Coil insertion device and coil insertion method

Abstract

The present invention is to suppress the coil end portion after the insertion into the slot from returning to the inside due to the springback, and to improve the operability of the coil insertion work. In order to solve the above problem, a coil insertion device is provided with a coil expanding means which expands the coil assembly in the wound state from the inside of the stator core, thereby inserting the coil assembly into the slot of the stator core, the coil expanding means having: a coil pressing portion which is arranged on the inner side of the coil assembly, presses the coil end portion of the coil assembly from the inside to the outside, and expands the coil end portion; and a restriction portion which is arranged on the outer side of the coil assembly, restricts the movement of the coil end portion expanded by the coil pressing portion to the outside, and sandwiches the coil end portion of the coil assembly inserted into the slot between the coil pressing portion.

Description

Technical Field

[0001] This invention relates to a coil insertion device and a coil insertion method. Background Technology

[0002] Previously, a method was known in which a coil wound into a ring shape was inserted into the inside of a stator core, and a roller eccentrically positioned on the inside of the coil was used to press the coil relative to the slot of the stator core from the inside out to expand the diameter of the coil, thereby installing it in the slot of the stator core (for example, see Patent Document 1).

[0003] [Previous Technical Documents]

[0004] (Patent Documents)

[0005] Patent Document 1: Japanese Patent No. 6390772 Summary of the Invention

[0006] [The problem the invention aims to solve]

[0007] Figure 16 The illustration depicts a coil 300 in a coil assembly mounted on a stator core 400 being pressed from the inside out to expand its diameter and inserted into a slot 401 from the inside of the stator core 400. Pressing the coil end 301 causes the coil 300 to expand its diameter while moving from the inside to the outside of the stator core 400. Simultaneously, the spacing of the straight portions 302 of the coil 300 inserted into the slot 401 widens, and the coil end 301 also widens circumferentially in the stator core 400.

[0008] However, when the coil is fully inserted into the slot and the pressing is released, due to the coil's rebound, such as Figure 17 As shown, the coil end 301, after being expanded, shrinks to return to its pre-expansion state. When the coil end 301 shrinks back to its pre-expansion state, the spacing P of the straight portions 302 decreases, and the coil 300 inserted into the slot 401 moves radially inward, potentially returning to the inside of the stator core 400. Therefore, this results in problems such as the need for repeated coil pressing operations, leading to poor operability of the coil insertion operation.

[0009] The purpose of this invention is to provide a coil insertion device and a coil insertion method, which can suppress the coil end from springing back inward after insertion into the slot, thereby improving the operability of the coil insertion operation.

[0010] [Technical means to solve the problem]

[0011] (1) The coil insertion device of the present invention has a coil diameter expansion means (e.g., the coil diameter expansion device 5 described later), which expands the diameter of a coil assembly (e.g., the strip coil 100 described later) in a wound state from inside a stator core (e.g., the stator core 2 described later), thereby inserting the coil assembly into a slot (e.g., slot 22 described later) of the stator core. In the coil insertion device (e.g., the coil insertion device 1 described later), the coil diameter expansion means includes: a coil pressing part (e.g., the coil pressing part 53 described later), disposed inside the coil assembly, which presses the coil end (e.g., the coil end 103 described later) of the coil assembly from the inside out to expand its diameter; and a limiting part (e.g., the limiting part 55 described later), disposed outside the coil assembly, which limits the outward movement of the coil end expanded by the coil pressing part, and clamps the coil end of the coil assembly inserted into the slot between the coil pressing part and the coil pressing part.

[0012] (2) In the coil insertion device described in (1) above, the inner circumferential surface of the aforementioned limiting part (e.g., the inner circumferential surface 55a described later) may be a surface perpendicular to the end face of the aforementioned stator core (e.g., the end face 2a described later).

[0013] (3) In the coil insertion device described in (1) above, the inner peripheral surface of the aforementioned limiting part (e.g., the inner peripheral surface 55a described later) may be an inclined surface that is radially outward as it moves away from the end face (e.g., the end face 2a described later) of the aforementioned stator core.

[0014] (4) The coil insertion method of the present invention expands the diameter of a coil assembly (e.g., a strip coil 100) in a wound state from inside a stator core (e.g., stator core 2 described later), thereby inserting the coil assembly into a slot (e.g., slot 22 described later) of the stator core. The coil insertion method includes: pressing the coil end (e.g., coil end 103 described later) of the coil assembly from the inside out using a coil pressing part (e.g., coil pressing part 53 described later) disposed inside the coil assembly to expand its diameter and insert the coil assembly into the slot; and restricting the outward movement of the coil end expanded by the coil pressing part by means of a limiting part (e.g., limiting part 55 described later) disposed outside the coil end, and clamping the coil end of the coil assembly inserted into the slot between the coil pressing part and the limiting part.

[0015] (The effect of the invention)

[0016] According to (1) above, by clamping the coil end of the coil assembly inserted into the slot between the pressing part and the limiting part, the springback generated at the coil end can be eliminated. Therefore, it is possible to suppress the coil end from returning to the inside of the coil due to springback after insertion into the slot, thereby improving the operability of the coil insertion operation. By clamping the coil end between the pressing part and the limiting part, the gap between the coils stacked in the slot is also eliminated.

[0017] According to (2) above, it is possible to apply pressure evenly to the ends of the coil and to arrange the ends of the coil neatly on the end face of the stator core.

[0018] According to (3) above, since the coil end can be tilted radially outward, the protrusion height of the coil end can be suppressed, and the space on the inner diameter side of the coil end can be easily ensured.

[0019] According to (4) above, by clamping the coil end of the coil assembly inserted into the slot between the pressing part and the limiting part, the springback generated at the coil end can be eliminated. Therefore, it is possible to suppress the coil end from returning to the inside of the coil due to springback after insertion into the slot, thereby improving the operability of the coil insertion operation. By clamping the coil end between the pressing part and the limiting part, the gap between the coils stacked in the slot is also eliminated. Attached Figure Description

[0020] Figure 1 This is a perspective view illustrating a coil insertion device according to an embodiment of the present invention.

[0021] Figure 2 It is an exploded perspective view showing the stator core fixing fixture and the coil winding fixture in the coil insertion device.

[0022] Figure 3 It is a three-dimensional drawing showing the insulating paper installed in the slots of the stator core.

[0023] Figure 4 This is a front view illustrating one embodiment of the coil assembly.

[0024] Figure 5 This is a cross-sectional view of a coil insertion device depicting the installation of a coil diameter expansion device onto a coil assembly.

[0025] Figure 6 It is a top view showing the coil assembly and limiting parts inside the stator core.

[0026] Figure 7 It is a perspective view showing the situation where a coil expansion device is inserted inside the coil.

[0027] Figure 8 This is a side view of the pressing part, showing the coil expansion device in its reduced diameter state.

[0028] Figure 9 This is a front view of the pressing part, showing the reduced diameter state of the coil expansion device.

[0029] Figure 10 This is a side view of the pressing part, showing the expansion state of the coil expansion device.

[0030] Figure 11 This is a side view of the pressing part, showing the expansion state of the coil expansion device.

[0031] Figure 12A This diagram illustrates the situation where the coil is pressed into the slot by the pressing part.

[0032] Figure 12B This diagram illustrates the situation where the coil is pressed against the limiting part.

[0033] Figure 12C This diagram illustrates the situation where the coil is pressed against the limiting part.

[0034] Figure 12D This diagram illustrates the situation where the coil is pressed against the limiting part.

[0035] Figure 13 It is a cross-sectional view showing the state in which the coil inserted into the slot is held between the pressing part and the limiting part.

[0036] Figure 14 It is a three-dimensional diagram of the stator.

[0037] Figure 15A This diagram illustrates the situation where the coil is pressed against the limiting part.

[0038] Figure 15B This diagram illustrates the situation where the coil is pressed against the limiting part.

[0039] Figure 16 It is a top view showing the coil being inserted into the slot of the stator core.

[0040] Figure 17 This diagram illustrates the situation where springback causes the coil to return at the end. Detailed Implementation

[0041] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Figure 1 and Figure 2As shown, the coil insertion device 1 includes: a stator core 2; a stator core fixing fixture 3 for fixing the stator core 2; a coil winding fixture 4 for inserting into the inner side of the stator core 2 to wind the strip coil 100 into a ring shape; and a coil diameter expansion device 5 for expanding the diameter of the strip coil 100 wound on the coil winding fixture 4.

[0042] like Figure 2 and Figure 3 As shown, the stator core 2 has, for example, an annular portion 21, which is composed of a laminate of multiple thin-walled core plates. A through hole 20 extending axially through the center of the annular portion 21 is present. The stator core 2 has multiple slots 22 extending axially along the stator core 2. Each slot 22 has an opening 22a, which is arranged radially at certain intervals along the circumference of the annular portion 21 and opens toward the through hole 20. The stator core 2 of this embodiment has 72 slots 22. Six lugs 23 protrude at certain intervals from the outer periphery of the annular portion 21 of the stator core 2.

[0043] In addition, such as Figure 2 As shown, in the stator core 2, the X direction of the slots 22 is circumferential. The Y direction, extending radially from the center of the through hole 20, is radial. The Z direction is axial.

[0044] like Figure 2 As shown, the stator core fixing fixture 3 has a hexagonal prism shape, the hexagonal prism shape having an axial dimension approximately equal to the axial dimension of the stator core 2, and having a stator core insertion hole 31 in the center for inserting and arranging the stator core 2. In the coil insertion device 1 of this embodiment, the stator core fixing fixture 3 is fixed to the central part of the base 11 of the coil insertion device 1 in such a way that the axial direction of the stator core 2 fixed in the stator core insertion hole 31 is horizontal.

[0045] The stator core fixing fixture 3 secures the stator core 2, which is inserted into the hole 31, to a specified position and posture. More specifically, as... Figure 2 As shown, the stator core fixing fixture 3 has six core pressing blocks 32, which are capable of moving in a manner that protrudes and retracts relative to the stator core insertion holes 31, corresponding to the positions of the six lugs 23 of the stator core 2. After the stator core 2 is inserted into the stator core insertion hole 31, the stator core fixing fixture 3 is driven by an actuator such as a pressure cylinder (not shown) to cause the core pressing blocks 32 to protrude into the stator core insertion hole 31 respectively. Thus, as Figure 2 As shown, the core pressing blocks 32 hold the ears 23 of the stator core 2 respectively, fixing the stator core 2 inserted into the hole 31 in the specified position and posture.

[0046] like Figure 3As shown, insulating paper 24 is pre-installed in the slots 22 of the stator core 2. The insulating paper 24 is bent into a roughly U-shape to conform to the roughly U-shaped inner surface shape of the slots 22 when viewed from the axial direction. Figure 4 As shown, the insulating paper 24 installed in the slot 22 has a flanged portion 24a, which protrudes from the slot 22 toward the stator core 2 along the axial direction at a predetermined height. The flanged portion 24a protrudes from the slot 22 toward the two outer sides along the axial direction of the stator core 2.

[0047] like Figure 2 As shown, multiple flanged guides 33 are radially arranged at certain intervals along the circumference on both end faces 3a, 3a of the stator core fixing fixture 3, on which the stator core 2 is fixed. The flanged guides 33 are configured to move radially along the stator core 2 by means of an actuator such as a pressure cylinder (not shown). The flanged guides 33 are formed into elongated thin plates along the radial direction of the stator core 2. The flanged guides 33 open towards the inner side of the stator core fixing fixture 3, and when the strip coil 100 is inserted, the flanged portions 24a that hold the insulating paper 24 from both sides support the insulating paper 24 within the support groove 22.

[0048] like Figure 2 As shown, the coil winding fixture 4 has: a generally cylindrical fixture body 41; a plurality of comb-shaped portions 42 that radiate outwards from the outer periphery of the fixture body 41; a plurality of comb-shaped grooves 43 formed between adjacent comb-shaped portions 42 in the circumferential direction; and a shaft hole 44 that opens at the center of the fixture body 41. The comb-shaped portions 42 and the comb-shaped grooves 43 are respectively provided at both ends of the fixture body 41 in the axial direction. The phases of the comb-shaped portions 42 and the comb-shaped grooves 43 at both ends of the fixture body 41 are aligned in the axial direction. The number of comb-shaped grooves 43 arranged in the circumferential direction of the fixture body 41 is the same as the number of grooves 22 provided in the stator core 2. Therefore, the coil winding fixture 4 of this embodiment has 72 comb-shaped grooves 43. The coil winding fixture 4 is formed such that the outer diameter of the coil winding fixture 4 is smaller than the inner diameter of the stator core 2, as determined by the position of the front end of the comb portion 42, so that it can be inserted into the inner side of the annular portion 21 of the stator core 2.

[0049] The strip coil 100 is wound in a circular shape on the coil winding fixture 4. For example... Figure 4As shown, the strip coil 100 is a coil assembly consisting of a continuous, long strip of corrugated coil formed from flat wires 101 of copper, aluminum, or the like, with a generally rectangular cross-sectional shape. Besides corrugated coils, multiple segmented coils formed in a generally U-shape can also be used as coil assemblies. However, when a continuous corrugated coil is placed in a slot in the stator core, since it eliminates the need for the conventional technique of dividing coils into multiple segments and welding the ends after insertion into the slot, it eliminates the need for, for example, using high-purity copper in the coil to withstand heat treatment at the welding points. Therefore, recycled copper containing impurities can be used, contributing to resource recycling. Furthermore, since corrugated coils do not require welding, coil weight reduction is possible, enabling the reduction of weight in the rotary electric motor using the coil. In the case of a rotary electric motor mounted in a hybrid vehicle, reducing vehicle weight reduces carbon dioxide emissions and mitigates adverse environmental impacts.

[0050] The strip coil 100 has multiple straight portions 102 and multiple coil ends 103. The straight portions 102 are parts inserted into slots 22 of the stator core 2, extending generally in a straight line and arranged parallel to each other at certain intervals. The coil ends 103 are located closer to the side ends of the strip coil 100 than the straight portions 102, and adjacent straight portions 102 are alternately connected at one end to the other in a mountain-shaped configuration. When the strip coil 100 is installed in the slots 22 of the stator core 2, the coil ends 103 are positioned such that they protrude axially from the slots 22 toward the stator core 2. In this embodiment, the strip coil 100 is formed into a long strip by bundling six flat wires 101, each bent to form multiple straight portions 102 and multiple coil ends 103, parallel to each other at certain intervals along the straight portions 102.

[0051] Before being inserted into the inner side of the stator core 2, the coil winding fixture 4 sequentially inserts the straight portion 102 of the strip coil 100 into the comb-shaped grooves 43, thereby winding the strip coil 100 into multiple layers. Thus, as... Figure 2 As shown, a coil winding fixture 4 is configured to wind the strip coil 100 into a circular ring.

[0052] A coil winding fixture 4 winds a strip coil 100 into a circular ring. A coil diameter expanding device 5, which clamps a stator core fixing fixture 3 in the middle and is positioned on either side of the fixture, holds the coil in a predetermined position within the stator core insertion hole 31. In this embodiment, the coil diameter expanding device 5 constitutes a coil diameter expanding means. Figure 1 As shown, the coil diameter expansion device 5 is axially opposite to the coil winding fixture 4 inserted into the inner side of the stator core 2.

[0053] like Figure 1 and Figure 5 As shown, in the coil insertion device 1, a pair of support base plates 12, 12 are erected on the base 11 of the stator core fixing fixture 3, facing each other across the stator core fixing fixture 3. The coil diameter expansion device 5 protrudes horizontally from the support base plates 12 toward the coil winding fixture 4, which is inserted into the stator core 2. The coil diameter expansion device 5 is configured such that the support base plates 12 can move linearly on the base 11 by being driven by a motor (not shown), thereby being able to move in both the direction of contact with the coil winding fixture 4 and the direction of departure.

[0054] like Figure 5 and Figure 7 As shown, the coil diameter expanding device 5 has a main shaft portion 51 at its center, which extends from the support base plate 12 toward the coil winding fixture 4 inserted into the stator core 2. A holding portion 52 is provided at the front end of the main shaft portion 51, which holds the coil winding fixture 4 in a predetermined position and orientation inside the stator core 2. The holding portion 52 has: a shaft protrusion 522 protruding from the center of a circular end plate portion 521 disposed at the front end of the main shaft portion 51; and a positioning protrusion 523 protruding from the end plate portion 521 radially outward of the shaft protrusion 522 in the same direction as the shaft protrusion 522. The shaft protrusion 522 engages with the shaft hole 44 of the coil winding fixture 4. The positioning protrusion 523 engages with a positioning hole 45 provided radially outward of the shaft hole 44 of the coil winding fixture 4.

[0055] The positioning hole 45 of the coil winding fixture 4 and the positioning protrusion 523 of the holding part 52 are pre-positioned so that when they are engaged, the phase of the groove 22 of the stator core 2 fixed on the stator core fixing fixture 3 is consistent with the phase of the comb-shaped groove 43 of the coil winding fixture 4 inserted into the inner side of the stator core 2. Therefore, when the coil diameter expanding device 5 moves toward the stator core fixing fixture 3, and the shaft hole 44 and positioning hole 45 of the coil winding fixture 4 engage with the shaft protrusion 522 and positioning protrusion 523 of the holding part 52, as... Figure 6 As shown, the coil winding fixture 4 is maintained in a state where the phase of the comb-shaped groove 43 is aligned with the groove 22 of the stator core 2. Thus, the interior of the groove 22 of the stator core 2 is radially connected to the interior of the comb-shaped groove 43 of the coil winding fixture 4.

[0056] The coil expansion device 5 has a coil pressing part 53 on the outer periphery of the main shaft part 51. The coil pressing part 53 has: a movable cylinder part 531, which is fitted into the outer periphery of the main shaft part 51; a plurality of movable arm parts 532, which are further disposed on the outer periphery of the movable cylinder part 531; and a plurality of stop members 533, which are respectively disposed at the front end of the movable arm parts 532.

[0057] The movable cylinder 531 has a length shorter than that of the main shaft 51, and is slidably disposed along the axial direction of the main shaft 51 by means of an actuator 54 such as a pressure cylinder disposed behind the support base plate 12.

[0058] The movable arm portion 532 extends axially along the main shaft portion 51, and a plurality of them are arranged at certain intervals in the circumferential direction on the outer periphery of the movable cylinder portion 531. The coil pressing portion 53 of this embodiment has 12 movable arms 532 arranged circumferentially along the main shaft portion 51. Twelve guide rails 121 are provided on the surface of the support base plate 12, arranged radially outward from the main shaft portion 51. The rear ends 532b of the movable arms 532 are respectively mounted to be movable along the guide rails 121. The movable arm portion 532 bends from the guide rail along the axial direction of the movable cylinder portion 531 and extends to the vicinity of the outer periphery of the holding portion 52. The front ends 532a of the movable arms 532 are connected to the outer peripheral surface of the front end side of the movable cylinder portion 531 via two connecting rod portions 534 that are respectively rotatably mounted.

[0059] like Figures 8-11 As shown, the stop members 533 have a generally fan shape, and one is provided at the front end of the movable arm portion 532. Therefore, the coil pressing portion 53 of this embodiment has 12 stop members 533 arranged in a ring shape. Each stop member 533 has a pair of engaging tabs 533a at one end of the coil pressing portion 53 in the circumferential direction (circumferential direction of the ring-shaped stop members 533), and a pair of engaging grooves 533b at the other end of the circumferential direction, which engage with the pair of engaging tabs 533a. The pair of engaging tabs 533a are arranged parallel to the axial direction of the coil pressing portion 53, and protrude continuously and parallel to the outer peripheral surface 530 of the coil pressing portion 53 in the circumferential direction. By the engagement of the pair of engaging tabs 533a and the pair of engaging grooves 533b of the adjacent stop members 533 in the circumferential direction, the 12 stop members 533 are arranged in a ring shape on the outer peripheral side of the holding portion 52. In addition, the circumferential direction of the coil pressing part 53 is Figures 8-11 The direction C is shown in the diagram.

[0060] Figure 5 The illustration shows the movable cylinder 531 retracted to the rear end side (support base plate 12 side) of the main shaft 51. At this time, the movable arms 532 move towards the inner ends of the radial guide rails 121, positioning themselves closest to the outer peripheral surface of the movable cylinder 531. Thus, as... Figure 8 and Figure 9As shown, the coil pressing part 53 is positioned such that the 12 stop members 533 are in close contact with each other at their smallest diameter. When the stop members 533 are reduced in diameter, the outer diameter of the coil pressing part 53 is smaller than the inner diameter of the coil end 103, which protrudes axially in a cylindrical shape from the coil winding fixture 4 on which the strip coil 100 is wound. The coil expanding device 5, with the multiple stop members 533 of the coil pressing part 53 in a reduced-diameter state, is inserted into the coil end 103 protruding axially in a cylindrical shape from the coil winding fixture 4, and the coil winding fixture 4 is held in place by the retaining part 52.

[0061] When the movable cylinder 531, driven by the actuator 54, advances along the main shaft 51 toward the coil winding fixture 4, the connecting rods 534 connected to the movable cylinder 531 rotate in a manner extending radially outward from the movable cylinder 531, causing the movable arms 532 to move parallel outward along the guide rails. As a result, the 12 movable arms 532 move radially outward from the movable cylinder 531. At this time, as... Figure 10 and Figure 11 As shown, the coil pressing part 53 causes adjacent stop members 533 to move in a mutually expanding manner, thus reaching the maximum diameter expansion state. When the diameter has been expanded, the outer diameter of the coil pressing part 53 is larger than the outer diameter of the coil winding fixture 4. By expanding the diameter of the coil pressing part 53, the coil end 103 is moved from the inside to the outside.

[0062] In addition, such as Figure 9 and Figure 11 As shown, when the coil pressing portion 53 is expanded to its maximum diameter, adjacent stop members 533, 533 separate from each other, but a pair of engaging tabs 533a extend circumferentially between the stop members 533, 533. The engaging tabs 533a are not completely pulled out of the engaging grooves 533b of the adjacent stop members 533, maintaining engagement with the engaging grooves 533b. Therefore, the expanded annular multiple stop members 533 have a continuous closed outer peripheral surface 530 in the circumferential direction. Therefore, when the coil pressing portion 53 is viewed circumferentially, adjacent stop members 533, 533 are continuous by a pair of engaging tabs 533a, and no groove (gap) is formed that penetrates the coil pressing portion 53 radially.

[0063] like Figure 1 , Figures 5-7 As shown, the coil diameter expansion device 5 also includes a limiting portion 55. In this embodiment, the limiting portion 55 is formed in a cylindrical shape, but it can also be formed as a plate with a circular opening in the center. The limiting portion 55 can also be divided into multiple portions in the circumferential direction. In this case, the limiting portion 55 can also be configured to move radially relative to the stator core 2. Furthermore, this limiting portion 55... Figure 2 The middle part is omitted. Figure 6 The stator core fixing fixture 3 is omitted in the text.

[0064] The limiting part 55 is concentrically arranged with the stator core 2 on the outer side of the coil end 103 of the strip coil 100. More specifically, as... Figure 5 and Figure 6 As shown, the limiting portion 55 is arranged concentrically with the coil 100 wound on the coil winding fixture 4, so as to completely surround the outer side of the annular strip coil 100 on both end faces 2a, 2a of the stator core 2 in the axial direction. In this embodiment, the inner circumferential surface 55a of the limiting portion 55 is positioned slightly outward from the position on the outer diameter side of the slot 22 of the stator core 2.

[0065] In this embodiment, the limiting part 55 is installed, for example, by a mounting mechanism (not shown), between the limiting part 55 and the end face 2a, on the two end faces 2a, 2a of the stator core 2 after it is mounted on the stator core fixing fixture 3, respectively. This is done so that multiple flange guides 33 are clamped between the limiting part 55 and the end face 2a. Furthermore, although not shown, the limiting part 55 can be concentrically arranged on the outer periphery of the coil pressing part 53 of the coil diameter expanding device 5, and when the coil pressing part 53 is inserted into the inner side of the strip coil 100, the limiting part 55 can simultaneously be arranged on the outer side of the strip coil 100.

[0066] The limiting part 55 is disposed on the outside of the slot 22 of the stator core 2. As described later, when the strip coil 100 is inserted into the slot 22 by means of the expanded diameter coil pressing part 53, the coil end 103 is clamped between the limiting part 55 and the stop member 533 of the coil pressing part 53. In this embodiment, the inner peripheral surface 55a of the limiting part 55 is formed as a surface perpendicular to the end face 2a of the stator core 2. This inner peripheral surface 55a is a surface perpendicular to the moving direction of the strip coil 100 and a surface parallel to the axial direction Z of the stator core 2.

[0067] Next, refer to Figures 12A-12D ,and Figure 13 The method of inserting a strip coil 100 wound on a coil winding fixture 4 into a slot 22 inside a stator core 2 fixed to a stator core fixing fixture 3 in the coil insertion device 1 will be described. Furthermore, Figures 12A-12D Only one end face 2a of the stator core 2 is shown.

[0068] First, a coil winding fixture 4, in which the strip coil 100 is wound into a ring shape, is inserted into the inside of the stator core 2, which is already fixed to the stator core fixing fixture 3. Then, the flange guide 33, driven by an actuator (not shown), moves radially inward, clamping and supporting the flanged portion 24a of the insulating paper 24 within the groove 22. Thus, the insulating paper 24 is positioned at a predetermined location within the groove 22.

[0069] like Figure 5 and Figure 7As shown, by moving a pair of coil diameter expanding devices 5 toward the coil winding fixture 4, the coil winding fixture 4, inserted into the inner side of the stator core 2, is held by the holding part 52 of the coil diameter expanding device 5. At this time, as... Figure 8 and Figure 9 As shown, the stop member 533 of the coil pressing part 53 is in a state where it is smaller than the inner diameter of the annular strip coil 100, and is inserted into the inner side of the coil end 103 of the strip coil 100.

[0070] Then, the stop member 533 of the coil pressing part 53 is driven by the actuator 54, such as Figure 10 and Figure 11 As shown, it moves in a manner that expands from a reduced diameter state. Consequently, the coil end 103 of the strip coil 100 wound on the coil winding fixture 4 is pressed from the inside to the outside by the stop member 533 of the coil pressing part 53. The strip coil 100 pressed by the coil pressing part 53 gradually expands throughout its circumference. Simultaneously, the straight portion 102 moves towards the slot 22 of the stator core 2, which communicates with the comb-shaped groove 43, while being guided by the comb-shaped groove 43 of the coil winding fixture 4. The straight portion 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. Figure 12A ).

[0071] When the coil pressing portion 53 further expands in diameter, the coil end 103 of the strip coil 100 is pressed by the stop member 533 of the coil pressing portion 53 and abuts against the end of the groove 22 on the outer diameter side. Since the inner circumferential surface 55a of the limiting portion 55 is positioned slightly outward from the position on the outer diameter side of the groove 22, the coil end 103 is slightly separated from the inner circumferential surface 55a of the limiting portion 55. Figure 12B ).

[0072] After the coil end 103 abuts against the outer diameter side of the groove 22, if the coil end 103 is pressed further, the coil end 103 deforms in a radially outward tilt and abuts against the inner circumferential surface 55a of the limiting part 55. Figure 12C ).

[0073] Then, the coil end 103 is pressed against the inner circumferential surface of the limiting portion 55 by the pressing force of the stop member 533 of the expanded diameter coil pressing portion 53. Thus, the coil end 103 is clamped between the stop member 533 and the limiting portion 55. Figure 12D ).

[0074] When the coil end 103 is clamped between the stop member 533 and the limiting part 55, as Figure 13As shown, the position of the outer diameter side of the coil end 103 is restricted to an outer diameter restriction position Ya defined by the inner circumferential surface 55a of the restriction portion 55. Since the restriction portion 55 is positioned fixedly on the outside of the groove 22, the coil end 103 is clamped between the outer circumferential surface 530 of the stop member 533 of the coil pressing portion 53 and the inner circumferential surface 55a of the restriction portion 55, thereby compressing the coil end 103 radially outward towards the inner circumferential surface 55a of the restriction portion 55. The position of the inner diameter side of the compressed coil end 103 moves to a position further radially outward than the inner diameter reference position Yb before compression.

[0075] By compressing the coil end 103 for a predetermined time between the stop member 533 and the limiting part 55 of the expanded diameter coil pressing part 53, stress exceeding plastic deformation is applied to the coil end 103. As a result, the direction of the residual stress generated in the coil end 103 due to the diameter expansion changes, and springback is eliminated. Consequently, the inward return of the strip coil 100 inserted into the slot 22 due to springback is suppressed. Furthermore, since the limiting part 55 restricts the outward movement of the coil end 103, the dispersion of the strip coil 100 in the forward direction of movement is suppressed, and the gap between the straight portions 102 stacked in the slot 22 is eliminated. Furthermore, since excessive contact between the straight portions 102 and the back 24b of the insulating paper 24 within the slot 22 is suppressed, crushing of the insulating paper 24 is also suppressed.

[0076] Therefore, as Figure 14 As shown, a stator 200 was obtained in which the return of the strip coil 100 was suppressed.

[0077] Since the inner circumferential surface 55a of the limiting part 55 is perpendicular to the end face 2a of the stator core 2, a uniform pressing force can be applied to the coil end 103, and the coil end 103 can be neatly arranged on the end face 2a of the stator core 2. However, the inner circumferential surface 55a of the limiting part 55 is not limited to a perpendicular surface. The inner circumferential surface 55a can also be an inclined surface that slopes radially outward as it moves away from the end face 2a of the stator core 2 along the axial direction.

[0078] Figure 15A , Figure 15B The illustration shows the case where the limiting part 55, which is inclined relative to the inner circumferential surface 55a, presses down on the coil end 103. The coil end 103, pressed down by the stop member 533 of the coil pressing part 53, abuts against the lower edge of the inclined inner circumferential surface 55a of the limiting part 55 (the end edge on the end face 2a side of the stator core 2). Figure 15A Then, when the coil end 103 is further pressed, the coil end 103 is compressed while tilting radially outward along the inclined inner circumferential surface 55a of the limiting portion 55. Figure 15BThe compressed coil end 103 is shaped to be radially outward as it moves away from the end face 2a of the stator core 2 along the axial direction. Therefore, the protrusion height of the coil end 103 can be suppressed, and the space on the inner diameter side of the coil end 103 (rotor insertion space, etc.) can be easily ensured.

[0079] When using such a limiting part 55, the outer peripheral surface of the stop member 533 of the coil pressing part 53, like the inner peripheral surface 55a of the limiting part 55, can also be composed of an inclined surface that is radially outward as it moves away from the end face 2a of the stator core 2 along the axial direction.

[0080] The coil insertion device 1 according to this embodiment achieves the following effects. Specifically, the coil insertion device 1 of this embodiment is a device having a coil diameter expansion device 5, which expands the diameter of the wound strip coil 100 from inside the stator core 2, thereby inserting the strip coil 100 into the slot 22 of the stator core 2. The coil diameter expansion device 5 includes: a coil pressing part 53 disposed inside the strip coil 100, which presses the coil end 103 of the strip coil 100 from the inside out to expand its diameter; and a limiting part 55 disposed outside the strip coil 100, which restricts the outward movement of the coil end 103 expanded by the coil pressing part 53, and clamps the coil end 103 of the strip coil 100 inserted into the slot 22 between the coil pressing part 53 and the coil pressing part 53. Accordingly, by clamping the coil end 103 of the strip coil 100 inserted into the slot 22 between the coil pressing part 53 and the limiting part 55, the springback generated at the coil end 103 can be eliminated. Therefore, the return of the coil end 103 to the inside of the strip coil 100 due to springback after insertion into the slot 22 can be suppressed, improving the operability of the coil insertion operation. By clamping the coil end 103 between the coil pressing part 53 and the limiting part 55, the gaps between the straight portions 102 of the strip coil 100 stacked in the slot 22 are also eliminated. Since excessive contact between the straight portions 102 and the back surface 24b of the insulating paper 24 within the slot 22 is suppressed, the crushing of the insulating paper 24 is also suppressed.

[0081] When the inner circumferential surface 55a of the limiting part 55 is a surface perpendicular to the end face 2a of the stator core 2, a pressing force can be applied evenly to the coil end 103, and the coil end 103 can be neatly arranged on the end face 2a of the stator core 2.

[0082] When the inner circumferential surface 55a of the limiting part 55 is an inclined surface that slopes radially outward as it moves away from the end face 2a of the stator core 2, the protrusion height of the coil end 103 can be suppressed, and the space on the inner diameter side of the coil end 103 can be easily ensured.

[0083] Furthermore, the coil insertion method according to this embodiment achieves the following effects. Specifically, the coil insertion method of this embodiment expands the diameter of the wound strip coil 100 from inside the stator core 2, thereby inserting the strip coil 100 into the slot 22 of the stator core 2. The method includes: a step of using a coil pressing portion 53 disposed inside the strip coil 100 to press the coil end 103 of the strip coil 100 from the inside out to expand its diameter, thereby inserting the strip coil 100 into the slot 22; and a step of using a limiting portion 55 disposed outside the coil end 103 to restrict the outward movement of the coil end 103 expanded by the coil pressing portion 53, and clamping the coil end 103 of the strip coil 100 inserted into the slot 22 between the coil pressing portion 53 and the limiting portion 55. Accordingly, by clamping the coil end 103 of the strip coil 100 inserted into the slot 22 between the coil pressing part 53 and the limiting part 55, the springback generated at the coil end 103 can be eliminated. Therefore, the return of the coil end 103 to the inside of the strip coil 100 due to springback after insertion into the slot 22 can be suppressed, improving the operability of the coil insertion operation. By clamping the coil end 103 between the coil pressing part 53 and the limiting part 55, the gaps between the straight portions 102 of the strip coil 100 stacked in the slot 22 are also eliminated. Since excessive contact between the straight portions 102 and the back surface 24b of the insulating paper 24 within the slot 22 is suppressed, the crushing of the insulating paper 24 is also suppressed.

[0084] The coil insertion device 1 described above is configured such that the stator core 2 and the coil winding fixture 4 are axially arranged in the horizontal direction. However, it can also be configured such that the stator core 2 and the coil winding fixture 4 are axially arranged in a direction other than the horizontal direction, such as the vertical direction.

[0085] Figure Labels

[0086] 1. Coil Insertion Device

[0087] 2 stator core

[0088] 2a end face

[0089] 22 slots

[0090] 5. Coil diameter expansion device (coil diameter expansion method)

[0091] 53 coil pressing part

[0092] 55 Restriction Department

[0093] 55a inner circumferential surface

[0094] 100 strip coil (coil assembly)

[0095] 103 coil end

Claims

1. A coil insertion device comprising a coil diameter expansion means, said coil diameter expansion means expanding the diameter of a wound coil assembly from inside a stator core, thereby inserting the coil assembly into a slot in the stator core, characterized in that, The aforementioned methods for expanding the diameter of the coil include: A coil pressing part, disposed inside the aforementioned coil assembly, presses the coil end of the aforementioned coil assembly from the radially inner side to the radially outer side to expand its diameter, thereby inserting the aforementioned coil assembly into the aforementioned groove; and, The limiting part is located radially outward from the end of the groove on the outer diameter side, thereby limiting the radial outward movement of the end of the coil, which is expanded by the coil pressing part. The aforementioned coil pressing part deforms the aforementioned coil end, which abuts against the aforementioned outer diameter side of the aforementioned groove, in a radially outward inclined manner and abuts against the inner circumferential surface of the aforementioned limiting part, thereby clamping the aforementioned coil end of the aforementioned coil assembly inserted into the aforementioned groove between the aforementioned coil pressing part and the aforementioned limiting part.

2. The coil insertion device according to claim 1, wherein, The aforementioned inner circumferential surface of the aforementioned limiting part is a surface perpendicular to the end face of the aforementioned stator core.

3. The coil insertion device according to claim 1, wherein, The aforementioned inner circumferential surface of the aforementioned limiting part is an inclined surface that tilts radially outward as it moves away from the end face of the aforementioned stator core.

4. A coil insertion method comprising expanding the diameter of a wound coil assembly from inside a stator core, thereby inserting the coil assembly into a slot in the stator core, the coil insertion method being characterized by comprising: The process of inserting the coil assembly into the groove by pressing the coil end of the coil assembly from the radially inner side to the radially outer side using the coil pressing part disposed on the inner side of the aforementioned coil assembly to expand its diameter; and, The process involves using a limiting portion located radially outward from the end of the aforementioned groove on the outer diameter side to restrict the movement of the aforementioned coil end, which has been expanded by the aforementioned coil pressing portion, in a radially outward manner, and using the aforementioned coil pressing portion to deform the aforementioned coil end, which abuts against the aforementioned outer diameter side end of the aforementioned groove, so that it abuts against the inner circumferential surface of the aforementioned limiting portion. The process also involves clamping the aforementioned coil end of the aforementioned coil assembly inserted into the aforementioned groove between the aforementioned coil pressing portion and the aforementioned limiting portion.

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