Coil Installation Device and Coil Installation Method

Abstract

The problem to be solved by the present invention is to provide a coil mounting device in which, when the straight portion of an annular strip-shaped coil is inserted into a slot from the inside of a stator core, the straight portion does not catch an insulating paper. To solve the above problem, the insulating paper has a flange portion that projects from the axial end face of the stator core. The coil mounting device includes: a stator core fixing jig that fixes the stator core; a coil winding jig that is disposed inside the stator core and winds the strip-shaped coil into an annular shape by inserting the straight portion of the strip-shaped coil into comb-shaped grooves arranged radially along the outer circumference; and a flange guide that is provided on the stator core fixing jig and has a guide groove that supports the flange portion. The guide groove has: a flange portion support groove portion that supports the flange portion in a manner of clamping it from the circumferential direction of the stator core; and a coil guide groove portion that has a groove width narrower than that of the flange portion support groove portion on a side farther from the end face of the stator core than the flange portion support groove portion.

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 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 mounting the coil in the slot of the stator core (for example, refer to Patent Document 1).

[0003] In the above prior art, the coil is wound around a cylindrical insertion jig having grooves on the outer periphery, inserted into the inside of the stator core, and then the diameter of the coil wound around the insertion jig is expanded using 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] In the slots of the stator core, insulating papers are respectively installed to achieve insulation between the coil and the stator core. Therefore, when the circular coil inserted into the inside of the stator core is expanded in diameter and inserted into the slot, the insulating paper may be damaged because it is caught between the coil and the inner wall surface of the slot.

[0009] However, in the above prior art, a specific device and method for preventing the coil and the insulating paper in the slot from getting stuck together are not disclosed.

[0010] An object of the present invention is to provide a coil mounting device and a coil mounting method that prevent the straight portion of a strip-shaped coil wound in a circular shape from catching the insulating paper in the slot when the straight portion is inserted into the slot from the inside of the stator core.

[0011] [Means for Solving the Problems]

[0012] (1) The coil mounting device of the present invention (for example, the following coil mounting device 1) mounts the strip-shaped coil wound into a circular ring (for example, the following strip-shaped coil 100) along the circumferential direction of the stator core by inserting the straight portion (for example, the following straight portion 102) of the strip-shaped coil from the inside of the stator core (for example, the following stator core 2) into the slot (for example, the following slot 22) having an insulating paper (for example, the following insulating paper 24). The insulating paper has a flanging portion (for example, the following flanging portion 24a) extending from the axial end face (for example, the following end face 2a) of the stator core. And the coil mounting device includes: a stator core fixing jig (for example, the following stator core fixing jig 3) that fixes the stator core at a specific position and posture; a coil winding jig (for example, the following coil winding jig 4) disposed inside the stator core fixed by the stator core fixing jig, which winds the strip-shaped coil into a circular ring by inserting the straight portion of the strip-shaped coil into the comb-shaped slots (for example, the following comb-shaped slots 43) arranged radially along the outer circumference; and a flanging guide (for example, the following flanging guide 33) provided on the stator core fixing jig and having a guide groove (for example, the following guide groove 331) for supporting the flanging portion. And the guide groove has: a flanging portion supporting groove portion (for example, the following flanging portion supporting groove portion 331a) that supports the flanging portion in a manner of clamping it from the circumferential direction of the stator core; and a coil guiding groove portion (for example, the following coil guiding groove portion 331b) that has a groove width (for example, the following groove width W2) narrower than the groove width (for example, the following groove width W1) of the flanging portion supporting groove portion on the side farther from the end face of the stator core than the flanging portion supporting groove portion.

[0013] (2) In the coil mounting device described in the above (1), the comb-shaped slots of the coil winding jig have a width narrowing portion (for example, the following width narrowing portion 43a) on the outer diameter side with a groove width (for example, the following groove width W3) narrower than the groove width of the coil guiding groove portion of the guide groove.

[0014] (3) The coil installation method of the present invention inserts the straight portion (e.g., the following straight portion 102) of a strip coil wound into a circular ring shape (e.g., the following strip coil 100) from the inside of a stator core (e.g., the following stator core 2) into a slot (e.g., the following slot 22) having an insulating paper (e.g., the following insulating paper 24), and installs the strip coil along the circumferential direction of the stator core. The insulating paper has a flanging portion (e.g., the following flanging portion 24a) extending from the axial end face (e.g., the following end face 2a) of the stator core. The flanging portion is supported by a flanging portion support groove of a flanging guide (e.g., the following flanging guide 33). The flanging guide (e.g., the following flanging guide 33) has a guiding groove (e.g., the following guiding groove 331). The guiding groove (e.g., the following guiding groove 331) has: a flanging portion support groove portion (e.g., the following flanging portion support groove portion 331a) that supports the flanging portion in a manner of clamping from the circumferential direction of the stator core; and a coil guiding groove portion (e.g., the following coil guiding groove portion 331b) that has a groove width (e.g., the following groove width W2) narrower than the groove width (e.g., the following groove width W1) of the flanging portion support groove portion on a side farther from the end face of the stator core than the flanging portion support groove portion. In a state where the flanging portion is supported by the flanging portion support groove portion, the circular strip coil is expanded in diameter, the straight portion is inserted into the slot, and the straight portion is guided to move by the coil guiding groove portion.

[0015] (Advantages of the Invention)

[0016] According to the above (1), since the flanging portion of the insulating paper in the slot is supported in a manner of clamping from the circumferential direction of the stator core by the flanging portion support groove of the guiding groove of the flanging guide, the flanging portion is positioned relative to the slot, and the straight portion is guided into the slot by abutting against the coil guiding groove portion of the guiding groove without jamming the flanging portion. Therefore, a coil installation device can be provided in which, when the straight portion of a strip coil wound into a circular ring shape is inserted into the slot from the inside of the stator core, the straight portion does not jam the insulating paper in the slot.

[0017] According to the above (2), when the straight portion in the comb-shaped groove of the coil winding jig is about to be inserted into the slot of the stator core, the position of the straight portion is corrected by the width narrowing portion. Therefore, the straight portion in the comb-shaped groove can be smoothly inserted inside the insulating paper in the slot.

[0018] According to the above (3), since the flanging portion of the insulating paper in the insertion slot is supported in a manner of being clamped in the circumferential direction of the stator core by the support groove portion of the flanging guide member using the flanging guide groove, the flanging portion can be positioned relative to the insertion slot, and by bringing the straight portion into contact with the coil guiding groove portion of the guide groove, it can be guided into the insertion slot without jamming the flanging portion. Therefore, a coil mounting method can be provided in which when the straight portion of the strip-shaped coil wound into a circular ring is inserted into the insertion slot from the inside of the stator core, the straight portion does not jam the insulating paper in the insertion slot. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 FIG. is a perspective view showing a coil mounting device according to an embodiment of the present invention.

[0020] Figure 2 FIG. is a perspective view showing an exploded view of a stator core fixing jig and a coil winding jig for fixing a stator core in the coil mounting device.

[0021] Figure 3 FIG. is a partially enlarged view showing a fixing portion of the stator core in the stator core fixing jig.

[0022] Figure 4 FIG. is a perspective view showing an insulating paper mounted in an insertion slot of the stator core.

[0023] Figure 5 FIG. is a partially enlarged view showing a state where the insertion slot of the stator core and the comb-shaped grooves of the coil winding jig are phase-aligned.

[0024] Figure 6 FIG. is a side view showing a flanging guide member.

[0025] Figure 7 is from Figure 6 FIG. of the flanging guide member viewed from direction A in

[0026] Figure 8 FIG. is a perspective view showing a coil winding jig.

[0027] Figure 9 FIG. is a front view showing a strip-shaped coil.

[0028] Figure 10 FIG. is a plan view showing a situation where a strip-shaped coil is wound around a coil winding jig.

[0029] Figure 11 FIG. is a perspective view showing a coil winding jig for winding a strip-shaped coil.

[0030] Figure 12 FIG. is a side view showing a situation where a coil expanding mechanism portion is mounted on a coil winding jig inserted into the inside of a stator core in a sectional view.

[0031] Figure 13 It is a perspective view showing a coil winding jig inserted into the inner side of a stator core and a holding part of a coil expanding mechanism part.

[0032] Figure 14 It is a perspective view showing the coil expanding mechanism part in a reduced diameter state.

[0033] Figure 15 It is a side view showing the coil expanding part of the coil expanding mechanism part in a reduced diameter state.

[0034] Figure 16 It is a front view showing the coil expanding part of the coil expanding mechanism part in a reduced diameter state.

[0035] Figure 17 It is a perspective view showing the coil expanding mechanism part in an expanded diameter state.

[0036] Figure 18 It is a side view showing the coil expanding part of the coil expanding mechanism part in an expanded diameter state.

[0037] Figure 19 It is a front view showing the coil expanding part of the coil expanding mechanism part in an expanded diameter state.

[0038] Figure 20 It is a perspective view showing the state where the insulating paper in the slot of the stator core is supported by the flanging guide.

[0039] Figure 21 It is a partial enlarged view showing the state where the insulating paper in the slot of the stator core is supported by the flanging guide.

[0040] Figure 22 It is shown along Figure 21 the view of the stator core when observed along the B - B line in

[0041] Figure 23 It is a side view showing in section the situation where the strip - shaped coil fixed by the stator core fixing jig is expanded by the coil expanding mechanism part.

[0042] Figure 24 It is a partial enlarged view showing the state where the strip - shaped coil pushed by the coil expanding mechanism part is inserted into the slot of the stator core.

[0043] Figure 25 It is a view showing the comb - shaped groove of the coil winding jig and the guide groove of the flanging guide.

[0044] Figure 26 It is shown the situation where the straight part of the strip - shaped coil is guided by the guide groove of the flanging guide Figure 6 in the sectional view at the P1 position in

[0045] Figure 27 is a sectional view of the P2 position in Figure 6 showing the case where the straight portion of the strip coil is guided by the guide groove of the flanging guide.

[0046] Figure 28 is a partial enlarged view showing the state where the flanging guide retracts after the strip coil is inserted into the slot.

[0047] Figure 29 is a perspective view of the stator in which the strip coil is mounted circumferentially in the slot. DETAILED DESCRIPTION OF THE INVENTION

[0048] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. As Figure 1 shown, the coil mounting device 1 includes: a stator core 2; a stator core fixing jig 3 for fixing the stator core 2; a coil winding jig 4 inserted into the inside of the stator core 2 and winding the strip coil 100 into a circular ring shape; and a coil expanding mechanism portion 5 for expanding the strip coil 100 wound around the coil winding jig 4.

[0049] As Figure 2 and Figure 3 shown, the stator core 2 has a circular ring portion 21 which is, for example, formed of a laminate of a plurality of thin-walled core plates. A through hole 20 penetrating the axial direction is provided at the center of the circular ring portion 21. The stator core 2 has a plurality of slots 22 penetrating the axial direction of the stator core 2. The slots 22 are arranged radially at fixed intervals along the circumferential direction of the circular ring portion 21 and have an opening portion 22a opening to the through hole 20 on the radially inner side 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. Further, as Figure 2 and Figure 3 shown, in the stator core 2 and the stator core fixing jig 3, the X direction in which the slots 22 are arranged is the circumferential direction, and the Y direction along the radial direction from the center of the through hole 20 is the radial direction, Figure 2 the Z direction shown in Figure 3 (the direction perpendicular to the paper surface in

[0050] As Figure 1 , Figure 2 and Figure 3 shown, the stator core fixing jig 3 has a hexagonal prism shape having an axial dimension substantially equal to the axial dimension of the stator core 2, and a stator core insertion hole 31 capable of inserting and disposing the stator core 2 at the center. In the coil mounting 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 mounting device 1 in such a manner that the axial direction of the stator core 2 fixed in the stator core insertion hole 31 is the horizontal direction.

[0051] The stator core fixing jig 3 fixes the stator core 2 inserted into the hole 31 at 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, which correspond to the positions of six ears 23 of the stator core 2 and can move in a manner of protruding and retracting 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 into the stator core insertion hole 31 respectively by using an actuator such as a cylinder (not shown). Thus, as Figure 2 shown, the core pressing blocks 32 respectively hold the ears 23 of the stator core 2, and fix the stator core 2 inserted into the stator core insertion hole 31 at a specified position and posture.

[0052] As Figure 3 and Figure 4 shown, insulating papers 24 are respectively pre-installed in the slots 22 of the stator core 2. The insulating papers 24 are bent into a substantially U-shaped manner to mimic the inner surface shape of the slots 22 when observing the stator core 2 from the axial direction. That is, the insulating paper 24 has: a pair of radial portions 241, 241, which are along the inner wall surface of the slot 22, and the slot 22 extends along the radial direction of the stator core 2; and a circumferential portion 242, which connects the radially outer ends of the radial portions 241, 241 along the circumferential direction of the stator core 2.

[0053] As Figure 4 shown, the insulating paper 24 installed in the slot 22 has a flanging portion 24a. The flanging portion 24a is a part where the radial portions 241, 241 and the circumferential portion 242 of the insulating paper 24 extend along the axial direction of the stator core 2 and protrude from the slot 22, and protrude outward from the axial end face 2a of the stator core 2. Figure 4 Only one flanging portion 24a of the insulating paper 24 protruding from one end face 2a of the stator core 2 is shown, but the flanging portions 24a protrude from both axial end faces 2a, 2a of the stator core 2 respectively.

[0054] As Figure 1 and Figure 2 shown, on the axial end faces 3a, 3a at both ends of the stator core fixing jig 3 that pre-fixes the stator core 2, a plurality of flanging guides 33 are respectively installed in a radial manner with a fixed interval along the circumferential direction. The flanging guides 33 are respectively arranged to be able to move forward and backward along the radial direction of the stator core 2 under the drive of an actuator such as a cylinder (not shown). In addition, in Figure 3 , for the sake of easy understanding of the description of the core pressing block 32, the illustration of the flanging guide 33 is omitted.

[0055] The flanging guide 33 is formed as a relatively long thin plate shape along the radial direction of the stator core 2. As Figure 5 shown, on the inner end 33a side of the flanging guide 33, there is a guide groove 331, and the guide groove 331 supports the flanging portion 24a of the insulating paper 24 in a manner of clamping from both circumferential sides of the stator core 2. The guide groove 331 is cut into a U shape along the length direction of the flanging guide 33 on the inner end 33a side of the flanging guide 33 and opens toward the inner side of the stator core fixing jig 3. On the outer end 33b side more 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.

[0056] As Figure 6 and Figure 7 shown, the flanging guide 33 has a tapered surface 33c, and on the tapered surface 33c, as it approaches the inner end 33a more than the long hole 332, the plate thickness gradually becomes thinner. The tapered surface 33c is provided on the surface opposite to the bottom surface 33d facing the end surface 3a of the stator core fixing jig 3. The guide groove 331 is provided in the entire area of the flanging guide 33 where the tapered surface 33c is provided. The groove depth D of the guide groove 331 along the radial direction of the stator core 2 is greater than or equal to the depth of the slot 22 along the radial direction of the stator core 2.

[0057] As Figure 7 shown, the guide groove 331 is formed by a flanging portion support groove portion 331a with a relatively wide groove width along the circumferential direction of the stator core 2 and a coil guiding groove portion 331b with a relatively narrow groove width along the circumferential direction of the stator core 2. The flanging portion support groove portion 331a and the coil guiding groove portion 331b are continuously formed in the plate thickness direction ( Figure 6 and Figure 7 the up and down direction) of the flanging guide 33. The flanging portion support groove portion 331a is arranged on the side close to the end surface 2a of the stator core 2 fixed by the stator core fixing jig 3, and the coil guiding groove portion 331b is arranged on the side far from the end surface 2a of the stator core 2 fixed by the stator core fixing jig 3.

[0058] The flanging portion support groove portion 331a is disposed on the bottom surface 33d side of the flanging guide member 33 that faces the end surface 3a of the stator core fixing jig 3 in the plate thickness direction. The groove width W1 of the flanging portion support groove portion 331a along the circumferential direction of the stator core 2 is substantially equal to the width of the slot 22 along the circumferential direction of the stator core 2. The height H1 of the flanging portion support groove portion 331a along the axial direction of the stator core 2 is greater than or equal to the protruding height of the flanging portion 24a protruding from the end surface 2a of the stator core 2. This height H1 is fixed in the length direction of the guide groove 331. When the flanging guide member 33 advances toward the slot 22 of the stator core 2, the flanging portion support groove portion 331a supports the portions of the pair of radial portions 241, 241 of the flanging portion 24a in a manner of clamping from both circumferential sides of the stator core 2 (reference Figure 22 ).

[0059] The coil guiding groove portion 331b is disposed on the tapered surface 33c side of the flanging guide member 33 in the plate thickness direction, and is provided in the entire portion between the flanging portion support groove portion 331a and the tapered surface 22c. The groove width W2 of the coil guiding groove portion 331b along the circumferential direction of the stator core 2 is narrower than the opening width of the slot 22 along the circumferential direction of the stator core 2. Therefore, the coil guiding groove portion 331b is configured to protrude slightly into the slot 22 compared with the insulating paper 24 mounted in the slot 22. However, the groove width W2 of the coil guiding groove portion 331b is greater than or equal to the width Wc of the straight portion 102 of the following strip coil 100 inserted into the slot 22 (reference Figure 25 ). Therefore, the coil guiding groove portion 331b does not prevent the straight portion 102 from being inserted into the slot 22.

[0060] In addition, the stator core fixing jig 3 of the present embodiment has 36 flanging guide members 33 corresponding to every other slot 22 of the stator core 2 at each end surface 3a. The flanging guide members 33 are configured such that when they move radially inward of 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 guide members 33, 33 is consistent with the groove width W2 of the coil guiding groove portion 331b of the guide groove 331.

[0061] As Figure 6 and Figure 7 shown, on both side surfaces on the inner end 33a side of the flanging guide member 33, there are cutout portions 333a, 333a that narrow the overall width of the flanging guide member 33 on the bottom surface 33d side along the length direction of the flanging guide member 33. The cutout portion 333a has the same fixed height H1 as the flanging portion support groove portion 331a. Thus, when all the flanging guide members 33 move radially inward and support the flanging portion 24a of the corresponding insulating paper 24 in a clamping manner (reference Figure 21) The cut portions 333a, 333a of the flanging guide members 33, 33 adjacent in the circumferential direction form a flanging portion support groove portion. Similarly to the flanging portion support groove portion 331a, the flanging portion support groove portion supports the flanging portion 24a of the insulating paper 24 of the slot 22 disposed between the flanging guide members 33, 33 in a manner of clamping from both circumferential sides of the stator core 2. Further, on the outer side surface closer to the tapered surface 33c than the cut portion 333a of the flanging guide member 33, a protruding portion 333b that protrudes more laterally than the cut portion 333a is formed. Thereby, between the protruding portions 333b, 333b of the adjacent flanging guide members 33, 33, a coil guiding groove portion similar to the coil guiding groove portion 331b is formed.

[0062] As Figure 5 shown, on both end faces 3a, 3a of the stator core fixing jig 3, a pair of inner diameter side restricting pins 34a and outer diameter side restricting pins 34b are provided corresponding to the flanging guide members 33 respectively. The long holes 332 of the flanging guide members 33 engage the pair of inner diameter side restricting pins 34a and outer diameter side restricting pins 34b on the inner side, and are mounted on both end faces 3a, 3a of the stator core fixing jig 3.

[0063] When the flanging guide member 33 moves toward the radially outer side of the stator core fixing jig 3, the inner diameter side restricting pin 34a abuts against the inner end portion 332a of the long hole 332. Thereby, as Figure 2 shown, the flanging guide member 33 is positioned at the radially outermost non-guiding position. At the non-guiding position, the inner end 33a of the flanging guide member 33 is arranged more radially outside than the stator core insertion hole 31.

[0064] When the flanging guide member 33 moves toward the radially inner side of the stator core fixing jig 3, the outer diameter side restricting pin 34b abuts against the outer end portion 332b of the long hole 332. Thereby, the flanging guide member 33 is positioned at the radially innermost guiding position. At this time, the inner end 33a of the flanging guide member 33 is arranged more radially outside than the coil winding jig 4 (refer to Figure 20 and Figure 21 ).

[0065] 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, so as Figure 5As shown, the flange guide 33 disposed on the opposite side of the insertion side of the stator core 2 can also be configured such that, in a state where the outer diameter side limit pin 34b abuts against the inner end portion 332a of the long hole 332, the inner end 33a side interferes with the annular portion 21 of the stator core 2. However, the inner diameter side limit pin 34a and the outer diameter side limit pin 34b can 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), the retracting and extending mechanism being provided inside the stator core fixing jig 3 and having an actuator such as a cylinder. Thus, when the flange guide 33 is arranged as shown in Figure 5 , the inner diameter side limit pin 34a and the outer diameter side limit pin 34b can be recessed with respect to the surface of the stator core fixing jig 3 as needed, whereby the flange guide 33 is further moved radially outward, as shown in Figure 2 , so that the flange guide 33 can be in a state of completely withdrawing from the annular portion 21 of the stator core 2.

[0066] As shown in Figure 8 , the coil winding jig 4 has: a substantially cylindrical jig body 41; a plurality of comb teeth portions 42 projecting radially on 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.

[0067] The comb teeth portions 42 and the comb tooth-shaped grooves 43 are respectively provided at both axial end portions of the jig body 41. The phases of the comb teeth portions 42 and the comb tooth-shaped grooves 43 at both end portions of the jig body 41 are aligned along the axial direction. The number of the comb tooth-shaped grooves 43 arranged in the circumferential direction of the jig body 41 is the same as the number of the slot grooves 22 provided in the stator core 2. Therefore, the coil winding jig 4 of the present embodiment has 72 comb tooth-shaped grooves 43. The coil winding jig 4 is formed such that the outer diameter of the coil winding jig 4 defined by the positions of the front ends of the comb teeth portions 42 is smaller than the inner diameter of the stator core 2 so that it can be inserted inside the annular portion 21 of the stator core 2.

[0068] On the coil winding jig 4, a strip-shaped coil 100 for mounting on the stator core 2 is wound in a circular shape. As shown in Figure 9 , 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.

[0069] The strip coil 100 has a plurality of straight portions 102 and a plurality of coil end portions 103. The straight portions 102 are the portions inserted into the slots 22 of the stator core 2, and each extends in a substantially straight line and is arranged in parallel at a fixed interval. The coil end portions 103 are respectively arranged at positions closer to the side ends of the strip coil 100 than the straight portions 102, and alternately connect one end and the other end of adjacent straight portions 102 to form a substantially triangular mountain shape. When the strip coil 100 is installed in the slot 22 of the stator core 2, the coil end portions 103 are the portions arranged to project axially from the slot 22 along the stator core 2. The strip 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.

[0070] As Figure 10 shown, before the coil winding jig 4 is inserted into the inside of the stator core 2, the strip coil 100 is multi-wound by sequentially inserting the straight portions 102 of the strip coil 100 from the outside of the comb-shaped groove 43. Thus, as Figure 11 shown, the coil winding jig 4 that winds the strip coil 100 into a circular shape is formed (coil winding step).

[0071] The distance between the comb-shaped portions 42 in the axial direction of the jig body 41 corresponds to the length of the straight portion 102 of the strip coil 100. Therefore, the straight portions 102 of the strip coil 100 wound around the coil winding jig 4 are received by the in-phase comb-shaped grooves 43, 43 at both ends of the jig body 41. The coil end portions 103 of the multi-wound strip coil 100 project cylindrically from the comb-shaped grooves 43 in the axial direction of the jig body 41. As Figure 1 , Figure 2 and Figure 3 shown, the coil winding jig 4 that winds the strip coil 100 into a circular shape in the above manner is inserted into the inside of the through hole 20 of the stator core 2 fixed by the stator core fixing jig 3 by the operation of a robot (not shown), for example. In addition, in Figure 1 , the illustration of the strip coil 100 of the coil winding jig 4 is omitted.

[0072] The coil winding jig 4 inserted into the through hole 20 inside the stator core 2 is held in a specific position and posture by the coil expanding mechanism portion 5, and the coil expanding mechanism portion 5 sandwiches the stator core fixing jig 3 and is respectively arranged on both sides of the stator core fixing jig 3. As Figure 1 shown, the coil expanding mechanism portion 5 of the present embodiment has a substantially cylindrical outer shape and faces the coil winding jig 4 inserted into the inside of the stator core 2 in the axial direction.

[0073] As Figure 1 and Figure 12 shown, in the coil expanding mechanism portion 5, on the base 11 of the fixed stator core fixture 3, a pair of support substrates 12, 12 are erected so as to face each other with the stator core fixture 3 interposed therebetween. The coil expanding mechanism portion 5 projects in the horizontal direction from the support substrate 12 toward the coil winding fixture 4 inserted into the inside of the stator core 2. The coil expanding mechanism portion 5 is configured such that, by driving a motor or the like (not shown), the support substrate 12 linearly moves on the base 11, whereby it can move in the directions of abutting against and separating from the coil winding fixture 4, respectively.

[0074] As Figure 12 and Figure 13 shown, the coil expanding mechanism portion 5 has a main shaft portion 51 at the center, and the main shaft portion 51 extends from the support substrate 12 toward the coil winding fixture 4 inserted into the inside of the stator core 2. A holding portion 52 is provided at the front end of the main shaft portion 51, and the holding portion 52 holds the coil winding fixture 4 at a specific position and posture inside the stator core 2. The holding portion 52 has: a shaft protrusion portion 522 that protrudes from the center of the circular end plate portion 521 disposed at the front end of the main shaft portion 51; and a positioning protrusion portion 523 that protrudes from the end plate portion 521 on the radially outer side of the shaft protrusion portion 522 in the same direction as the shaft protrusion portion 522. The shaft protrusion portion 522 is fitted into the shaft hole 44 of the coil winding fixture 4. The positioning protrusion portion 523 is fitted into one positioning hole 45 provided on the radially outer side of the shaft hole 44 of the coil winding fixture 4.

[0075] The positioning hole 45 of the coil winding fixture 4 and the positioning protrusion portion 523 of the holding portion 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 fixture 3 coincides with the phase of the comb-shaped groove 43 of the coil winding fixture 4 inserted into the inside of the stator core 2. Therefore, when the coil expanding mechanism portion 5 moves toward the stator core fixture 3 and the shaft hole 44 and the positioning hole 45 of the coil winding fixture 4 are fitted to the shaft protrusion portion 522 and the positioning protrusion portion 523 of the holding portion 52, as Figure 5 shown, the coil winding fixture 4 is held in a state where the phase of the comb-shaped groove 43 is matched with 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 fixture 4 communicate with each other in the radial direction.

[0076] The coil expanding mechanism portion 5 has a coil expanding portion 53 on the outer peripheral side of the main shaft portion 51. The coil expanding portion 53 has: a movable cylinder portion 531 that is fitted to the outer peripheral side of the main shaft portion 51; a plurality of movable arm portions 532 that are disposed more on the outer peripheral side than the movable cylinder portion 531; and a plurality of joint members 533 that are respectively provided at the front ends of the movable arm portions 532.

[0077] The movable cylinder portion 531 has a length shorter than that of the main shaft portion 51 and is arranged to be slidable along the axial direction of the main shaft portion 51 by the drive of an actuator 54 such as a working cylinder disposed behind the support substrate 12.

[0078] 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 along 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 along 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 respectively rotatably mounted.

[0079] The joint members 533 have 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 15 and Figure 16 shown, each of the joint members 533 has a pair of engaging tabs 533a at one circumferential end portion, and a pair of engaging grooves 533b for engaging with the pair of engaging tabs 533a at the other circumferential end portion. 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 are engaged with each other, whereby they are arranged in a circular ring shape on the outer peripheral side of the holding portion 52.

[0080] Figure 12 , Figure 13 and Figure 14 shown, the coil expansion portion 53 of the coil expansion mechanism portion 5 represents a state where the movable cylinder portion 531 retracts 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 15 and Figure 16As shown, the coil expansion part 53 is reduced in diameter to the maximum extent so that the twelve joint members 533 are in close contact with each other. The outer diameter of the coil expansion part 53 when it is reduced in diameter to the maximum extent is slightly smaller than the inner diameter of the coil end 103 that protrudes cylindrically along the axial direction from the coil winding jig 4 for winding the strip coil 100. With the coil expansion part 53 in the state of being reduced in diameter, the coil expansion mechanism part 5 is inserted into the coil end 103 that protrudes cylindrically along the axial direction of the coil winding jig 4, and the coil winding jig 4 is held by the holding part 52.

[0081] Next, if the actuator 54 is driven, the movable cylinder part 531 advances along the main shaft part 51 toward the coil winding jig 4, and the link parts 534 connected to the movable cylinder part 531 rotate so as to protrude radially outward of the movable cylinder part 531, thereby causing the movable arm parts 532 to move parallel to the outside along the guide rails respectively. As a result, the twelve movable arm parts 532 are separated from the movable cylinder part 531 toward the radially outer side. At this time, as Figure 17 , Figure 18 and Figure 19 shown, the coil expansion part 53 expands in diameter by moving the joint members 533 in such a way as to increase the distance between adjacent joint members 533. The outer diameter of the coil expansion part 53 after expanding in diameter to the maximum extent is slightly larger than the outer diameter of the coil winding jig 4.

[0082] In addition, as Figure 18 and Figure 19 shown, when the coil expansion part 53 expands in diameter to the maximum extent, adjacent joint members 533, 533 are separated from each other, but between the joint members 533, 533, a pair of engaging tabs 533a away from the engaging groove 533b protrude along the circumferential direction. Therefore, when observing the coil expansion part 53 along the circumferential direction, adjacent joint members 533, 533 are connected by a pair of engaging tabs 533a, and no groove part that penetrates the coil expansion part 53 along the radial direction is formed.

[0083] 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 by the stator core fixing jig 3 in the coil mounting device 1 will be described.

[0084] In the coil winding jig 4, before being inserted into the inside of the stator core 2, as described above, in the coil winding step, 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 by the stator core fixing jig 3, as Figure 20 shown, the flanging guide 33 moves toward the radially inner side under the drive of an actuator (not shown).

[0085] If the flanging guide 33 moves toward the radially inner side, then as Figure 21As shown, the guide groove 331 of the flanging guide member 33 supports the flanged portion 24a of the insulating paper 24 in the corresponding slot 22 in a manner that clamps it from both circumferential sides. Specifically, as Figure 22 shown, the flanged portion support groove portion 331a of the guide groove 331 supports the flanged portion 24a by clamping a pair of radial portions 241, 241 of the flanged portion 24a. At an axially outer side of the stator core 2 compared to the flanged portion 24a ( Figure 22 above the paper surface in the figure), the coil guiding groove portion 331b of the guide groove 331 is arranged to cover the flanged portion 24a.

[0086] At this time, the flanged portion support groove portion formed by the cutout portion 333a of the flanging guide member 33 between the circumferentially adjacent flanging guide members 33, 33 is also used to support the flanged portion 24a of the insulating paper 24 in the slot 22 between the flanging guide members 33, 33 in a manner that clamps it from both circumferential sides. In addition, the protruding portions 333b, 333b of the flanging guide members 33, 33 are arranged to cover the flanged portion 24a. In this way, the flanged portions 24a of all the insulating papers 24 in the slot 22 are supported by the flanged portion support groove portion 331a and the cutout portion 333a of the flanging guide member 33, and thus all the insulating papers 24 are positioned at specific positions in the slot 22.

[0087] In addition, in Figure 20 the figure, the coil expanding mechanism portion 5 of the coil winding jig 4 is not shown, but after the stator core 2 is fixed to the stator core fixing jig 3, at an appropriate timing before the strip coil 100 is inserted into the slot 22 of the stator core 2 by the operation of the following coil expanding portion 53, the flanging guide member 33 performs the supporting operation on the flanged portion 24a.

[0088] By moving the coil expanding mechanism portion 5 in a state where the coil expanding portion 53 is reduced in diameter toward the coil winding jig 4 respectively, the holding portion 52 of the coil expanding mechanism portion 5 is used to hold the coil winding jig 4 inserted inside the stator core 2 (coil winding jig holding step).

[0089] In addition, after the flanged portion 24a of the insulating paper 24 in the slot 22 is positioned by the flanged portion support groove portion 331a of the guide groove 331 of the flanging guide member 33, as Figure 23 and Figure 24As shown, the coil expansion parts 53 of the coil expansion mechanism part 5 expand in diameter respectively under the drive of the actuator 54. Thereby, the coil expansion parts 53 push against the coil ends 103 of the strip coil 100 wound around the coil winding jig 4 in such a way that they expand from the inside to the outside of the strip coil 100. The strip coil 100 gradually expands after being pushed by the coil expansion parts 53. Along with this, the straight part 102 is guided to the comb-shaped groove 43 while moving toward the slot 22 of the stator core 2 communicating with the comb-shaped groove 43. Thereby, the straight part 102 of the strip coil 100 is inserted into the slot 22 from the opening 22a of the slot 22 without interfering with the slot 22 of the stator core 2 (coil expansion step).

[0090] Here, as Figure 25 shown, the comb-shaped groove 43 of the coil winding jig 4 has a width narrowing part 43a on the outer diameter side. The groove width W3 of the width narrowing part 43a in the circumferential direction of the coil winding jig 4 is narrower than the groove width W2 of the coil guiding groove part 331b of the guiding groove 331 of the flanging guide 33. However, the groove width W3 of this width narrowing part 43a is substantially equal to the width Wc of the straight part 102 of the strip coil 100. Thereby, when the straight part 102 in the comb-shaped groove 43 moving toward the slot 22 passes through the width narrowing part 43a, the position of the straight part 102 is corrected in such a way that it is along the slot center line 22b passing through the center of the opening 22a of the slot 22 when about to be inserted into the slot 22. Therefore, the straight part 102 in the comb-shaped groove 43 smoothly inserts into the inside of the insulating paper 24 through the opening 22a of the slot 22.

[0091] As Figure 26 shown, the straight part 102 passing through the opening 22a of the slot 22 abuts against the coil guiding groove part 331b and the protruding part 333b of the guiding groove 331 of the flanging guide 33 while moving in the slot 22, and is guided along the coil guiding groove part 331b and the protruding part 333b. Since the width of the coil guiding groove part 331b is narrower than that of the flanging part supporting groove part 331a, the flanging part 24a supported by the flanging part supporting groove part 331a does not contact the straight part 102. Therefore, it is possible to prevent the flanging part 24a of the insulating paper 24 from being caught between the straight part 102 inserted into the slot 22 and the slot 22.

[0092] As Figure 26 shown, the coil end 103 of the strip coil 100 with the straight part 102 inserted into the slot 22 bends and extends outward from between the guiding groove 331 of the flanging guide 33 and the adjacent flanging guides 33, 33, and abuts against the corner part 331c between the coil guiding groove part 331b of the guiding groove 331 and the conical surface 33c and the corner part 333c between the protruding part 333b and the conical surface 33c( Figure 6At the P1 position in). As the straight portion 102 is inserted deeper into the slot 22, the strip coil 100 gradually expands in diameter, and the interval between the circumferentially adjacent straight portions 102, 102 expands from each other. Therefore, the strip coil 100 deforms in such a manner that the angle θ of the inner side formed by the coil end portion 103 and the straight portion 102 gradually increases. At this time, a stress that bends in the circumferential direction of the stator core 2 acts on the straight portion 102 in the slot 22. If the straight portion 102 bends in the slot 22, it may come into contact with the radial portion 241 of the insulating paper 24 in the slot 22 and damage the insulating paper 24. However, since the corner portions 331c, 333c of the flanging guide member 33 of the present embodiment are formed along the tapered surface 33c, as the straight portion 102 is inserted deeper into the slot 22, the coil end portions 103, 103 at both ends of the straight portion 102 are as Figure 27 shown by the arrows in, with the corner portions 331c, 333c as fulcrums, a tension F( Figure 27 in the up-and-down direction of the axial direction of the stator core 2) is applied to the straight portion 102. Figure 6 At the P2 position in). As a result, the straight portion 102 in the slot 22 extends straight, and it is possible to suppress damage to the insulating paper 24 due to bending when the straight portion 102 moves in the slot 22.

[0093] The corner portions 331c, 333c of the coil guiding groove portion 331b of the guiding groove 331 are each formed in an R shape with a curvature. Therefore, even if the coil end portion 103 comes into contact with the corner portion 331c, it is possible to suppress damage to the protective coating film formed on the surface of the strip coil 100. The coil guiding groove portion 331b and the protruding portion 333b may also be integrally formed in an arc shape with a curvature.

[0094] If the coil expansion portions 53 of the two coil expansion mechanism portions 5 expand in diameter to the maximum extent, as Figure 28 shown, the straight portions 102 of the strip coil 100 of the coil winding jig 4 are respectively completely inserted into the slots 22 of the stator core 2, so that the strip coil 100 is installed in the slots 22 of the stator core 2. The coil expansion portions 53 of the two coil expansion mechanism portions 5 may act in a manner of expanding in diameter simultaneously, or may act in a manner of expanding in diameter sequentially with a set time difference, to insert the straight portion 102 into the opening portion 22a of the slot 22 obliquely with respect to the radial direction.

[0095] After that, the flanging guide member 33 moves radially outward, completely exits from the end face 2a of the stator core 2, and the coil expansion portions 53 contract in diameter respectively, so that the coil expansion mechanism portions 5 leave the coil winding jig 4 respectively. As a result, as Figure 29 shown, the stator 200 in which the strip coil 100 is installed in the slot 22 of the stator core 2 is obtained.

[0096] As described above, in the coil mounting device 1 of the present embodiment, the straight portion 102 of the strip coil 100 wound in an annular shape is inserted into the slot 22 having the insulating paper 24 from the inside of the stator core 2, and the strip coil 100 is mounted along the circumferential direction of the stator core 2. The insulating paper 24 has a flange portion 24a extending from the axial end face 2a of the stator core 2. The coil mounting device 1 includes: a stator core fixing jig 3 that fixes the stator core 2 in a specific position and posture; a coil winding jig 4 that is disposed inside the stator core 2 fixed by the stator core fixing jig 3, and winds the strip coil 100 into an annular shape by inserting the straight portion 102 of the strip coil 100 into the comb-shaped grooves 43 arranged radially along the outer circumference; and a flange guide 33 that is provided on the stator core fixing jig 3 and has a guide groove 311 that supports the flange portion 24a. The guide groove 331 has: a flange portion support groove portion 331a that supports the flange portion 24a in a manner of clamping from the circumferential direction of the stator core 2; and a coil guide groove portion 311b that has a groove width W2 narrower than the groove width W1 of the flange portion support groove portion 331a on a side farther from the end face 2a of the stator core 2 than the flange portion support groove portion 331a. Thus, the flange portion 24a of the insulating paper 24 in the slot 22 is supported in a manner of clamping from the circumferential direction of the stator core 2 by the flange portion support groove portion 331a of the guide groove 331 of the flange guide 33. Therefore, the flange portion 24a is positioned relative to the slot 22, and the straight portion 102 is guided into the slot 22 by abutting against the coil guide groove portion 331b of the guide groove 331 without catching the flange portion 24a. Therefore, a coil mounting device 1 can be provided in which, when the straight portion 102 of the strip coil 100 wound in an annular shape is inserted into the slot 22 from the inside of the stator core 2, the straight portion 102 does not catch the insulating paper 24 in the slot 22.

[0097] The comb-shaped groove 43 of the coil winding jig 4 of the present embodiment has a width narrowing portion 43a on the outer diameter side having a groove width W3 narrower than the groove width W2 of the coil guide groove portion 311b of the guide groove 311. Thus, when the straight portion in the comb-shaped groove of the coil winding jig is about to be inserted into the slot of the stator core, the position of the straight portion is corrected by the width narrowing portion. Therefore, the straight portion in the comb-shaped groove can be smoothly inserted inside the insulating paper in the slot.

[0098] The coil mounting method of this embodiment mounts the strip-shaped coil 100 wound in a circular ring shape along the circumferential direction of the stator core 2 by inserting the straight portion 102 of the strip-shaped coil 100 wound in a circular ring shape into the slot 22 having the insulating paper 24 from the inside of the stator core 2. The insulating paper 24 has a flange portion 24a extending from the axial end face 2a of the stator core 2, and the flange portion 24a is supported by using the flange portion support groove portion 331a of the flange guide member 33. The flange guide member 33 has a guide groove 331, and the guide groove 331 has: a flange portion support groove portion 331a that supports the flange portion 24a in a manner of clamping it from the circumferential direction of the stator core 2; and a coil guide groove portion 331b that has a groove width W2 narrower than the groove width W1 of the flange portion support groove portion 331a on a side farther from the end face 2a of the stator core 2 than the flange portion support groove portion 331a. In a state where the flange portion 24a is supported by the flange portion support groove portion 331a, the circular strip-shaped coil 100 is expanded in diameter, the straight portion 102 is inserted into the slot 22, and the straight portion 102 is guided to move by using the coil guide groove portion 331b. Thus, the flange portion support groove portion 331a of the guide groove 331 of the flange guide member 33 supports the flange portion 24a of the insulating paper 24 in the slot 22 in a manner of clamping it from the circumferential direction of the stator core 2. Therefore, the flange portion 24a can be positioned relative to the slot 22, and by bringing the straight portion 102 into contact with the coil guide groove portion 331b of the guide groove 331, the straight portion 102 can be guided into the slot 22 without catching the flange portion 24a. Therefore, a coil mounting method can be provided in which when the straight portion 102 of the strip-shaped coil 100 wound in a circular ring shape is inserted into the slot 22 from the inside of the stator core 2, the straight portion 102 does not catch the insulating paper 24 in the slot 22.

[0099] The coil mounting device 1 of the embodiment described above is configured to arrange the axial directions of the stator core 2 and the coil winding jig 4 in the horizontal direction, but it can also be configured to arrange the axial directions of the stator core 2 and the coil winding jig 4 in a direction other than the horizontal direction, such as the vertical direction.

[0100] The coil winding jig 4 that winds the strip-shaped coil 100 into a circular ring shape can also be inserted into the inside of the stator core 2 fixed by the stator core fixing jig 3 while being mounted and held in the holding portion 52 of any one of the coil expansion mechanism portions 5.

[0101] Flange guide members 33 corresponding to the number of slots 22 of the stator core 2 can be provided on both end faces 3a, 3a of the stator core fixing jig 3, respectively.

[0102] Reference numerals

[0103] 1: Coil mounting device

[0104] 2: Stator core

[0105] 2a: End face

[0106] 22: Slot

[0107] 24: Insulating paper

[0108] 24a: Flanging part

[0109] 3: Stator core fixing jig

[0110] 33: Flanging guide

[0111] 331: Guide groove

[0112] 331a: Flanging part support groove part

[0113] 331b: Coil guiding groove part

[0114] 4: Coil winding jig

[0115] 43: Comb-shaped groove

[0116] 43a: Width narrowing part

[0117] 100: Strip coil

[0118] 102: Straight part

Claims

1. A coil mounting device, which mounts a strip-shaped coil wound into a circular ring by inserting a straight portion of the strip-shaped coil into a slot having an insulating paper from the inner side of a stator core, and mounts the strip-shaped coil along the circumferential direction of the stator core. The insulating paper has a flanging portion extending from an axial end face of the stator core, and the coil mounting device includes: A stator core fixing jig that fixes the stator core in a certain position and posture; A coil winding jig disposed inside the stator core fixed by the stator core fixing jig, which winds the strip-shaped coil into a circular ring by inserting the straight portion of the strip-shaped coil into comb-shaped grooves radially arranged along the outer circumference; and A flanging guide provided on the stator core fixing jig and having a guide groove for supporting the flanging portion; and The guide groove has: a flanging portion supporting groove portion that supports the flanging portion in a manner of clamping from the circumferential direction of the stator core; and a coil guiding groove portion that has a groove width narrower than that of the flanging portion supporting groove portion on a side farther from the axial end face of the stator core than the flanging portion supporting groove portion.

2. The coil mounting device according to claim 1, wherein, The comb-shaped grooves of the coil winding jig have a width narrowing portion on the outer diameter side with a groove width narrower than that of the coil guiding groove portion of the guide groove.

3. A coil mounting method, which mounts a strip-shaped coil wound into a circular ring by inserting a straight portion of the strip-shaped coil into a slot having an insulating paper from the inner side of a stator core, and mounts the strip-shaped coil along the circumferential direction of the stator core. The insulating paper has a flanging portion extending from an axial end face of the stator core. The flanging portion is supported by using the flanging portion supporting groove portion of a flanging guide, and the flanging guide has a guide groove that has: a flanging portion supporting groove portion that supports the flanging portion in a manner of clamping from the circumferential direction of the stator core; and a coil guiding groove portion that has a groove width narrower than that of the flanging portion supporting groove portion on a side farther from the axial end face of the stator core than the flanging portion supporting groove portion. In a state where the flanging portion is supported by the flanging portion supporting groove portion, the circular strip-shaped coil is expanded in diameter, the straight portion is inserted into the slot, and the straight portion is guided to move by using the coil guiding groove portion.

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