Stator assembly device and stator assembly method

Abstract

A stator assembly apparatus is provided that allows a coil to be inserted into a slot from the inside of a stator core without engaging an insulating component fitted into the slot. The stator assembly apparatus includes: a first guide member inserted into the inside of the insulating component in the slot; a second guide member inserted into the inside of the insulating component and positioned radially outward of the slot than the first guide member; and a control means for controlling the movement of the first and second guide members. The first guide member is positioned in front of the coil, which is moved by a pushing means, in the direction of movement, and is pushed by the coil to move radially outward of the slot. After the first guide member moves radially outward of the slot until it abuts against or approaches the second guide member disposed on the inner diameter side, as the coil moves radially outward by the pushing means, a plurality of second guide members move sequentially from the side closest to the first guide member outward toward the central axis of the stator core, thereby retracting from the slot.

Description

Technical Field

[0001] This invention relates to a stator assembly apparatus and a stator assembly method. Background Technology

[0002] Previously, as a technique for inserting the coil from the inside of the stator core into the slot of the stator core where the insulating components are assembled, while preventing it from biting into the insulating components, the technique described in Patent Document 1 is known.

[0003] In the technology described in Patent Document 1, two guide clamps are inserted from the outside of the stator core in the direction of the central axis of the stator core into the slot where the insulating components are assembled and before the coil is inserted, thereby opening the insulating components. In this state, the coil moves in the slot while abutting against one of the guide clamps, and after the guide components abut against each other, the two guide clamps are retracted from the slot.

[0004] [Previous Technical Documents]

[0005] (Patent Documents)

[0006] Patent Document 1: Japanese Patent No. 6733823 Summary of the Invention

[0007] [The problem the invention aims to solve]

[0008] However, in the technology described in Patent Document 1, since the coil moves further within the slot after the guide clamp retracts from the slot, the coil comes into contact with the insulating component during this movement. When the coil comes into contact with the insulating component, the insulating component is bitten between the coil and the slot, and as the coil moves, the insulating component may be twisted or bent.

[0009] The purpose of this invention is to provide a stator assembly apparatus and a stator assembly method that, when inserting a coil from the inside of the stator core into a slot, can insert it in a manner that does not bite into the insulating components already assembled in the slot.

[0010] [Technical means to solve the problem]

[0011] (1) The stator assembly apparatus of the present invention (e.g., the stator assembly apparatus 1 described later) assembles a stator (e.g., the stator core 2 described later) by inserting a coil (e.g., the strip coil 100 described later) into a slot (e.g., the slot 22 described later) of the stator core from the inside of the stator core (e.g., the insulating paper 24 described later) where insulating components (e.g., the insulating paper 24 described later) are assembled. The stator assembly apparatus includes a pushing means (e.g., the coil pushing part 51 described later) that pushes the coil radially outward, so that... The aforementioned coil moves to the inside of the aforementioned insulating member within the aforementioned slot; at least one first guide member (e.g., the advance guide member 61 described later) is provided relative to one of the aforementioned slots and is configured to move along the central axis of the aforementioned stator core, thereby being inserted into the inside of the aforementioned insulating member within the aforementioned slot by moving toward the aforementioned stator core; a second guide member (e.g., the reinforcing guide member 62, the first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c described later), relative to... For a given slot, multiple slots are provided and configured to move along the central axis of the stator core, and by moving toward the stator core, they are inserted into the inner side of the insulating member and into a radially outer position within the slot, which is further outward than the first guide member; and a control means (e.g., the control unit 10 described later) controls the movement of the first guide member and the multiple second guide members along the central axis of the stator core, respectively; the first guide member is configured such that, when inserted into the slot, it is located in front of the moving direction of the coil moved by the pushing means, and is pushed by the coil to move radially outward within the slot, and the control means controls it as follows: after the first guide member moves radially outward within the slot until it comes into contact with or approaches the second guide member disposed on the inner diameter side among the multiple second guide members, the multiple second guide members are moved sequentially from the side close to the first guide member toward the outer side of the central axis of the stator core to retract from the slot.

[0012] (2) The stator assembly apparatus of the present invention (e.g., the stator assembly apparatus 1 described later) assembles a stator (e.g., the stator core 2 described later) by inserting a coil (e.g., the strip coil 100 described later) into a slot (e.g., the slot 22 described later) of the stator core from the inside of the stator core (e.g., the insulating paper 24 described later) where insulating components (e.g., the insulating paper 24 described later) are assembled. The stator assembly apparatus includes a pushing means (e.g., the coil pushing part 51 described later) that pushes the coil radially outward, causing the coil to move into the slot. The inner side of the insulating component; at least one first guide member (e.g., the advance guide member 61 described later) is provided relative to one of the aforementioned slots and is configured to be movable along the central axis of the aforementioned stator core, and inserted into the inner side of the aforementioned insulating component in the aforementioned slot by moving toward the aforementioned stator core; multiple second guide members (e.g., the reinforcing guide member 62, the first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c described later) are provided relative to one of the aforementioned slots and are configured to be movable along the central axis of the aforementioned stator core. The first guide member moves along the central axis direction and is inserted into the inner side of the insulating member and into the radially outer side of the slot, which is closer to the first guide member than the first guide member; and the control means (e.g., the control unit 10 described later) controls the movement of the first guide member and the plurality of second guide members along the central axis direction of the stator core; the first guide member is configured such that, when inserted into the slot, it is located in front of the direction of movement of the coil moved by the pushing means, and is pushed by the coil to move radially outward in the slot. The control means controls the movement as follows: after the first guide member moves radially outward in the slot until it comes into contact with or approaches the second guide member disposed on the inner diameter side among the plurality of second guide members, the first guide member is first moved outward in the central axis direction of the stator core to retract from the slot. Then, as the coil moves radially outward using the pushing means, the plurality of second guide members move sequentially from the inner diameter side to the central axis direction of the stator core to retract from the slot.

[0013] (3) Optionally, the stator assembly device according to (1) or (2) above has a pressing means (e.g., the connecting plate 613 or the elastic member 614 described later) that presses the first guide member toward the radial inner side of the stator core to the coil.

[0014] (4) In the stator assembly apparatus according to any one of (1) to (3) above, optionally, the first guide member is configured such that, in the state of being inserted into the slot before the coil is inserted, at least a portion of the first guide member hangs in the opening end (e.g., opening end 24a described later) of the insulating member in the slot.

[0015] (5) The stator assembly apparatus according to any one of (1) to (4) above, optionally, the first guide member and the second guide member are respectively arranged face to face on both sides of the central axis direction of the stator core, and when they are inserted into the slot from the two outer sides of the central axis direction of the stator core, they are arranged in the slot with their front ends facing each other.

[0016] (6) In the stator assembly apparatus according to any one of (1) to (5) above, optionally, the longitudinal widths (e.g., the longitudinal widths W11 and W21 described later) of the first guide member and the second guide member along the radial direction of the stator core are approximately the same.

[0017] (7) In the stator assembly apparatus according to any one of (1) to (6) above, optionally, the lateral width (e.g., the lateral width W12, W22 described later) of the first guide member and the second guide member along the circumference of the stator core is greater than the width (e.g., the width W0) of the coil along the circumference of the stator core.

[0018] (8) The stator assembly method of the present invention involves inserting a coil (e.g., the strip coil 100 described later) into a slot (e.g., slot 22 described later) of the stator core (e.g., stator core 2 described later) from the inside of the stator core on which the insulating component (e.g., the insulating paper 24 described later) is assembled, thereby assembling the stator (e.g., stator 200 described later). The stator assembly method comprises the following steps: before inserting the coil into the slot, inserting at least one first guide member (e.g., the advance guide member 61 described later) from the outside of the central axis direction of the stator core, in a manner disposed inside the insulating component within the slot, relative to one of the slots. Furthermore, the first guide member is inserted radially outward from the inside of the insulating component and further outward than the first guide member within the slot. The process of positioning the coil relative to the aforementioned slot, including the process of inserting multiple second guides (e.g., the reinforcing guide 62, the first reinforcing guide 62a, the second reinforcing guide 62b, and the third reinforcing guide 62c described later); the process of moving the coil toward the aforementioned slot and abutting against the aforementioned first guide, and moving the aforementioned first guide toward the radially outward side of the aforementioned slot as the coil moves; and the process of moving the aforementioned first guide toward the radially outward side of the aforementioned slot until it abuts against or approaches the aforementioned second guide among the multiple aforementioned second guides disposed on the inner diameter side, and then moving the aforementioned second guide from the side closest to the aforementioned first guide toward the outer side in the direction of the central axis of the aforementioned stator core to retract from the aforementioned slot.

[0019] (9) The stator assembly method of the present invention assembles a stator (e.g., the strip coil 100 described later) by inserting a coil (e.g., the slot 22 described later) into a slot of the stator core (e.g., the slot 22 described later) from the inside of the stator core (e.g., the insulating paper 24 described later) that assembles the insulating component (e.g., the insulating paper 24 described later) to assemble the stator (e.g., the stator core 200 described later). The stator assembly method includes the following steps: before inserting the coil into the slot, inserting at least one first guide member (e.g., the advance guide member 61 described later) relative to one of the slots from the outside of the central axis direction of the stator core, in a manner disposed inside the insulating component in the slot; and inserting a plurality of second guide members relative to one of the slots in a manner disposed inside the insulating component and further radially outward than the first guide member in the slot. The process of the guide (e.g., the reinforcing guide member 62, the first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c described later); the process of moving the aforementioned coil toward the aforementioned slot and abutting against the aforementioned first guide member, and moving the aforementioned first guide member toward the radially outward side of the aforementioned slot as the aforementioned coil moves; and the process of, after the aforementioned first guide member moves toward the radially outward side of the aforementioned slot until it abuts or approaches the aforementioned second guide member disposed on the inner diameter side among the plurality of the aforementioned second guide members, first moving the aforementioned first guide member outward in the direction of the central axis of the aforementioned stator core to retract from the aforementioned slot, and then, as the aforementioned coil moves toward the radially outward side, moving the plurality of the aforementioned second guide members sequentially from the inner diameter side toward the outer direction of the central axis of the aforementioned stator core to retract from the aforementioned slot.

[0020] (10) Optionally, in accordance with the stator assembly method described in (8) or (9) above, the first guide member pushes the coil toward the radial inner side of the stator core during the period when the first guide member is moved by the coil.

[0021] (11) According to any one of (8) to (10) above, the process of inserting the first guide member and the second guide member into the slot is optionally the process of inserting the first guide member into the slot in such a way that at least a portion of the first guide member is hung in the opening end (e.g., the opening end 24a described later) of the insulating member in the slot.

[0022] (12) According to any one of (8) to (11) above, the stator assembly method may optionally be arranged face-to-face on both sides of the central axis direction of the stator core, and the process of inserting the first guide member and the second guide member into the slot is as follows: the first guide member and the second guide member are inserted from the two outer sides of the central axis direction of the stator core into the slot, and the first guide member and the second guide member are arranged in the slot with their front ends facing each other.

[0023] (13) In the stator assembly method according to any one of (8) to (12) above, optionally, the longitudinal widths (e.g., the longitudinal widths W11 and W21 described later) of the first guide member and the second guide member along the radial direction of the stator core are approximately the same.

[0024] (14) In the stator assembly method according to any one of (8) to (13) above, optionally, the lateral width (e.g., the lateral width W12, W22 described later) of the first guide member and the second guide member along the circumference of the stator core is greater than the width (e.g., the width W0 described later) of the coil along the circumference of the stator core.

[0025] (The effect of the invention)

[0026] According to (1) above, when the coil is inserted into the slot from the inside of the stator core, the first guide member and a plurality of second guide members are supported by opening the insulating member assembled in the slot. Furthermore, as the first guide member moves within the slot while being pushed by the coil, the plurality of second guide members retract sequentially from the slot. Therefore, the space within the slot can be kept below a set thickness (the radial thickness of the guide member). Thus, the coil can be inserted into the slot without biting into or winding into the insulating member, and the bending resistance of the insulating member can be improved. By changing the radial thickness of each guide member, variations in coil tension (rigidity) and insertion load can be easily accommodated.

[0027] According to (2) above, when the coil is inserted into the slot from the inside of the stator core, the first guide member and the plurality of second guide members are supported by opening the insulating member assembled in the slot. Furthermore, as the coil moves within the slot, the first guide member and the plurality of second guide members retract sequentially from the slot from the inner diameter side, from the first guide member to the plurality of second guide members. Therefore, the space within the slot can be kept below a set thickness (the radial thickness of the guide member). Thus, the coil can be inserted into the slot without biting into or winding into the insulating member, and the bending resistance of the insulating member can be improved. By changing the radial thickness of each guide member, variations in coil tension (rigidity) and insertion load can be easily accommodated. Since the first guide member retracts from the slot first, the distance the first guide member moves radially while rubbing against the insulating member can be suppressed, and the insulating member can be prevented from contacting and twisting with the radially moving first guide member.

[0028] According to (3) above, by pressing the coil toward the radial inner side of the stator core by the first guide member, the deviation of the front side of the coil's movement direction can be suppressed.

[0029] According to (4) above, by placing the first guide member inside the opening of the insulating member, the opening of the insulating member can be kept open before the coil is inserted. This prevents the coil moving toward the slot from contacting the insulating member, thus allowing the coil to be smoothly guided into the inside of the insulating member.

[0030] According to (5) above, since the moving distance of the first guide component and the plurality of second guide components toward the slot is reduced, the device can be miniaturized and space-saving can be achieved.

[0031] According to (6) above, as the coil and the first guide member move, the multiple second guide members are successively retracted from the slot, the width of the radial gap in the slot can be maintained below a fixed width. Therefore, the effect of being supported by the first guide member and the multiple second guide members in the manner of opening the insulating member can be taken into account, as well as the effect of improving the insertability of the coil.

[0032] According to (7) above, it is possible to more reliably prevent the coil moving toward the slot from biting into the insulating part inside the slot while the first guide member and a plurality of second guide members are supported in a manner that opens the insulating part.

[0033] According to (8) above, when the coil is inserted into the slot from the inside of the stator core, the first guide member and a plurality of second guide members are supported by opening the insulating member assembled in the slot. Furthermore, as the first guide member moves within the slot while being pushed by the coil, the plurality of second guide members retract sequentially from the slot. Therefore, the space within the slot can be kept below a set thickness (the radial thickness of the guide member). Thus, the coil can be inserted into the slot without biting into or winding into the insulating member, and the bending resistance of the insulating member can be improved. By changing the radial thickness of each guide member, variations in coil tension (rigidity) and insertion load can be easily accommodated.

[0034] According to (9) above, when the coil is inserted into the slot from the inside of the stator core, the first guide member and the plurality of second guide members are supported by opening the insulating member assembled in the slot. Furthermore, as the coil moves within the slot, the first guide member and the plurality of second guide members retract sequentially from the slot from the inner diameter side, from the first guide member to the plurality of second guide members. Therefore, the space within the slot can be kept below a set thickness (the radial thickness of the guide member). Thus, the coil can be inserted into the slot without biting into or winding into the insulating member, and the bending resistance of the insulating member can be improved. By changing the radial thickness of each guide member, variations in coil tension (rigidity) and insertion load can be easily accommodated. Since the first guide member retracts from the slot first, the distance the first guide member moves radially while rubbing against the insulating member can be suppressed, and the insulating member can be prevented from contacting and twisting with the radially moving first guide member.

[0035] According to (10) above, during the movement of the coil by the first guide member being pushed towards the inner side of the stator core, the deviation of the front side of the movement direction of the coil can be suppressed.

[0036] According to (11) above, by placing the first guide member inside the opening of the insulating member, the opening of the insulating member can be kept open before the coil is inserted. As a result, contact between the coil moving toward the slot and the insulating member can be suppressed, and thus the coil can be smoothly guided into the inside of the insulating member.

[0037] According to (12) above, since the moving distance of the first guide member and the plurality of second guide members toward the slot is reduced, the device can be miniaturized and space-saving can be achieved.

[0038] According to (13) above, as the coil and the first guide member move, the multiple second guide members are successively retracted from the slot, the width of the radial gap in the slot can be maintained below a fixed width. Therefore, the effect of being supported by the first guide member and the multiple second guide members in the manner of opening the insulating member can be taken into account, as well as the effect of improving the insertability of the coil.

[0039] According to (14) above, it is possible to more reliably prevent the coil moving toward the slot from biting into the insulating part inside the slot while the first guide member and a plurality of second guide members are supported in such a way as to open the insulating part. Attached Figure Description

[0040] Figure 1 This is a side view showing the appearance of the stator assembly.

[0041] Figure 2 It is a perspective view showing the positioning fixture and coil winding fixture in the stator assembly device.

[0042] Figure 3 It is a three-dimensional drawing showing the insulating components assembled in the slots of the stator core.

[0043] Figure 4 This is a diagram showing the unfolded form of an example coil.

[0044] Figure 5 It is a perspective view showing the installation of a coil expansion device on a coil winding jig mounted on the inside of the stator core.

[0045] Figure 6 This is a diagram showing the guide mechanism in the stator assembly as viewed from the central axis direction.

[0046] Figure 7 It is a cross-sectional view of the first guide component in the guide mechanism.

[0047] Figure 8 This is a cross-sectional view of the second guide component in the guide mechanism.

[0048] Figure 9 It is a diagram illustrating the insertion of the first guide component and the second guide component into the slot of the stator core.

[0049] Figure 10A It is a diagram illustrating the process of inserting the coil into the slot from the inside of the stator core.

[0050] Figure 10B It is a diagram illustrating the process of inserting the coil into the slot from the inside of the stator core.

[0051] Figure 10CIt is a diagram illustrating the process of inserting the coil into the slot from the inside of the stator core.

[0052] Figure 10D It is a diagram illustrating the process of inserting the coil into the slot from the inside of the stator core.

[0053] Figure 10E It is a diagram illustrating the process of inserting the coil into the slot from the inside of the stator core.

[0054] Figure 10F It is a diagram illustrating the process of inserting the coil into the slot from the inside of the stator core.

[0055] Figure 10G It is a diagram illustrating the process of inserting the coil into the slot from the inside of the stator core.

[0056] Figure 10H It is a diagram illustrating the process of inserting the coil into the slot from the inside of the stator core.

[0057] Figure 10I It is a diagram illustrating the process of inserting the coil into the slot from the inside of the stator core.

[0058] Figure 10J It is a diagram illustrating the process of inserting the coil into the slot from the inside of the stator core.

[0059] Figure 11A It is a diagram illustrating the insertion of a coil into a slot.

[0060] Figure 11B It is a diagram illustrating the insertion of a coil into a slot.

[0061] Figure 11C It is a diagram illustrating the insertion of a coil into a slot.

[0062] Figure 11D It is a diagram illustrating the insertion of a coil into a slot.

[0063] Figure 11E It is a diagram illustrating the insertion of a coil into a slot.

[0064] Figure 11F It is a diagram illustrating the insertion of a coil into a slot.

[0065] Figure 11G It is a diagram illustrating the insertion of a coil into a slot.

[0066] Figure 11H It is a diagram illustrating the insertion of a coil into a slot.

[0067] Figure 11I It is a diagram illustrating the insertion of a coil into a slot.

[0068] Figure 11J It is a diagram illustrating the insertion of a coil into a slot.

[0069] Figure 12 It is a three-dimensional drawing showing the appearance of the stator.

[0070] Figure 13A This is a diagram illustrating another embodiment of inserting a coil into a slot.

[0071] Figure 13B This is a diagram illustrating another embodiment of inserting a coil into a slot.

[0072] Figure 13C This is a diagram illustrating another embodiment of inserting a coil into a slot.

[0073] Figure 13D This is a diagram illustrating another embodiment of inserting a coil into a slot.

[0074] Figure 13E This is a diagram illustrating another embodiment of inserting a coil into a slot.

[0075] Figure 13F This is a diagram illustrating another embodiment of inserting a coil into a slot.

[0076] Figure 13G This is a diagram illustrating another embodiment of inserting a coil into a slot.

[0077] Figure 13H This is a diagram illustrating another embodiment of inserting a coil into a slot.

[0078] Figure 13I This is a diagram illustrating another embodiment of inserting a coil into a slot.

[0079] Figure 13J This is a diagram illustrating another embodiment of inserting a coil into a slot. Detailed Implementation

[0080] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Figure 1 , Figure 2 As shown, the stator assembly device 1 includes: a stator core 2; a positioning clamp 3 for positioning and fixing the stator core 2; a coil winding clamp 4 for winding a strip coil 100 in a circular shape; a coil expansion mechanism 5 for expanding the strip coil 100 wound on the coil winding clamp 4; and a guiding mechanism 6 for guiding the strip coil 100 into the slot 22 of the stator core 2.

[0081] The stator core 2 has an annular portion 21, for example, formed by a stack of multiple thin-walled core plates. A through-hole 20 extending axially is present at the center of the annular portion 21. The stator core 2 has a plurality of slots 22 extending axially. The slots 22 are arranged radially at fixed intervals along the circumference of the annular portion 21 and have openings 22a that open toward the through-hole 20 radially inward of the annular portion 21. The stator core 2 of this embodiment has 72 slots 22. Six lugs 23 protrude at fixed intervals on the outer periphery of the annular portion 21 of the stator core 2.

[0082] In addition, such as Figure 2 As shown, in the stator core 2 and the positioning fixture 3, 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, orthogonal to the X and Y directions and along the central axis of the through hole 20 of the stator core 2, is the central axis direction.

[0083] like Figure 1 and Figure 2 As shown, the positioning clamp 3 has a stator core insertion hole 31 in the center. The stator core insertion hole 31 is formed into a hexagonal prism shape with a dimension in the central axis direction that is approximately equal to that of the stator core 2, allowing the stator core 2 to be inserted. The positioning clamp 3 supports the six lugs 23 of the stator core 2, thereby fixing the stator core 2 in a predetermined position and posture within the stator core insertion hole 31. In the stator assembly apparatus 1 of this embodiment, the positioning clamp 3 is fixed to the center of the base 11 of the stator assembly apparatus 1 so that the central axis direction of the stator core 2 fixed within the stator core insertion hole 31 is horizontal.

[0084] like Figure 3 As shown, insulating paper 24, serving as insulating components, is pre-assembled in the slots 22 of the stator core 2. The insulating paper 24 is bent into a roughly U-shape, mimicking the roughly U-shaped inner surface shape of the slots 22 when viewed from the axial direction. The insulating paper 24 opens toward the through-hole 20 on the radially inner side of the stator core 2. Its open end 24a is positioned at the opening 22a of the slot 22, opening the inner side of the insulating paper 24 toward the through-hole 20.

[0085] like Figure 2As shown, on both end faces 3a, 3a of the positioning fixture 3 along the central axis, a plurality of flanged guides 32 are arranged radially at fixed intervals in the circumferential direction, forming long strips of thin plates. When the strip coil 100 (described later) is inserted into the slot 22 of the stator core 2, the flanged guides 32 support the insulating paper 24 protruding from both end faces of the stator core 2 along the central axis and guide the strip coil 100 to move into the slot 22. The flanged guides 32 are respectively configured to move radially forward and backward along the stator core 2 by means of an actuator such as a cylinder (not shown).

[0086] The coil winding jig 4 has a generally cylindrical jig body 41 and a plurality of comb-like teeth 42 that radiate outward from the outer periphery of the jig body 41. The comb-like teeth 42 are respectively provided at both ends in the direction of the central axis of the jig body 41. The number of adjacent comb-like teeth 42 in the circumferential direction of the jig body 41 is the same as the number of slots 22 provided on the stator core 2. The coil winding jig 4 is formed such that the outer diameter of the coil winding jig 4, defined by the position of the front end of the comb-like teeth 42, is less than the diameter of the through hole 20 of the stator core 2, so that it can be inserted into the through hole 20 of the stator core 2.

[0087] A strip coil 100, for mounting on the stator core 2, is wound in a circular pattern on multiple comb-tooth sections 42 of the coil winding fixture 4. For example... Figure 4 As shown, the strip coil 100 is composed of a continuous wave-wound coil in the shape of a long strip formed by a flat conductor 101 with a generally rectangular cross-sectional shape. Regarding the continuous wave-wound coil, when placing the coil in the slot of the stator core, the commonly used technique of dividing the coil into multiple segments and welding the ends after insertion into the slot is not required. Therefore, for example, it is no longer necessary to use high-purity copper in the coil to withstand heat treatment at the welding points. Thus, recycled copper containing impurities can be used, which is beneficial for resource recycling. Furthermore, since the wave-wound coil does not require welding, the coil can be lightweight, and the rotating electric motor using the coil can also be lightweight. When the rotating electric motor is installed in a hybrid vehicle, the reduction in vehicle weight can reduce carbon dioxide emissions, thereby mitigating the adverse impact on the global environment.

[0088] The strip coil 100 has multiple straight portions 102 and multiple coil end portions 103. The straight portions 102 are parts that are inserted into the slots 22 of the stator core 2, extending generally in a straight line and arranged parallel to each other at fixed intervals. The coil end portions 103 are each located further to the side end of the strip coil 100 than the straight portions 102, and adjacent straight portions 102 are alternately connected at one end to the other along the length of the strip coil 100 to form a generally triangular, mountain-shaped structure. The coil end portions 103 protrude from the slots 22 along the axial direction of the stator core 2 when the strip coil 100 is assembled into the slots 22 of the stator core 2, and are pressed by the coil expansion mechanism 5 (described later) when the strip coil 100 is inserted into the slots 22. The strip coil 100 of this embodiment is formed into a long strip by bundling six flat wires 101, which are bent to form multiple straight sections 102 and multiple coil end sections 103, in a parallel manner with straight sections 102 arranged at fixed intervals.

[0089] Before being inserted into the through hole 20 of the stator core 2, the coil winding jig 4 winds the strip coil 100 multiple times by sequentially inserting the straight portion 102 of the strip coil 100 from the outside into the comb portions 42, 42. Thus, as... Figure 2 As shown, a coil winding fixture 4 is configured to form a circular coil 100 wound around a strip coil.

[0090] The coil winding clamp 4, inserted into the through hole 20 inside the stator core 2, is supported by a pair of coil expansion mechanism parts 5 that clamp the positioning clamp 3 in the middle and are arranged face-to-face on both sides of the central axis of the stator core 2, thereby being held in a predetermined position and maintained in a predetermined posture. Figure 5 As shown, the coil expansion mechanism 5 of this embodiment has a generally cylindrical external shape, and as... Figure 1 As shown, the coil winding clamp 4 is arranged opposite to the coil winding clamp 4 inserted into the inside of the stator core 2 from the direction of the central axis. The coil expansion mechanism 5 is configured to move linearly on the base 11 by means of an actuator (not shown), and to move in the direction of contact with the coil winding clamp 4 and away from it, respectively.

[0091] The coil expansion mechanism 5 is generally cylindrical and has multiple coil pressing portions 51 on its outer periphery at the front end. These multiple coil pressing portions 51 are arranged along the outer periphery at the front end of the coil expansion mechanism 5 and are configured to expand and contract radially by an actuator (not shown). In the contracted state, the outer diameter of the coil pressing portion 51 is less than the inner diameter of the annular strip coil 100 wound on the coil winding jig 4. In the expanded state, the outer diameter of the coil pressing portion 51 is larger than the outer diameter of the coil winding jig 4. The coil expansion mechanism 5 holds the coil winding jig 4 by inserting the coil pressing portion 51 in the contracted state into the inner side of the annular strip coil 100 wound on the coil winding jig 4. When the coil pressing portion 51 inserted into the inner side of the strip coil 100 expands, the strip coil 100 is pushed outwards and its diameter expands. As a result, the straight portion 102 of the strip coil 100 moves toward the inside of the insulating paper 24 disposed in the slot 22 on the radially outer side and is inserted into the slot 22. The coil pushing portion 51 of the coil expansion mechanism portion 5 constitutes a pushing means, which pushes the strip coil 100 toward the radially outer side, causing the straight portion 102 of the strip coil 100 to move to the inside of the insulating paper 24 in the slot 22.

[0092] like Figure 1 As shown, the guide mechanism 6, like the coil expansion mechanism 5, clamps the positioning clamp 3 in the middle and is arranged as a pair facing each other on both sides of the central axis of the stator core 2. The pair of guide mechanism parts 6 are respectively arranged in a coaxial shape on the outer periphery of the coil expansion mechanism 5.

[0093] Since the pair of guide mechanism parts 6 have the same structure, therefore refer to Figures 6-8 The structure of one of the guiding mechanisms, part 6, will be explained. Figure 6 This is a view of one of the guide mechanism sections 6 as seen along the central axis of the stator core 2. The guide mechanism section 6 has a plurality of leading guide members 61 arranged in a ring, and a plurality of reinforcing guide members 62 arranged in a ring outside the leading guide members 61. The leading guide members 61 correspond to the first guide members, and the reinforcing guide members 62 correspond to the second guide members.

[0094] The guide member 61 is a rod-shaped body with sufficient length to be inserted along the central axis of the stator core 2 into the inner side of the insulating paper 24 fitted into the slot 22. The cross-section orthogonal to the long side of the guide member 61, except for the pointed front end, is a quadrilateral shape with rounded corners. The longitudinal width W11 of the guide member 61 along the radial direction of the stator core 2 (see reference) Figure 11AThe depth of the slot 22 along the radial direction of the stator core 2 is sufficiently smaller than that of the slot 22. In this embodiment, the longitudinal width W11 of the guide member 61 is set to approximately 1 / 5 of the depth of the slot 22. The lateral width W12 of the guide member 61 along the circumference of the stator core 2 (see reference) Figure 11A The width of the guide member 61 along the circumference of the stator core 2 is less than the width of the straight portion 102 of the strip coil 100 inserted into the slot 22. The lateral width W12 of the guide member 61 is greater than the width W0 along the circumference of the stator core 2 of the straight portion 102 of the strip coil 100 inserted into the slot 22 (see reference). Figure 11A (It is larger.)

[0095] At least one advance guide member 61 is provided relative to each slot 22, arranged in a ring with the same arrangement spacing as the slot 22. In this embodiment, one advance guide member 61 is provided relative to each slot 22, but multiple advance guide members 61 may also be provided relative to each slot 22.

[0096] like Figure 7 As shown, operating portions 611 protruding radially outward in an annular shape are formed on the base end side of the guide member 61. Guide holes 612 extending radially outward are provided in the operating portions 611. Within the guide holes 612, a radially ( Figure 7 The support plate portion 601, which is slidably engaged with the guide mechanism portion 6 in the vertical direction, allows the advance guide member 61 to be movably supported on the guide mechanism portion 6 in the radial direction.

[0097] At the front end of the operating section 611, one end of the connecting plate 613 is rotatably mounted via a rotating shaft 613a. The other end of the connecting plate 613 extends in the opposite direction to the extending direction of the advance guide member 61 relative to the operating section 611. Figure 7 Extending to the right, it is rotatably mounted on the advance guide member support 602 of the guide mechanism section 6 via the rotating shaft 613b. On the other end of the connecting plate 613, which is opposite to the operating section 611 relative to the rotating shaft 613b, an elastic member 614, such as a helical spring that applies force to the other end of the connecting plate 613 in a radially outward direction, is provided.

[0098] By applying force to the other end of the connecting plate 613 radially outward via the elastic member 614, the guide member 61 is pushed by the connecting plate 613 and is always pressed radially inward. However, when the pushing force exerted on the guide member 61 from radially inward toward outward exceeds the elastic force of the elastic member 614, the guide member 61 can move along... Figure 7The hollow arrow in the middle moves in a radially outward expansion manner. When the pushing force is released, the leading guide member 61 returns to a stable state by radially inward contraction due to the elastic force of the elastic member 614.

[0099] Multiple advance guide members 61 are configured to move along the central axis of the stator core 2 by means of an actuator 610 for driving the first guide member provided in the guide mechanism section 6. The actuator 610 is composed of... Figure 1 The control unit 10 of the stator assembly apparatus 1 shown is used for control. When the actuator 610 is driven, the actuator 610 causes the advance guide member support 602 to move along the central axis direction of the stator core 2 in the direction toward the stator core 2 and in the direction away from the stator core 2. By moving the advance guide member support 602 in the direction toward the stator core 2, a plurality of advance guide members 61 are inserted from the central axis direction of the stator core 2 into the inner side of the insulating paper 24 in the corresponding slot 22. By moving the advance guide member support 602 in the direction away from the stator core 2, a plurality of advance guide members 61 disengage from the inner side of the insulating paper 24 in the slot 22 to the outer side in the central axis direction of the stator core 2.

[0100] The reinforcing guide member 62 is composed of a rod-shaped body having a length that allows it to be inserted along the central axis of the stator core 2 into the inner side of the insulating paper 24 fitted into the slot 22, and this length is shorter than the length of the preceding guide member 61. The cross-section orthogonal to the long side of the reinforcing guide member 62 is a quadrilateral shape with rounded corners, except for the pointed front end. The longitudinal width W21 of the reinforcing guide member 62 along the radial direction of the stator core 2 (see reference) Figure 11A The longitudinal width W11 of the leading guide member 61 is approximately the same. The transverse width W22 of the reinforcing guide member 62 along the circumference of the stator core 2 (refer to...) Figure 11A It is approximately the same as the lateral width W12 of the lead guide component 61.

[0101] Three reinforced guide members 62 are provided for each slot 22. Specifically, each reinforced guide member 62 consists of a first reinforced guide member 62a on the innermost diameter side, a second reinforced guide member 62b disposed outside the first reinforced guide member 62a, and a third reinforced guide member 62c disposed radially outside the second reinforced guide member 62b. The first reinforced guide member 62a, the second reinforced guide member 62b, and the third reinforced guide member 62c are arranged in a ring with the same spacing as the slot 22, and are stacked radially. However, the distance L between the first reinforced guide member 62a on the innermost diameter side and the preceding guide member 61 is equivalent to the longitudinal width W11 of one preceding guide member 61 and the longitudinal width W21 of one first reinforced guide member 62a, the second reinforced guide member 62b, and the third reinforced guide member 62c (refer to...). Figure 9 , Figure 11A The specific distance L is set appropriately according to the specifications of the slot 22, the type of insulating paper 24, etc., and is not particularly limited, but it is set to 4.2mm in this embodiment.

[0102] like Figure 8 As shown, the front ends of the first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c are each formed into a tapered shape. Operating portions 621a, 621b, and 621c, respectively, protruding radially outward in an annular shape, are formed on the base end sides of the first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c. The operating portions 621a, 621b, and 621c are each independently connected to the actuator 620 of the guide mechanism section 6.

[0103] The first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c are configured to move independently along the central axis of the stator core 2 by means of an actuator 620 for driving the reinforcing guide members provided in the guide mechanism section 6. The actuator 620 is composed of the first reinforcing guide actuator 620a, the second reinforcing guide actuator 620b, and the third reinforcing guide actuator 620c, and consists of... Figure 1 The control unit 10 of the stator assembly device 1 shown is controlled independently.

[0104] When actuator 620 is driven, it causes the first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c to move independently along the central axis of the stator core 2, in the direction toward and away from the stator core 2. By moving the first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c toward the stator core 2, they are inserted from the central axis of the stator core 2 into the inner side of the insulating paper 24 within the corresponding slot 22. By moving the first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c away from the stator core 2, they are able to independently disengage from the inner side of the insulating paper 24 within the slot 22 to the outer side of the central axis of the stator core 2.

[0105] Next, the process of inserting the straight portion 102 of the strip coil 100 into the inside of the insulating paper 24 in the slot 22 of the stator core 2 in the stator assembly device 1 will be described. Figure 9 and Figures 10A to 10J The diagram schematically illustrates the process of inserting a strip coil 100 wound on a coil winding jig 4 from the inside of the stator core 2 into the inside of the insulating paper 24 within the slot 22 of the stator core 2. Since the actions on both sides of the stator core 2 along its central axis are performed synchronously, therefore... Figures 10A to 10J The operation process of only one side of the stator core 2 in the direction of the central axis is shown. Figures 11A to 11J The diagram schematically illustrates the advance guide 61 and the reinforcing guide 62 within a slot 22 of the stator core 2. Figures 11A to 11J In terms of time and Figures 10A to 10J Corresponding. Furthermore, in these... Figure 9 , Figures 10A to 10J and Figures 11A to 11J The illustration of positioning fixture 3 is omitted in the text.

[0106] First, such as Figure 9 As shown, after the coil winding jig 4 for winding the strip coil 100 is supported by the coil expansion mechanism 5 in the through hole 20 of the stator core 2, the actuators 610 and 620 of the guide mechanism 6 are driven and controlled by the control unit 10 to insert the advance guide member 61 and the reinforcing guide member 62 from both outer sides in the direction of the central axis of the stator core 2 into the inner side of the insulating paper 24 in the slot 22. The front ends of the advance guide member 61 and the reinforcing guide member 62 inserted into the inner side of the insulating paper 24 in the slot 22 are arranged facing each other in the slot 22.

[0107] With the guide component 61 and the reinforcing guide component 62 just inserted into the inner side of the insulating paper 24 inside the slot 22, as follows: Figure 10A and Figure 11A As shown, at least a portion of the advance guide member 61 is disposed within the slot 22, suspended within the opening 24a of the insulating paper 24. That is, the advance guide member 61 is disposed between a pair of openings 24a, 24a of the insulating paper 24. The first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62 are disposed radially outward (inner side of the slot 22) and stacked within the slot 22. The advance guide member 61 is separated from the first reinforcing guide member 62a on the innermost diameter side by a distance L.

[0108] Thus, the state in which the advance guide member 61 and the reinforcing guide member 62 are inserted into the inner side of the insulating paper 24 in the slot 22 is similar to the state in which the straight portion 102 of the strip coil 100 is inserted into the inner side of the insulating paper 24. Therefore, the state of the insulating paper 24 before the straight portion 102 of the strip coil 100 is inserted is the state of the insulating paper 24 after the straight portion 102 of the strip coil 100 is inserted, and the shape of the insulating paper 24 is maintained in a suitable shape before the strip coil 100 is inserted. Moreover, since it is arranged in the slot 22 with at least a part of the advance guide member 61 hanging in the open end 24a of the insulating paper 24, the open end 24a of the insulating paper 24 can be kept open before the strip coil 100 is inserted. As a result, contact between the insulating paper 24 and the moving strip coil 100 can be suppressed, so the strip coil 100 can be smoothly guided into the inner side of the insulating paper 24.

[0109] After the insertion of the pre-guide member 61 and the reinforcing guide member 62 is completed, the control unit 10 activates the coil expansion mechanism 5, causing the coil pushing part 51 to... Figure 10A The blank arrows shown indicate the direction of the diameter expansion. As a result, the coil end 103 of the strip coil 100 wound on the coil winding jig 4 is pushed by the expanded coil pressing portion 51 and moves radially outward toward the stator core 2. With this movement, the strip coil 100 gradually expands in diameter, and the straight portion 102 slowly moves toward the inside of the insulating paper 24 within the slot 22. Figure 10A , Figure 11A ).

[0110] The expanded-diameter strip coil 100 abuts against the leading guide member 61 positioned in front of the moving direction of the strip coil 100. Further pressure from the coil pressing part 51 pushes the leading guide member 61 radially outward toward the stator core 2. The leading guide member 61, pushed by the strip coil 100, moves radially outward in a manner that overcomes the elastic force of the elastic member 614 and shortens the distance L. Thus, the leading guide member 61, pushed by the strip coil 100, abuts against or approaches the first reinforcing guide member 62a positioned on the innermost diameter side of the reinforcing guide member 62. Figure 10B , Figure 11B ).

[0111] When the guide member 61 is pressed by the strip coil 100, the elastic force of the elastic member 614 generates a radially inward pressing force on the guide member 61. Therefore, while the guide member 61 moves by being pushed by the strip coil 100, it presses radially inward toward the coil pressing part 51 while moving inside the insulating paper 24. As a result, the strip coil 100 is always held between the guide member 61 and the coil pressing part 51 during movement, thus suppressing deviation of the strip coil 100 from the forward direction of movement. In this embodiment, the connecting plate 613 and the elastic member 614 constitute a pressing means for pressing the strip coil 100 radially inward toward the stator core 2.

[0112] When the leading guide member 61 moves by a shortening distance L and comes into contact with or approaches the first reinforcing guide member 62a on the innermost diameter side, the control unit 10 drives the first reinforcing guide actuator 620a, causing the first reinforcing guide member 62a to move outward toward the central axis direction of the stator core 2. As a result, the first reinforcing guide member 62a retracts from the inside of the insulating paper 24 within the slot 22. After the first reinforcing guide member 62a retracts, the leading guide member 61 and the second reinforcing guide member 62b are separated by a distance L. Figure 10C , Figure 11C ).

[0113] As the strip coil 100 further expands in diameter, the leading guide member 61 is pushed by the strip coil 100 to move radially outward in a manner that shortens the distance L between it and the second reinforcing guide member 62b. Thus, the leading guide member 61 pushed by the strip coil 100 and the second reinforcing guide member 62b remaining in the slot 22 abut or approach the second reinforcing guide member 62b positioned on the innermost diameter side of the third reinforcing guide member 62c. Figure 10D , Figure 11D ).

[0114] When the leading guide member 61 moves by a shortening distance L and comes into contact with or approaches the second reinforcing guide member 62b, the control unit 10 drives the second reinforcing guide actuator 620b, causing the second reinforcing guide member 62b to move outward toward the central axis of the stator core 2. As a result, the second reinforcing guide member 62b retracts from the inside of the insulating paper 24 within the slot 22. After the second reinforcing guide member 62b retracts, the leading guide member 61 and the third reinforcing guide member 62c are separated by a distance L. Figure 10E , Figure 11E ).

[0115] As the strip coil 100 further expands in diameter, the leading guide member 61 is pushed by the strip coil 100 to move radially outward in a manner that shortens the distance L between it and the third reinforcing guide member 62c. Thus, the leading guide member 61, pushed by the strip coil 100, comes into contact with or approaches the third reinforcing guide member 62c, which remains in the slot 22 and is positioned on the innermost diameter side. Figure 10F , Figure 11F ).

[0116] When the leading guide member 61 moves by a shortening distance L and comes into contact with or approaches the third reinforcing guide member 62c, the control unit 10 drives the third reinforcing guide actuator 620c, causing the third reinforcing guide member 62c to move outward toward the central axis of the stator core 2. As a result, the third reinforcing guide member 62c retracts from the inside of the insulating paper 24 within the slot 22. On the inside of the insulating paper 24 after the third reinforcing guide member 62c has retracted, a gap corresponding to a distance L is formed at a position radially outward compared to the leading guide member 61. Figure 10G , Figure 11G ).

[0117] As the strip coil 100 further expands in diameter, the guide member 61 is pushed by the strip coil 100, moving radially outward in a manner that shortens the distance L remaining within the slot 22. Consequently, the guide member 61, pushed by the strip coil 100, abuts against or approaches the innermost radial wall 22b within the slot 22. Figure 10H , Figure 11H ).

[0118] When the guide member 61 moves by shortening the distance L and comes into contact with or approaches the innermost wall surface 22b of the slot 22, the control unit 10 drives the actuator 610 to move the guide member 61 outward in the direction of the central axis of the stator core 2. As a result, the guide member 61 retracts from the inside of the insulating paper 24 within the slot 22. On the inside of the insulating paper 24 after the guide member 61 has retracted, a gap equivalent to the distance L is formed between the straight portion 102 of the strip coil 100 and the wall surface 22b. Figure 10I , Figure 11I ).

[0119] As the strip coil 100 further expands in diameter, it moves radially outward in a manner that shortens the distance L remaining within the slot 22. Consequently, the straight portion 102 of the strip coil 100 is housed inside the insulating paper 24 within the slot 22. Figure 10J , Figure 11J Thus, the strip coil 100 is assembled into the slot 22 of the stator core 2, completing the stator 200. Figure 12 ).

[0120] In the above embodiments, after the lead guide member 61 and the plurality of reinforcing guide members 62 are inserted into the slot 22, the lead guide member 61 is the last to retract from the slot 22. However, the lead guide member 61 may also retract first. An embodiment in which the lead guide member 61 retracts first is shown below. Figures 13A to 13J . Figures 13A to 13J The diagram schematically illustrates the advance guide member 61 and the reinforcing guide member 62 within a slot 22 of the stator core 2. It also schematically illustrates the process of inserting a strip coil 100 wound on a coil winding jig 4 from the inside of the stator core 2 into the inside of the insulating paper 24 within the slot 22 of the stator core 2. Except for the different retraction order of the advance guide member 61 and the reinforcing guide member 62, the process is identical to the previous diagram. Figures 10A to 10J Since they are the same, the illustration is omitted.

[0121] The state after the guide component 61 and the reinforcing guide component 62 have been fully inserted into the inner side of the insulating paper 24 in the slot 22 is as follows: Figure 13A As shown, the advance guide member 61 is disposed between a pair of open ends 24a, 24a of the insulating paper 24, similar to the embodiment described above. The first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62 are disposed radially outward (inner side of the slot 22) stacked within the slot 22. The advance guide member 61 is separated from the first reinforcing guide member 62a on the innermost diameter side by a distance L. After the advance guide member 61 and the reinforcing guide member 62 are inserted, as the strip coil 100 is gradually expanded in diameter by being pushed by the coil pushing part 51, the straight part 102 slowly moves toward the inner side of the insulating paper 24 within the slot 22. Figure 13A ).

[0122] The expanded-diameter strip coil 100 abuts against the leading guide member 61 positioned in front of the moving direction of the strip coil 100. Further pressure from the coil pressing part 51 pushes the leading guide member 61 radially outward toward the stator core 2. The leading guide member 61, pushed by the strip coil 100, moves radially outward in a manner that overcomes the elastic force of the elastic member 614 and shortens the distance L. Thus, the leading guide member 61, pushed by the strip coil 100, abuts against or approaches the first reinforcing guide member 62a positioned on the innermost diameter side of the reinforcing guide member 62. Figure 13B ).

[0123] When the lead guide member 61 is pressed by the strip coil 100, the elastic force of the elastic member 614 generates a radially inward pressing force on the lead guide member 61. Therefore, while the lead guide member 61 is being pushed and moved by the strip coil 100, it is pressed radially inward toward the coil pressing part 51 while moving inside the insulating paper 24. As a result, the strip coil 100 is clamped between the lead guide member 61 and the coil pressing part 51 until the lead guide member 61 comes into contact with or approaches the first reinforcing guide member 62a, thus suppressing the forward deviation of the moving direction of the strip coil 100 during this period.

[0124] When the lead guide member 61 moves by a shortening distance L and comes into contact with or approaches the first reinforcing guide member 62a on the innermost diameter side, the control unit 10 drives the actuator 610 to move the lead guide member 61 outward in the direction of the central axis of the stator core 2. As a result, the lead guide member 61 retracts from the inside of the insulating paper 24 within the slot 22. After the lead guide member 61 retracts, the strip coil 100 is separated from the first reinforcing guide member 62a disposed on the innermost diameter side by a distance L. Figure 13C ).

[0125] As the strip coil 100 further expands in diameter, it moves radially outward in a manner that shortens the distance L between itself and the first reinforcing guide member 62a. Consequently, the strip coil 100 comes into contact with or approaches the first reinforcing guide member 62a located on the innermost diameter side within the slot 22. Figure 13D ).

[0126] When the strip coil 100 moves by a shortening distance L and comes into contact with or approaches the first reinforcing guide member 62a, the control unit 10 drives the first reinforcing guide actuator 620a, causing the first reinforcing guide member 62a to move outward toward the central axis of the stator core 2. As a result, the first reinforcing guide member 62a retracts from the inside of the insulating paper 24 within the slot 22. After the first reinforcing guide member 62a retracts, the strip coil 100 is separated from the second reinforcing guide member 62b, which is located on the innermost diameter side, by a distance L. Figure 13E ).

[0127] As the strip coil 100 further expands in diameter, it moves radially outward in a manner that shortens the distance L between itself and the second reinforcing guide member 62b. Consequently, the strip coil 100 comes into contact with or approaches the second reinforcing guide member 62b located on the innermost diameter side of the slot 22. Figure 13F ).

[0128] When the strip coil 100 moves by a shortening distance L and comes into contact with or approaches the second reinforcing guide member 62b, the control unit 10 drives the second reinforcing guide actuator 620b, causing the second reinforcing guide member 62b to move outward toward the central axis of the stator core 2. As a result, the second reinforcing guide member 62b retracts from the inside of the insulating paper 24 within the slot 22. After the second reinforcing guide member 62b retracts, the strip coil 100 is separated from the third reinforcing guide member 62c, which is located on the innermost diameter side, by a distance L. Figure 13G ).

[0129] As the strip coil 100 further expands in diameter, it moves radially outward in a manner that shortens the distance L remaining within the slot 22. Consequently, the strip coil 100 comes into contact with or approaches the third reinforcing guide member 62c remaining within the slot 22. Figure 13H ).

[0130] When the strip coil 100 moves by shortening the distance L and comes into contact with or approaches the third reinforcing guide member 62c remaining in the slot 22, the control unit 10 drives the third reinforcing guide actuator 620c, causing the third reinforcing guide member 62c to move outward toward the central axis of the stator core 2. As a result, the third reinforcing guide member 62c retracts from the inside of the insulating paper 24 within the slot 22. On the inside of the insulating paper 24 after the third reinforcing guide member 62c has retracted, a gap equivalent to the distance L is formed between the straight portion 102 of the strip coil 100 and the wall surface 22b. Figure 13I ).

[0131] As the strip coil 100 further expands in diameter, it moves radially outward in a manner that shortens the distance L remaining within the slot 22. Consequently, the straight portion 102 of the strip coil 100 is housed inside the insulating paper 24 within the slot 22. Figure 13J ).

[0132] The stator assembly apparatus 1 and stator assembly method according to the above embodiments achieve the following effects. That is, the stator assembly apparatus 1 inserts the strip coil 100 into the slot 22 of the stator core 2 from the inside of the stator core 2 which is fitted with insulating paper 24, thereby assembling the stator 200. The stator assembly device 1 includes: a coil pushing part 51 of a coil expansion mechanism 5, which pushes the strip coil 100 radially outward, causing the strip coil 100 to move to the inside of the insulating paper 24 in the slot 22; a lead guide member 61, one of which is provided relative to each slot 22, and is configured to move along the central axis of the stator core 2, and is inserted into the inside of the insulating paper 24 in the slot 22 by moving toward the stator core 2; a plurality of reinforcing guide members 62 (first reinforcing guide member 62a, second reinforcing guide member 62b, and third reinforcing guide member 62c), multiple of which are provided relative to each slot 22, and are configured to move along the central axis of the stator core 2, and are inserted into the inside of the insulating paper 24 and at a position further radially outward than the lead guide member 61 in the slot 22 by moving toward the stator core 2; and a control part 10, which controls the movement of the lead guide member 61 and the reinforcing guide member 62 along the central axis of the stator core 2. The advance guide member 61 is configured such that, when inserted into the slot 22, with at least a portion of it hanging in the opening end 24a of the insulating paper 24 within the slot 22, it is positioned in front of the moving direction of the strip coil 100, which is moved by the coil pushing part 51 of the coil expansion mechanism 5, and is pushed by the strip coil 100 to move radially outward toward the slot 22. The control unit 10 controls the movement as follows: after the advance guide member 61 moves radially outward toward the slot 22 until it comes into contact with or approaches any of the reinforcing guide members 62 (first reinforcing guide member 62a, second reinforcing guide member 62b, and third reinforcing guide member 62c) arranged on the inner diameter side among the plurality of reinforcing guide members 62, the reinforcing guide members 62 (first reinforcing guide member 62a, second reinforcing guide member 62b, and third reinforcing guide member 62c) are moved sequentially outward toward the central axis direction of the stator core 2 from the side closest to the advance guide member 61, thereby retracting from the slot 22.

[0133] Additionally, the stator assembly method involves inserting the strip coil 100 into the slot 22 of the stator core 2 from the inside of the stator core 2 with the insulating paper 24, thereby assembling the stator 200. This includes: before inserting the strip coil 100 into the slot 22, inserting at least one advance guide member 61 relative to one slot 22 from the outside of the central axis direction of the stator core 2, such that it is positioned inside the insulating paper 24 within the slot 22; and inserting reinforcing guide members 62 (first reinforcing guide member 62a, second reinforcing guide member 62b, and third reinforcing guide member 62c) relative to one slot 22, such that they are positioned radially outward within the slot 22, inside the insulating paper 24, and further outward than the advance guide member 61 within the slot 22; with at least a portion of the advance guide member 61 within the slot 22 suspended within the opening end 24a of the insulating paper 24 within the slot 22, and with the strip coil 100 facing... The process of moving the slot 22 to abut against the advance guide member 61, and moving the advance guide member 61 radially outward toward the slot 22 as the strip coil 100 moves; and the process of moving the advance guide member 61 radially outward toward the slot 22 until it abuts or approaches any of the reinforcing guide members 62 (first reinforcing guide member 62a, second reinforcing guide member 62b, and third reinforcing guide member 62c) arranged on the inner diameter side, and then moving the first reinforcing guide member 62a, second reinforcing guide member 62b, and third reinforcing guide member 62c sequentially outward toward the central axis of the stator core 2 from the side closest to the advance guide member 61 to retract from the slot 22.

[0134] Accordingly, when the strip coil 100 is inserted into the slot 22 from the inside of the stator core 2, the advance guide member 61 and a plurality of reinforcing guide members 62 (first reinforcing guide member 62a, second reinforcing guide member 62b, and third reinforcing guide member 62c) are supported in such a way that the insulating paper 24 assembled in the slot 22 is opened. Furthermore, as the advance guide member 61 moves within the slot 22 while being pushed by the strip coil 100, the first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c sequentially retract from the slot 22. Therefore, the space within the slot 22 can be kept below a set thickness (the radial thickness of the guide member). Thus, the strip coil 100 can be inserted into the slot 22 without biting into or winding into the insulating paper 24, and the pressure and bending resistance of the insulating paper 24 can be improved. Furthermore, by changing the radial thickness of each guide component 62a, 62b, 62c, it is possible to easily accommodate changes in the tension (rigidity) and insertion load of the strip coil 100.

[0135] In the following two cases, since the advance guide member 61 retracts from the slot 22 first, in addition to the effects described above, the distance the advance guide member 61 moves radially while rubbing the insulating paper 24 can also be suppressed, and the insulating paper 24 can also be prevented from contacting and being twisted by the radially moving advance guide member 61. These two cases are: In the stator assembly device 1, the control unit 10 controls the movement as follows: After the advance guide member 61 moves radially outward toward the slot 22 until it comes into contact with or approaches the first reinforcing guide member 62a, which is positioned on the inner diameter side among the plurality of reinforcing guide members 62, the advance guide member 61 is first moved outward toward the central axis of the stator core 2 to retract from the slot 22. Subsequently, as the strip coil 100 moves radially outward via the coil pushing part 51 of the coil expansion mechanism 5, the plurality of reinforcing guide members 62... (First reinforcing guide member 62a, second reinforcing guide member 62b, and third reinforcing guide member 62c) move sequentially from the inner diameter side outward toward the central axis of the stator core 2 to retract from the slot 22; and, in the stator assembly method, the following steps are included: after the advance guide member 61 moves radially outward toward the slot 22 until it comes into contact with or approaches the first reinforcing guide member 62a disposed on the inner diameter side among the plurality of reinforcing guide members 62, the advance guide member 61 is first moved outward toward the central axis of the stator core 2 to retract from the slot 22, and then, as the strip coil 100 moves radially outward, the plurality of reinforcing guide members 62 (first reinforcing guide member 62a, second reinforcing guide member 62b, and third reinforcing guide member 62c) move sequentially from the inner diameter side outward toward the central axis of the stator core 2 to retract from the slot 22.

[0136] In the stator assembly apparatus 1 and stator assembly method of various embodiments, a connecting plate 613 and an elastic member 614 are provided as a pressing means for pressing the advance guide member 61 toward the radially inner side of the stator core 2 towards the strip coil 100. During the movement of the advance guide member 61 by being pushed by the strip coil 100, the strip coil 100 is pressed toward the radially inner side of the stator core 2. Accordingly, during the movement of the advance guide member 61 by being pushed by the strip coil 100 moving toward the slot 22, the strip coil 100 can be pressed toward the radially inner side of the stator core 2, thus suppressing the deviation of the forward side of the movement direction of the strip coil 100.

[0137] In various embodiments, the advance guide member 61 is configured such that, in the state before being inserted into the slot 22 before the strip coil 100 is inserted, at least a portion of the advance guide member 61 hangs within the opening end 24a of the insulating paper 24 within the slot 22. Accordingly, by positioning the advance guide member 61 within the opening end 24a of the insulating paper 24, the opening end 24a of the insulating paper 24 can be kept open before the strip coil 100 is inserted. This suppresses contact between the strip coil 100 moving toward the slot 22 and the insulating paper 24, thus allowing the strip coil 100 to be smoothly guided into the inner side of the insulating paper 24.

[0138] In various embodiments, the advance guide member 61 and the reinforcing guide member 62 are respectively arranged face-to-face on both sides of the stator core 2 along the central axis. When they are inserted into the slot 22 from the two outer sides of the stator core 2 along the central axis, they are arranged with their front ends facing each other within the slot 22. Accordingly, the moving distance of the advance guide member 61 and the reinforcing guide member 62 toward the slot 22 is reduced, thus enabling miniaturization and space saving of the stator assembly device 1.

[0139] In each embodiment, the longitudinal widths W11 and W21 of the lead guide member 61 and the reinforcing guide member 62 along the radial direction of the stator core 2 are approximately the same. Accordingly, as the strip coil 100 and the lead guide member 61 move, causing the first reinforcing guide member 62a, the second reinforcing guide member 62b, and the third reinforcing guide member 62c to retract sequentially from the slot 22, the width of the radial gap within the slot 22 can be maintained below a fixed width. Therefore, the effect of support by the lead guide member 61 and the reinforcing guide member 62 in the manner of opening the insulating paper 24 can be achieved, along with the effect of improving the insertability of the strip coil 100.

[0140] In various embodiments, the lateral widths W12 and W22 of the lead guide member 61 and the reinforcing guide member 62 along the circumference of the stator core 2 are greater than the circumference width W0 of the strip coil 100 along the stator core 2. Accordingly, it is more reliable to prevent the straight portion 102 of the strip coil 100 moving toward the slot 22 from biting into the insulating paper 24 inside the slot 22 when the lead guide member 61 and the reinforcing guide member 62 are supported in a state where the insulating paper 24 is opened.

[0141] The stator assembly apparatus 1 of the embodiments described above is configured such that the central axis of the stator core 2 and the coil winding clamp 4 is arranged in the horizontal direction. However, it may also be configured such that the central axis of the stator core 2 and the coil winding clamp 4 is arranged in a direction other than the horizontal direction, such as the vertical direction.

[0142] Figure Labels

[0143] 1. Stator Assembly Device

[0144] 10. Control Department (Control Measures)

[0145] 2 stator core

[0146] 22 slots

[0147] 24 Insulating Paper (Insulating Components)

[0148] 24a open end

[0149] 51 Coil Pushing Section (Pushing Method)

[0150] 61. Preliminary guiding component (first guiding component)

[0151] 613 Connecting Plate (Pressing Method)

[0152] 614 Elastic Components (Pressing Mechanism)

[0153] 62. Reinforced Guiding Component (Second Guiding Component)

[0154] 62a First Enhanced Guidance Component

[0155] 62b Second Reinforced Guiding Component

[0156] 62c Third Enhanced Guidance Component

[0157] 100 strip coil

[0158] 200 stator

[0159] The width of the W0 strip coil

[0160] W11, W21 longitudinal width

[0161] W12, W22 Horizontal width

Claims

1. A stator assembly apparatus for assembling a stator by inserting a coil into a slot in the stator core from the inside of the stator core containing insulated components, the stator assembly apparatus being characterized in that it comprises: Multiple coil pressing parts are arranged radially inside the aforementioned coil along the circumference of the aforementioned coil and are capable of both reducing and expanding their diameter. By expanding the diameter, the aforementioned coil is pushed radially outward, causing the aforementioned coil to move to the inside of the aforementioned insulating member within the aforementioned slot. A first guide member is provided with at least one of the aforementioned slots and is configured to move along the central axis of the aforementioned stator core, thereby being inserted into the inner side of the aforementioned insulating member within the aforementioned slot by moving toward the aforementioned stator core; Multiple second guide members are provided relative to one of the aforementioned slots and are configured to move along the central axis of the aforementioned stator core, thereby being inserted into the inner side of the aforementioned insulating member and at a radially outer position within the aforementioned slot, which is further than the aforementioned first guide member, by moving towards the aforementioned stator core; and, The control unit controls the movement of the first guide component and the second guide component along the central axis of the stator core, respectively. The aforementioned first guide member is configured such that, when inserted into the aforementioned slot, it is positioned in front of the moving direction of the aforementioned coils, which are moved by the aforementioned plurality of coil pressing parts, and is pushed by the aforementioned coils to move radially outward within the aforementioned slot. The aforementioned control unit controls the movement as follows: the aforementioned first guide member moves radially outward toward the aforementioned slot until it comes into contact with or approaches the aforementioned second guide member disposed on the inner diameter side among the plurality of aforementioned second guide members. As the aforementioned coil moves radially outward using the aforementioned plurality of coil pressing parts, the plurality of aforementioned second guide members move sequentially from the side closest to the aforementioned first guide member toward the outer side of the central axis of the aforementioned stator core, thereby retracting from the aforementioned slot.

2. A stator assembly apparatus for assembling a stator by inserting a coil into a slot in the stator core from the inside of the stator core containing insulated components, the stator assembly apparatus being characterized by comprising: Multiple coil pressing parts are arranged radially inside the aforementioned coil along the circumference of the aforementioned coil and are capable of both reducing and expanding their diameter. By expanding the diameter, the aforementioned coil is pushed radially outward, causing the aforementioned coil to move to the inside of the aforementioned insulating member within the aforementioned slot. A first guide member is provided with at least one of the aforementioned slots and is configured to move along the central axis of the aforementioned stator core, thereby being inserted into the inner side of the aforementioned insulating member within the aforementioned slot by moving toward the aforementioned stator core; Multiple second guide members are provided relative to one of the aforementioned slots and are configured to move along the central axis of the aforementioned stator core, thereby being inserted into the inner side of the aforementioned insulating member and at a radially outer position within the aforementioned slot, which is further than the aforementioned first guide member, by moving towards the aforementioned stator core; and, The control unit controls the movement of the first guide component and the second guide component along the central axis of the stator core, respectively. The aforementioned first guide member is configured such that, when inserted into the aforementioned slot, it is positioned in front of the moving direction of the aforementioned coils, which are moved by the aforementioned plurality of coil pressing parts, and is pushed by the aforementioned coils to move radially outward within the aforementioned slot. The aforementioned control unit operates as follows: after the aforementioned first guide member moves radially outward toward the aforementioned slot until it comes into contact with or approaches the aforementioned second guide member disposed on the inner diameter side among the plurality of the aforementioned second guide members, the aforementioned first guide member is first moved outward toward the central axis direction of the aforementioned stator core to retract from the aforementioned slot. Subsequently, as the aforementioned coil moves radially outward using the aforementioned plurality of coil pushing parts, the plurality of the aforementioned second guide members are sequentially moved from the inner diameter side toward the central axis direction of the aforementioned stator core to retract from the aforementioned slot.

3. The stator assembly apparatus according to claim 1 or 2, comprising an elastic member that presses the aforementioned first guide member toward the radially inner side of the aforementioned stator core toward the aforementioned coil.

4. The stator assembly apparatus according to claim 1 or 2, wherein, The aforementioned first guide member is configured such that, when inserted into the aforementioned slot before the aforementioned coil is inserted, at least a portion of the aforementioned first guide member hangs within the opening end of the aforementioned insulating member in the aforementioned slot.

5. The stator assembly apparatus according to claim 1 or 2, wherein, The aforementioned first guide component and the aforementioned second guide component are respectively arranged face-to-face on both sides of the central axis direction of the aforementioned stator core. When they are inserted into the aforementioned slots from the two outer sides of the central axis direction of the aforementioned stator core, they are arranged with their front ends facing each other in the aforementioned slots.

6. The stator assembly apparatus according to claim 1 or 2, wherein, The longitudinal widths of the aforementioned first guide component and the aforementioned second guide component along the radial direction of the aforementioned stator core are approximately the same.

7. The stator assembly apparatus according to claim 1 or 2, wherein, The lateral width of the aforementioned first guide member and the aforementioned second guide member along the circumference of the aforementioned stator core is greater than the width of the aforementioned coil along the circumference of the aforementioned stator core.

8. A stator assembly method, comprising inserting a coil into a slot in a stator core from the inside of the stator core containing insulated components to assemble the stator, the stator assembly method being characterized by comprising the following steps: The process of inserting at least one first guide member into one of the slots from the outside of the central axis direction of the stator core, in a manner that is disposed inside the insulating member in the slot, and inserting a plurality of second guide members into one of the slots in a manner that is disposed inside the insulating member and further radially outward than the first guide member in the slot. The process of moving the aforementioned coil toward the aforementioned slot and abutting against the aforementioned first guide member, and moving the aforementioned first guide member radially outward within the aforementioned slot as the aforementioned coil moves; and, After the aforementioned first guide member moves radially outward toward the aforementioned slot until it comes into contact with or approaches the aforementioned second guide member disposed on the inner diameter side among the plurality of the aforementioned second guide members, as the aforementioned coil moves radially outward, the plurality of the aforementioned second guide members move sequentially from the side near the aforementioned first guide member toward the outer side of the central axis of the aforementioned stator core, thereby retracting from the aforementioned slot.

9. A stator assembly method, comprising inserting a coil into a slot in a stator core from the inside of the stator core containing insulating components to assemble the stator, the stator assembly method being characterized by comprising the following steps: The process of inserting at least one first guide member into one of the slots from the outside of the central axis direction of the stator core, in a manner that is disposed inside the insulating member in the slot, and inserting a plurality of second guide members into one of the slots in a manner that is disposed inside the insulating member and further radially outward than the first guide member in the slot. The process of moving the aforementioned coil toward the aforementioned slot and abutting against the aforementioned first guide member, and moving the aforementioned first guide member radially outward within the aforementioned slot as the aforementioned coil moves; and, After the aforementioned first guide member moves radially outward toward the aforementioned slot until it comes into contact with or approaches the aforementioned second guide member disposed on the inner diameter side among the plurality of the aforementioned second guide members, the aforementioned first guide member is first moved outward toward the central axis direction of the aforementioned stator core to retract from the aforementioned slot. Subsequently, as the aforementioned coil moves radially outward, the plurality of the aforementioned second guide members are sequentially moved from the inner diameter side toward the central axis direction of the aforementioned stator core to retract from the aforementioned slot.

10. The stator assembly method according to claim 8 or 9, wherein, During the movement of the aforementioned first guide member by the aforementioned coil, the aforementioned coil is pressed toward the radial inside of the aforementioned stator core.

11. The stator assembly method according to claim 8 or 9, wherein, The process of inserting the aforementioned first guide member and the aforementioned second guide member into the aforementioned slot is as follows: the aforementioned first guide member is inserted into the aforementioned slot in such a way that at least a portion of the aforementioned first guide member is hung in the open end of the aforementioned insulating member in the aforementioned slot.

12. The stator assembly method according to claim 8 or 9, wherein, The aforementioned first guide component and the aforementioned second guide component are respectively arranged face-to-face on both sides of the central axis of the aforementioned stator core. The process of inserting the aforementioned first guide component and the aforementioned second guide component into the aforementioned slot is as follows: the aforementioned first guide component and the aforementioned second guide component are respectively inserted into the aforementioned slot from the two outer sides in the direction of the central axis of the aforementioned stator core, and the aforementioned first guide component and the aforementioned second guide component are arranged in the aforementioned slot with their front ends facing each other.

13. The stator assembly method according to claim 8 or 9, wherein, The longitudinal widths of the aforementioned first guide component and the aforementioned second guide component along the radial direction of the aforementioned stator core are approximately the same.

14. The stator assembly method according to claim 8 or 9, wherein, The lateral width of the aforementioned first guide member and the aforementioned second guide member along the circumference of the aforementioned stator core is greater than the width of the aforementioned coil along the circumference of the aforementioned stator core.

Images