Coil forming device and method for manufacturing a stator

Abstract

A coil forming device is a coil forming device that forms at least a part of a coil inserted into a plurality of axially penetrating slots of a stator core, and includes: a first diameter expanding member that is disposed on one axial side of the stator core and moves in the radial direction; a second diameter expanding member that is disposed on the other axial side of the stator core and moves in the radial direction; and a moving mechanism that moves the first diameter expanding member and the second diameter expanding member outward in the radial direction, and the first diameter expanding member and the second diameter expanding member are different members.

Description

Technical Field

[0001] The present invention relates to a coil forming device and a method for manufacturing a stator. Background Art

[0002] Conventionally, a coil forming device for forming a coil bundle inserted into slots of a stator core has been known. For example, in Patent Document 1, a coil forming device capable of completely performing two processes of intermediate forming and expansion forming with one device is disclosed. In the coil forming device of Patent Document 1, intermediate forming of the coil is performed by a pushing-out operation of a blade member toward the radially outer side, and expansion forming of the coil is performed by a pushing-out operation of a first expansion member and a second expansion member toward the radially outer side.

[0003] Prior Art Documents

[0004] Patent Documents

[0005] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2005-110341

[0006] However, in the coil forming device of the above Patent Document 1, in order to perform intermediate forming, it is necessary to operate the blade member, and in order to perform expansion forming, it is necessary to operate the first expansion member and the second expansion member. Thus, since intermediate forming and expansion forming are performed by different members, the productivity is poor. Summary of the Invention

[0007] In view of the above problems, the present invention provides a coil forming device and a method for manufacturing a stator that improve productivity.

[0008] A coil forming device according to a first aspect of the present invention is a coil forming device that forms at least a part of a coil inserted into a plurality of axially penetrating slots of a stator core, and includes: a first diameter-expanding member that is disposed on one axial side of the stator core and moves in the radial direction; a second diameter-expanding member that is disposed on the other axial side of the stator core and moves in the radial direction; and a moving mechanism that moves the first diameter-expanding member and the second diameter-expanding member toward the radially outer side, and the first diameter-expanding member and the second diameter-expanding member are different members.

[0009] The manufacturing method of the stator according to the second aspect of the present invention is a manufacturing method of a stator having coils inserted into a plurality of axially penetrating slots of a stator core, including: a step of forming a coil, the coil including two coil side portions received in the slots and coil end portions connecting the two coil side portions and disposed on both axial sides of the stator core; a step of inserting the coil into the slots; a first moving step of moving the coil end portion located on one axial side of the stator core radially outward by using a first diameter-expanding member disposed radially inside the coil end portion on one axial side of the stator core and moving radially; and a second moving step of moving the coil end portion located on the other axial side of the stator core radially outward by using a second diameter-expanding member disposed radially inside the coil end portion on the other axial side of the stator core, moving radially, and different from the first diameter-expanding member, and the first moving step and the second moving step are performed at the same time.

[0010] (Advantageous effects of the invention)

[0011] The present invention can provide a coil forming device that improves productivity. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic view of a cross section perpendicular to the axis of the stator according to Embodiment 1.

[0013] Figure 2 It is a schematic view when observing a part of the coil forming device according to Embodiment 1 in cross section.

[0014] Figure 3 It is a schematic view of a cross section of the coil forming device on one axial side or the other side according to Embodiment 1.

[0015] Figure 4 It is a schematic view of a cross section of the coil forming device on one axial side or the other side according to Embodiment 1.

[0016] Figure 5 It is a flowchart showing the manufacturing method of the stator according to Embodiment 1.

[0017] Figure 6 It is a schematic view of the first diameter-expanding member or the second diameter-expanding member in a modification of Embodiment 1.

[0018] Figure 7 It is a schematic view of the first diameter-expanding member or the second diameter-expanding member in a modification of Embodiment 1.

[0019] Figure 8 It is a schematic view of the first diameter-expanding member or the second diameter-expanding member in a modification of Embodiment 1.

[0020] Figure 9 It is a schematic view when observing a part of the coil forming device according to Embodiment 2 in cross section.

[0021] Figure 10 is a perspective view of the stator in Embodiment 2.

[0022] Figure 11 is a schematic view of the first diameter-expanding member or the second diameter-expanding member in Embodiment 2.

[0023] Figure 12 is a schematic view of the first diameter-expanding member or the second diameter-expanding member in Embodiment 2.

[0024] Figure 13 is a schematic view of the first diameter-expanding member or the second diameter-expanding member in Embodiment 2. Detailed Embodiment

[0025] Hereinafter, exemplary embodiments of the present invention will be described based on the drawings. In addition, in the following drawings, the same or equivalent parts are denoted by the same reference numerals, and their descriptions are not repeated.

[0026] In addition, in the following description, the direction in which the central axis of the stator 1 extends, that is, the through direction of the slot 21, is defined as the "axial direction". One side along the axial direction is defined as the lower (rear) side, and the other side is defined as the upper (front) side. The up-down (front-rear) direction is used to determine the positional relationship and does not limit the actual direction. That is, the downward direction does not necessarily mean the direction of gravity. The axial direction is not particularly limited and includes the vertical direction, the horizontal direction, the direction intersecting these directions, etc.

[0027] In addition, the direction orthogonal to the central axis of the stator 1 is defined as the "radial direction". And, the direction along the arc centered on the central axis of the stator 1 is defined as the "circumferential direction".

[0028] In addition, in the drawings used in the following description, in order to emphasize the characteristic parts, sometimes the parts that become the characteristics are enlarged and shown for convenience. Therefore, the dimensions and ratios of the respective components are not necessarily the same as the actual ones. For the same purpose, sometimes the parts that do not have characteristics are omitted from the drawings.

[0029] [First Embodiment]

[0030] (Stator)

[0031] As Figure 1 shown, the stator 1 is a component of the motor and interacts with a rotor (not shown) to generate a rotational torque. The stator 1 of the present embodiment is a distributed winding in which the coil 10 is wound across several slots 21. The stator 1 has a coil 10 and a stator core 20.

[0032] [Stator Core]

[0033] The stator core 20 is formed in a hollow cylindrical shape. The stator core 20 is formed by stacking thin silicon steel plates. A plurality of pole teeth 23 are radially formed on the stator core 20. Slots 21 are formed between the pole teeth 23. The pole teeth 23 extend radially across the slots 21. The slots 21 are formed with slot openings 22 as radial openings. The stator core 20 of the present embodiment is an integrated stator core.

[0034] <Coil>

[0035] The coil 10 is formed by winding a coil wire in a ring shape. The coil wire in the present embodiment is a round wire, but is not particularly limited and may be a rectangular wire or the like.

[0036] like Figure 2 As shown in FIG. 1 , the coil 10 has two coil sides 11 and a coil end 12. The two coil sides 11 are received in the slots 21. Specifically, the slots 21 for receiving one coil side 11 are different from the slots 21 for receiving the other coil side 11. The slots 21 for receiving one coil side 11 and the slots 21 for receiving the other coil side 11 may be as follows: Figure 1 As shown, they are arranged in the circumferential direction with other grooves interposed therebetween, or they may be adjacent to each other (not shown).

[0037] The coil end 12 connects the two coil sides 11. In addition, the coil end 12 is arranged on both axial sides of the stator core 20. Specifically, the coil end 12 located on one axial side connects one end of the two coil sides 11. The coil end 12 located on the other axial side connects the other end of the coil side 11.

[0038] (Coil forming device)

[0039] Reference Figures 1 to 4 The coil forming device 2 of this embodiment will be described. Figure 3 and Figure 4 Show Figure 2 One of the first device 100 and the second device 200.

[0040] The coil forming device 2 forms at least a portion of the coil 10 inserted into a plurality of slots 21 penetrating the stator core 20 in the axial direction. Specifically, the coil forming device 2 forms the coil ends 12 on one and the other axial sides so as to expand in diameter radially outward.

[0041] The coil forming device includes a first device 100 and a second device 200. The first device 100 is arranged on one axial side of the stator core 20. The second device 200 is arranged on the other axial side of the stator core 20. The first device 100 and the second device 200 are different components. In addition, the first device 100 and the second device 200 are arranged separately.

[0042] As shown Figures 2 to 4 in FIG. 1, the coil forming device 2 includes a first diameter-expanding member 110, a second diameter-expanding member 210, and moving mechanisms 120 and 220. In the present embodiment, the first device 100 has the first diameter-expanding member 110 and the moving mechanism 120. The second device 200 has the second diameter-expanding member 210 and the moving mechanism 220. The first diameter-expanding member 110 and the moving mechanism 120 are arranged on the frame of the first device 100. The second diameter-expanding member 210 and the moving mechanism 220 are arranged on the frame of the second device 200.

[0043] The first diameter-expanding member 110 is arranged on one axial side of the stator core 20 and moves in the radial direction. The first diameter-expanding member 110 is arranged radially inside the coil end 12. Here, the first diameter-expanding member 110 is arranged radially inside the coil end 12 that protrudes axially from one axial end face of the stator core 20. The first diameter-expanding member 110 moves the coil end 12 radially outward.

[0044] The second diameter-expanding member 210 is arranged on the other axial side of the stator core 20 and moves in the radial direction. The second diameter-expanding member 210 is arranged radially inside the coil end 12. Here, the second diameter-expanding member 210 is arranged radially inside the coil end 12 that protrudes axially from the other axial end face of the stator core 20. The second diameter-expanding member 210 moves the coil end 12 radially outward.

[0045] The first diameter-expanding member 110 and the second diameter-expanding member 210 are different members. Therefore, the first diameter-expanding member 110 and the second diameter-expanding member 210 arranged on one axial side and the other axial side of the stator core 20 can move the coil ends 12 on one axial side and the other axial side of the stator core 20 radially outward, respectively. Therefore, it is possible to perform intermediate forming of moving the coil end 12 radially outward and expansion forming of plastically deforming it without generating a restoring force (springback) of the coil end 12 by the first diameter-expanding member 110 and the second diameter-expanding member 210. Therefore, the productivity can be improved.

[0046] The radially outer shape of the first diameter-expanding member 110 is the same as the radially outer shape of the second diameter-expanding member 210. By making the shapes the same, the axial offset of the coil 10 can be suppressed. In the present embodiment, the shape of the first diameter-expanding member 110 is the same as the shape of the second diameter-expanding member 210. In Figure 2In [the figure], the first diameter-expanding member 110 and the second diameter-expanding member 210 have shapes that are symmetric with respect to the radial line passing through the axial center of the stator core 20. Additionally, it is not limited to the radial outer shapes of the first diameter-expanding member 110 and the second diameter-expanding member 210 being the same; they may also have the same radial width. Additionally, the radial outer shapes of the first parts 113 and 213 and the radial outer shapes of the second parts 114 and 214 in the second embodiment described later may also be the same.

[0047] As Figure 3 and Figure 4 shown, the radial inner surfaces 111 and 211 of the first diameter-expanding member 110 and the second diameter-expanding member 210 incline radially inward as they approach the stator core 20. That is, the radial inner surfaces 111 and 211 have a conical shape. The radial inner surfaces 111 and 211 are in contact with the moving mechanisms 120 and 220.

[0048] Figure 3 and Figure 4 shown, the moving mechanisms 120 and 220 move the first diameter-expanding member 110 and the second diameter-expanding member 210 radially outward. By means of the moving mechanisms 120 and 220, the first diameter-expanding member 110 and the second diameter-expanding member 210 move radially outward, thereby enabling the coil ends 12 to move radially outward.

[0049] The moving mechanism 120 of this embodiment is arranged on one axial side of the first diameter-expanding member 110 and radially inside the first diameter-expanding member 110. The moving mechanism 220 is arranged on the other axial side of the second diameter-expanding member 210 and radially inside the second diameter-expanding member 210.

[0050] The moving mechanisms 120 and 220 have a shape that narrows in width as they approach the stator core 20. That is, the side surfaces 121 and 221 of the moving mechanisms 120 and 220 have a conical shape that inclines in the opposite direction to the radial inner surfaces 111 of the first diameter-expanding member 110 and the radial inner surfaces 211 of the second diameter-expanding member 210.

[0051] The moving mechanisms 120 and 220 move axially. Specifically, when the moving mechanism 120 moves from one axial side to the other, the side surface 121 of the moving mechanism 120 slides on the radial inner surface 111 of the first diameter-expanding member 110, thus causing the first diameter-expanding member 110 to move radially outward. When the moving mechanism 220 moves from the other axial side to one side, the side surface 221 of the moving mechanism 220 slides on the radial inner surface 211 of the second diameter-expanding member 210, thus causing the second diameter-expanding member 210 to move radially outward.

[0052] In addition, the moving mechanisms 120 and 220 of the present embodiment are different components respectively disposed on the first device 100 and the second device 200, but are not limited thereto. The moving mechanism may also be a single component that moves the first diameter-expanding member 110 and the second diameter-expanding member 210 simultaneously.

[0053] The coil forming device 2 further includes a control unit that controls the first diameter-expanding member 110 to move radially outward and the second diameter-expanding member 210 to move radially outward simultaneously. The control unit controls such that the timing of the first diameter-expanding member 110 moving radially outward coincides with the timing of the second diameter-expanding member 210 moving radially outward. By moving the first diameter-expanding member 110 radially outward and the second diameter-expanding member 210 radially outward simultaneously, when the coil end 12 moves radially outward, the movement of the coil side 11 in the axial direction can be suppressed, and thus the load applied to the coil end 12 can be reduced.

[0054] The coil forming device 2 of the present embodiment can perform an intermediate forming process of moving the coil end 12 radially outward and a diameter-expanding forming process of plastically deforming the coil end 12 after the intermediate forming process. That is, the first diameter-expanding member 110 and the second diameter-expanding member 210 perform plastic deformation while moving the coil end 12 radially outward.

[0055] (Method for manufacturing a stator)

[0056] Next, refer to Figures 1 to 5 A method for manufacturing the stator 1 will be described. The method for manufacturing the stator 1 of the present embodiment is a method for manufacturing the stator 1 having the coil 10 using the above-described coil forming device 2, and the coil 10 is inserted into a plurality of axially penetrating slots 21 of the stator core 20.

[0057] First, as Figure 5 shown, a coil 10 is formed (step S1), and the coil 10 includes two coil sides 11 accommodated in the slots 21 and coil ends 12 that connect the two coil sides 11 and are disposed on both axial sides of the stator core 20. The coil 10 formed in this process (S1) is annular.

[0058] Next, the coil 10 is inserted into the slots 21 (step S2). In this process (S2), for example, a coil insertion device having blades and a peeling member is used. When the insertion process (S2) is performed, the coil sides 11 are accommodated in the slots 21, and the coil ends 12 protrude from the end faces of the stator core 20.

[0059] Next, the coil forming device 2 is set (step S3). In this process (S3), the first device 100 is arranged on one axial side of the stator core 20, and the second device 200 is arranged on the other axial side of the stator core 20.

[0060] Next, the first moving process (S4) is performed. The coil end 12 located on one axial side of the stator core 20 is moved radially outward by the first diameter-expanding member 110 that is arranged on the radial inner side of the coil end 12 on one axial side of the stator core 20 and moves radially. In this process (S4), by moving the moving mechanism 120 from one axial side to the other side, the moving mechanism 120 moves the first diameter-expanding member 110 from the radial inner side to the outer side to become Figures 3 to 4 the state shown. By the first diameter-expanding member 110 moving radially outward, the coil end 12 moves radially outward. By performing this first moving process (S4), intermediate forming that moves the coil end 12 radially outward can be performed.

[0061] In addition, the second moving process (S5) is performed. The coil end 12 located on the other axial side of the stator core 20 is moved radially outward by the second diameter-expanding member 210 that is arranged on the radial inner side of the coil end 12 on the other axial side of the stator core 20, moves radially, and is different from the first diameter-expanding member 110. In this process (S5), by moving the moving mechanism 220 from the other axial side to one side, the moving mechanism 220 moves the second diameter-expanding member 210 from the radial inner side to the outer side to become Figures 3 to 4 the state shown. By the second diameter-expanding member 210 moving radially outward, the coil end 12 moves radially outward. By performing this second moving process (S5), intermediate forming that moves the coil end 12 radially outward can be performed.

[0062] The first moving process (S4) and the second moving process (S5) are performed at the same time. In the present embodiment, the control unit controls so that the movement of the first diameter-expanding member 110 radially outward and the movement of the second diameter-expanding member 210 radially outward are performed simultaneously.

[0063] In addition, by performing the first moving process (S4) and the second moving process (S5) at the same time, the intermediate forming process and the expansion forming process are performed at the same time.

[0064] By performing the above processes (S1 to S5), it is possible to manufacture Figure 1The stator 1 shown. In the present embodiment, in the intermediate forming process, the first diameter-expanding member 110 and the second diameter-expanding member 210, which are different components, are used. Therefore, the intermediate forming process and the expanding forming process can be implemented using the first diameter-expanding member 110 and the second diameter-expanding member 210, and thus the productivity can be improved.

[0065] In addition, by performing the first moving process (S4) and the second moving process (S5) at the same time, the load caused by the sliding between the coil end 12 and the axial end faces of the stator 1 can be reduced. Therefore, by using the coil forming device 2 of the present embodiment, the stator 1 having the coil 10 with a high duty factor can be manufactured.

[0066] [Modification Example]

[0067] In the above embodiment, as Figure 3 and Figure 4 shown, the first diameter-expanding member 110 and the second diameter-expanding member 210 are in a conical shape that widens as they approach the stator core 20, and the moving mechanisms 120, 220 are in a conical shape that narrows as they approach the stator core 20, but it is not limited thereto. For example, the first diameter-expanding member 110 and the second diameter-expanding member 210 may be in a conical shape that narrows as they approach the stator core 20, and the moving mechanisms 120, 220 may be in a conical shape that widens as they approach the stator core 20.

[0068] In addition, the radially inner side surfaces 111, 211 of the first diameter-expanding member 110 and the second diameter-expanding member 210 are in a conical shape, and the side surfaces 121, 221 of the moving mechanisms 120, 220 are also in a conical shape, but the moving mechanism only needs to move the first diameter-expanding member 110 and the second diameter-expanding member 210 radially outward, and it is not limited thereto. In this modification example, the side surfaces 121, 221 of the moving mechanisms 120, 220 extend in the axial direction. In this case, for example, as Figure 6 shown, the radially inner side surfaces 111, 211 of the first diameter-expanding member 110 and the second diameter-expanding member 210 extend without inclination in the axial direction.

[0069] In addition, in the above embodiment, as Figure 2 and Figure 3 shown, the radially outer side surfaces 112, 212 of the first diameter-expanding member 110 and the second diameter-expanding member 210 extend without inclination in the axial direction. In this modification, as Figure 7 and Figure 8As shown, the radially outer surfaces 112 and 212 of the first diameter-expanding member 110 and the second diameter-expanding member 210 are inclined radially inward as they approach the stator core 20. In other words, in the first diameter-expanding member 110 and the second diameter-expanding member 210, at least a part that contacts the coil end 12 is inclined radially inward as it approaches the stator core 20.

[0070] Furthermore, in other words, in the first diameter-expanding member 110 and the second diameter-expanding member 210, at least a part of the portion that axially overlaps with the stator core 20 is inclined radially inward as it approaches the stator core 20. In this case, the tapered portions of the first diameter-expanding member 110 and the second diameter-expanding member 210 can be brought into contact with the coil end 12. Therefore, a large load can be suppressed from being generated at the coil end 12.

[0071] Preferably, the radially outer surfaces 112 and 212 of the first diameter-expanding member 110 and the second diameter-expanding member 210 are inclined to Figure 1 the radially outer edge 21a of the slot 21 of the stator core 20 shown.

[0072] In addition, in Figure 8 the entirety of the first diameter-expanding member 110 and the second diameter-expanding member 210 that contacts the coil end 12 is inclined radially inward as it approaches the stator core 20.

[0073] [Second Embodiment]

[0074] Refer to Figures 9 to 13 to describe the coil forming device 3 of the second embodiment. The coil forming device 3 of the second embodiment is basically the same as the coil forming devices 2 of the first embodiment and the modified example, except that the first diameter-expanding member 110 and the second diameter-expanding member 210 include a first portion 113, 213 and a second portion 114, 214.

[0075] As Figure 9 shown, the first portions 113, 213 have portions that contact the coil 10 at positions radially inward of the second portions 114, 214. The second portions 114, 214 have portions that contact the coil 10 at positions radially outward of the first portions 113, 213. By the first portions 113, 213, the root of the coil end 12 that is relatively close to the stator core 20 can be moved radially outward. Therefore, the root of the coil end 12 can be pressed by the first portions 113, 213, and the front end portion of the coil end 12 that is relatively far from the stator core 20 can be moved radially outward by the second portions 114, 214. Therefore, when the coil end 12 moves radially outward, axial movement of the coil side 11 can be suppressed, and thus the load on the coil end 12 can be reduced.

[0076] The first parts 113 and 213 are relatively close to the stator core 20 axially. The second parts 114 and 214 are relatively far from the stator core 20 axially.

[0077] In the first diameter-expanding member 110, the first part 113 and the second part 114 are different members. In the second diameter-expanding member 210, the first part 213 and the second part 214 are different members.

[0078] The first parts 113 and 213 and the second parts 114 and 214 may be of the same shape, but are of different shapes here.

[0079] In addition, the first parts 113 and 213 and the second parts 114 and 214 may also be controlled to move at the same time, but are controlled to move separately here.

[0080] The first parts 113 and 213 and the second parts 114 and 214 may be arranged in contact or separated.

[0081] Specifically, the first part 113 of the first diameter-expanding member 110 is arranged on the other side axially at a position closer to one side than the axial one-side end face of the stator core 20. The second part 114 is arranged on the one side axially at a position closer to one side than the axial one-side end face of the stator core 20.

[0082] The first part 213 of the second diameter-expanding member 210 is arranged on the one side axially at a position closer to the other side than the axial other-side end face of the stator core 20. The second part 214 is arranged on the other side axially at a position closer to the other side than the axial other-side end face of the stator core 20.

[0083] In the present embodiment, the first part 113 of the first diameter-expanding member 110 and the first part 213 of the second diameter-expanding member 210 are of the same shape and are symmetrically arranged. In addition, the second part 114 of the first diameter-expanding member 110 and the second part 214 of the second diameter-expanding member 210 are of the same shape and are symmetrically arranged.

[0084] The first parts 113 and 213 cause Figure 10 the first coil end 12a shown to move radially outward. The second parts 114 and 214 cause Figure 10 the second coil end 12b shown to move radially outward.

[0085] In addition, as Figure 10 shown, the coil end 12 has a first coil end 12a that overlaps with the coil side 11 axially and a second coil end 12b that connects the first coil end 12a circumferentially. The first coil end 12a is the root of the coil end 12. The second coil end 12b is the front end part of the coil end 12, that is, the transition part.

[0086] In the present embodiment, the first diameter-expanding member 110 is composed of a first portion 113 and a second portion 114, and the second diameter-expanding member 210 is composed of a first portion 213 and a second portion 214. That is, the first diameter-expanding member 110 does not include components other than the first portion 113 and the second portion 114, and the second diameter-expanding member 210 does not include components other than the first portion 213 and the second portion 214.

[0087] In addition, similar to the modification of Embodiment 1 shown in Figure 7 and Figure 8 in the first diameter-expanding member 110 and the second diameter-expanding member 210 of the present embodiment, at least a part of the portion overlapping the stator core 20 in the axial direction inclines radially inward as it approaches the stator core 20.

[0088] Specifically, as shown in Figures 11 to 13 at least a part of the second portions 114 and 214 inclines radially inward as it approaches the stator core 20. Thereby, the second coil end portion 12b, which is the front end portion of the coil end portion 12, can be easily moved radially outward. Moreover, a large load can be suppressed from being generated in the second coil end portion 12b, which is the front end portion of the coil end portion 12.

[0089] In addition, at least a part of the first portions 113 and 213 and at least a part of the second portions 114 and 214 incline radially inward as they approach the stator core 20. Thereby, the first coil end portion 12a as the root portion and the second coil end portion 12b as the front end portion can be easily moved in the radial direction. Moreover, a large load can be suppressed from being generated in the first coil end portion 12a as the root portion and the second coil end portion 12b as the front end portion.

[0090] In detail, as shown in Figure 11 the first portions 113 and 213 are composed of roots 113a and 213a closest to the stator core 20 in the axial direction and first intermediate portions 113b and 213b farther from the stator core 20 than the roots 113a and 213a in the axial direction. The first intermediate portions 113b and 213b are the portions of the first portions 113 and 213 other than the roots 113a and 213a. That is, the roots 113a and 213a and the first intermediate portions 113b and 213b are different portions of a single component.

[0091] The second parts 114 and 214 are composed of front end portions 114a and 214a that are axially the farthest from the stator core 20 and second intermediate portions 114b and 214b that are axially closer to the stator core 20 than the front end portions 114a and 214a. The second intermediate portions 114b and 214b are the portions of the second parts 114 and 214 other than the front end portions 114a and 214a. That is to say, the front end portions 114a and 214a and the second intermediate portions 114b and 214b are different portions of a single component.

[0092] Although described as "a single component", different components may also be connected to form the first parts 113 and 213 and the second parts 114 and 214. For example, the roots 113a and 213a and the first intermediate portions 113b and 213b of the first parts 113 and 213 may be screwed together using an adhesive material or the like. The same applies to the second parts 114 and 214. In addition, in this case, it is preferable that the first intermediate portions 113b and 213b and the second intermediate portions 114b and 214b are a single component. Furthermore, it is preferable that at least the radially outer sides 112 and 212 (the portions in contact with the coil) of the first intermediate portions 113b and 213b and the second intermediate portions 114b and 214b are a single component.

[0093] At least a part of the first intermediate portions 113b and 213b and the second intermediate portions 114b and 214b inclines radially inward as it approaches the stator core 20. Thereby, the portion in contact with the coil end 12 can be reliably moved radially outward, and a large load generated at the coil end 12 can be suppressed. In the present embodiment, the entire radially outer sides of the first intermediate portions 113b and 213b and the second intermediate portions 114b and 214b incline radially inward as they approach the stator core 20. Specifically, the entire radially outer sides 112 and 212 of the first intermediate portions 113b and 213b and the second intermediate portions 114b and 214b incline radially inward as they approach the stator core 20.

[0094] In addition, as Figure 12As shown, the entire radially outer sides of the first parts 113, 213 and the second parts 114, 214 can also be inclined radially inward as they approach the stator core. Thereby, the portion in contact with the coil end 12 can be reliably moved radially outward, and a large load generated in the coil end 12 can be suppressed. Specifically, the radially outer surfaces 112 of the first intermediate portions 113b, 213b and the root portions 113a, 213a are inclined radially inward as they approach the stator core 20. The entire radially outer surfaces 112, 212 of the second intermediate portions 114b, 214b and the front end portions 114a, 214a are inclined radially inward as they approach the stator core 20. That is, the entire radially outer surface 112 of the first diameter-expanding member 110 and the entire radially outer surface 212 of the second diameter-expanding member 210 have a tapered shape.

[0095] In Figure 11 and Figure 12 , the circumferential width of the end face on the second part 114, 214 side of the first parts 113, 213 is the same as the circumferential width of the end face on the first part 113, 213 side of the second parts 114, 214. That is, the circumferential width of the end face on the second intermediate portion 114b, 214b side of the first intermediate portions 113b, 213b is the same as the circumferential width of the end face on the first intermediate portion 113b, 213b side of the second intermediate portions 114b, 214b. In this case, since they have the same width, the coil end 12 can be further bent radially outward. Therefore, when the coil end 12 moves radially outward, the movement of the coil side 11 in the axial direction can be suppressed, and thus the load on the coil end 12 can be reduced.

[0096] As Figure 13 shown, the circumferential width of the end face on the first part 113, 213 side of the second parts 114, 214 can also be smaller than the circumferential width of the end face on the second part 114, 214 side of the first parts 113, 213. That is, the circumferential width of the end face on the first intermediate portion 113b, 213b side of the second intermediate portions 114b, 214b can also be smaller than the circumferential width of the end face on the second intermediate portion 114b, 214b side of the first intermediate portions 113b, 213b. In this case, there is a step between the radially outer surface of the first parts 113, 213 and the radially outer surface of the second parts 114, 214. In this case, the shape can be changed along the coil end 12, and the coil end 12 can be bent radially outward more reliably. Therefore, when the coil end 12 moves radially outward, the movement of the coil side 11 in the axial direction can be suppressed, and thus the load on the coil end 12 can be reduced.

[0097] The moving mechanism of this embodiment moves at least one of the first parts 113, 213 and the second parts 114, 214 radially outward. Here, the moving mechanism moves the first parts 113, 213 and the second parts 114, 214 radially outward. The moving mechanism includes, for example, a component that moves the first parts 113, 213 radially outward and a component that moves the second parts 114, 214 radially outward. In this case, by moving the first parts 113, 213, only the first coil end 12a can be formed, and by moving the second parts 114, 214, only the second coil end 12b can be formed.

[0098] The speed at which the moving mechanism moves the first parts 113, 213 radially outward can be the same as or different from the speed at which it moves the second parts 114, 214 radially outward. In the former case, the shaping of the root and the front end portion of the coil end 12 can be made the same. In the latter case, the shaping of the root and the front end portion of the coil end 12 can be changed.

[0099] The manufacturing method of the stator of this embodiment is the same as that of the stator in Embodiment 1, except that the first parts 113, 213 and the second parts 114, 214 are moved radially outward respectively.

[0100] Specifically, in the first moving step (S4), after the moving mechanism moves the first part 113 radially outward, the second part 114 is moved radially outward. In the second moving step (S5), after the moving mechanism moves the first part 213 radially outward, the second part 214 is moved radially outward. The timing at which the first part 113 is moved radially outward in the first moving step (S4) is the same as the timing at which the first part 213 is moved radially outward in the second moving step (S5). The timing at which the second part 114 is moved radially outward in the first moving step (S4) is the same as the timing at which the second part 214 is moved radially outward in the second moving step (S5). Thereby, it is easy to form the first coil end 12a, which is the root of the coil end 12, before the second coil end 12b, which is the front end portion of the coil end 12.

[0101] In addition, the movement of the first part 113 in the first moving step (S4) and the movement of the first part 213 in the second moving step (S5) can also be implemented simultaneously with the setting of the first device 100 and the second device 200 on the axial one side and the other side of the stator core 20.

[0102] In addition, the first parts 113, 213 and the second parts 114, 214 can be moved radially outward simultaneously.

[0103] The embodiments disclosed herein should be considered as illustrative in all respects and not restrictive. The scope of the present invention is shown not by the above embodiments but by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims.

[0104] (Symbol Explanation)

[0105] 1: Stator

[0106] 2, 3: Coil Forming Device

[0107] 10: Coil

[0108] 11: Coil Side

[0109] 12: Coil End

[0110] 20: Stator Core

[0111] 110: First Diameter-Expanding Member

[0112] 113, 213: First Part

[0113] 113a: Root

[0114] 113b: First Intermediate Part

[0115] 114, 214: Second Part

[0116] 120, 220: Moving Mechanism

[0117] 210: Second Diameter-Expanding Member

[0118] 213b: Second Intermediate Part

[0119] 214a: Front End

[0120] 214b: Second Intermediate Part.

Claims

1. A coil forming device for forming at least a part of a coil inserted into a plurality of axially penetrating slots of a stator core, comprising: A first diameter-expanding member disposed on one axial side of the stator core and movable in the radial direction; A second diameter-expanding member disposed on the other axial side of the stator core and movable in the radial direction; and A moving mechanism for moving the first diameter-expanding member and the second diameter-expanding member radially outward, At least a part of the portion where the first diameter-expanding member and the second diameter-expanding member overlap the stator core in the axial direction has a radially outer surface that inclines radially inward as it approaches the stator core, The radially outer surface contacts at least a part of the coil and pushes the coil radially outward, The first diameter-expanding member and the second diameter-expanding member are different members.

2. The coil forming device according to claim 1, wherein The first diameter-expanding member and the second diameter-expanding member include a first part and a second part, The first part has a part in contact with the coil at a position radially inner than the second part, The second part has a part in contact with the coil at a position radially outer than the first part.

3. The coil forming device according to claim 2, wherein At least a part of the second part inclines radially inward as it approaches the stator core.

4. The coil forming device according to claim 2, wherein At least a part of the first part and at least a part of the second part incline radially inward as they approach the stator core.

5. The coil forming device according to claim 2, wherein The first diameter-expanding member is composed of the first part and the second part, The second diameter-expanding member is composed of the first part and the second part, The first part is composed of a root closest to the stator core in the axial direction and a first intermediate part farther from the stator core than the root in the axial direction, The second part is composed of a front end portion farthest from the stator core in the axial direction and a second intermediate part closer to the stator core than the front end portion in the axial direction, At least a part of the first intermediate part and the second intermediate part inclines radially inward as they approach the stator core.

6. The coil forming device according to claim 5, wherein The entire radially outer side of the first intermediate part and the second intermediate part inclines radially inward as they approach the stator core.

7. The coil forming device according to claim 5, wherein The circumferential width of the end face on the second part side of the first part is the same as the circumferential width of the end face on the first part side of the second part.

8. The coil forming device according to claim 5, wherein The circumferential width of the end face on the first part side of the second part is smaller than the circumferential width of the end face on the second part side of the first part.

9. The coil forming device according to claim 2, wherein The moving mechanism moves the first part and the second part radially outward at different speeds.

10. The coil forming device according to claim 2, wherein the moving mechanism moves the first part radially outward at the same speed as it moves the second part radially outward.

11. The coil forming device according to claim 2, wherein the moving mechanism moves at least one of the first part and the second part radially outward.

12. The coil forming device according to claim 1, wherein the radially outer shape of the first diameter-expanding member is the same as the radially outer shape of the second diameter-expanding member.

13. The coil forming device according to claim 1, wherein it further includes a control unit that controls so that the movement of the first diameter-expanding member radially outward and the movement of the second diameter-expanding member radially outward are performed simultaneously.

14. A method of manufacturing a stator, the stator having coils inserted into a plurality of axially penetrating slots of a stator core, wherein, Comprising: a process of forming the coil, the coil including two coil side parts and a coil end part, the coil side parts being received in the slots, and the coil end part connecting the two coil side parts and being arranged on both axial sides of the stator core; a process of inserting the coil into the slots; a first moving process, using the radially outer surface of a first diameter-expanding member that is arranged on one axial side of the stator core and radially inside the coil end part and moves radially, to move the coil end part located on one axial side of the stator core radially outward, the radially outer surface being inclined radially inward as it approaches the stator core; and a second moving process, using the radially outer surface of a second diameter-expanding member that is arranged on the other axial side of the stator core and radially inside the coil end part, moves radially and is different from the first diameter-expanding member, to move the coil end part located on the other axial side of the stator core radially outward, the radially outer surface being inclined radially inward as it approaches the stator core, wherein the first moving process and the second moving process are implemented at the same time.

15. The manufacturing method of the stator according to claim 14, wherein, Comprising: an intermediate forming process of moving the coil end part radially outward; and a expanding forming process that is implemented after the intermediate forming process and plastically deforms the coil end part, wherein the intermediate forming process and the expanding forming process are implemented at the same time through the first moving process and the second moving process.

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