of joint members arranged in a circular ring on the outer periphery of the holding portion, Each of the plurality of joint members has an engaging tab and an engaging groove, In each of the plurality of joint members, the engaging tab is provided at one end portion in the circumferential direction of the joint member and protrudes in the circumferential direction, and the engaging groove is provided at the other end portion in the circumferential direction of the joint member and can be engaged with the engaging tab of the adjacent joint member, The plurality of joint members are arranged to be inserted into the inside of the coil end portion of the strip coil wound on the coil winding jig and can be expanded in diameter by moving in such a way as to increase the distance between adjacent joint members, In a state where the plurality of joint members are expanded to the maximum extent, the engaging tabs of each of the plurality of joint members are partially engaged with the engaging grooves of the adjacent joint members in the circumferential direction, so that the adjacent joint members are continuous with each other, whereby the plurality of joint members contact the coil end portion in the circumferential direction and press the coil end portion.

2. The coil mounting device according to claim 1, wherein, The coil expanding mechanism portion is arranged to be movable in directions of abutting against and away from the coil winding jig on both axial sides of the coil winding jig held inside the stator core.

3. A coil mounting method for mounting a strip coil along the circumferential direction of a stator core by inserting a straight portion of the strip coil into a slot from the inside of the stator core, the coil mounting method comprising: A coil winding step of winding the strip coil into a circular ring by inserting the straight portion into the comb-shaped grooves of a coil winding jig from the outside, the coil winding jig having the comb-shaped grooves radially arranged on the outer periphery and an outer diameter formed to be smaller than the inner diameter of the stator core; The coil winding jig holding step of inserting the coil winding jig for winding the strip coil into the inner side of the stator core and holding it in a state where the phase of the comb-shaped groove is aligned with the slot; and, The coil expansion step of pressing the coil end of the strip coil on the held coil winding jig in a manner of contacting along the circumferential direction of the coil end and expanding it from the inner side to the outer side of the strip coil, thereby expanding the strip coil and inserting the straight portion into the slot of the stator core, In the aforementioned coil expansion step, a plurality of joint members are used, and the plurality of joint members are arranged in a circular ring shape on the outer circumference of the holding portion for holding the coil winding jig. Each of the aforementioned plurality of joint members has an engaging tab and an engaging groove. In each of the aforementioned plurality of joint members, the engaging tab is provided at one end in the circumferential direction of the joint member and protrudes in the circumferential direction, and the engaging groove is provided at the other end in the circumferential direction of the joint member and can be engaged with the engaging tab of the adjacent joint member. The aforementioned plurality of joint members are arranged to be inserted into the inner side of the coil end of the strip coil wound on the coil winding jig, and can be expanded in diameter by moving in a manner of increasing the distance between adjacent joint members. In a state where the aforementioned plurality of joint members are expanded to the maximum extent, the engaging tabs of each of the aforementioned plurality of joint members are partially engaged with the engaging grooves of the adjacent joint members in the circumferential direction, so that the adjacent joint members are continuous with each other. Thus, the plurality of joint members contact the coil end in the circumferential direction and press the coil end.

4. The coil mounting method according to claim 3, wherein, The aforementioned coil expansion step is performed from both axial sides of the coil winding jig held inside the stator core.

Images