Clamping device and manufacturing method of a stator

Abstract

The present disclosure relates to a clamping device and a method of manufacturing a stator. The clamping device performs a clamping action to join a first peeled portion at a first end portion and a second peeled portion at a second end portion by laser welding. The second claw extends in a radial direction of the second shaft. The clamping device performs a clamping action to rotate the second shaft about a center axis of the second shaft to bring the second claw into abutment with the second end portion, in a state where the first shaft and the second shaft are moved toward the stator core to press the first shaft against the second bent portion and to press the second shaft against the first bent portion in order to clamp the first end portion and the second end portion between the first shaft and the second shaft.

Description

Technical Field

[0001] This disclosure relates to a clamping device and a method for manufacturing a stator. Background Technology

[0002] Japanese Patent Application Publication No. 2018-082543 discloses a method for manufacturing a stator for a rotating electrical machine. The method involves using a clamping device to clamp multiple sections of coil disposed on a stator core, and then welding the clamped sections of coil together to manufacture the stator. The multiple sections of coil are covered with an insulating film, and the ends with the film removed are welded together.

[0003] The first segment coil in the plurality of segment coils has a first bend and a first end. The first bend protrudes from the stator core and extends in a clockwise direction when viewed from the axial direction of the stator core. The first end is continuous with the first bend and extends along the axial direction of the stator core. The first end has a first peeled portion from which the coating has been removed.

[0004] The second segment coil in the plurality of segment coils has a second bend and a second end. The second bend protrudes from the stator core and extends counterclockwise when viewed from the axial direction of the stator core. The second end is continuous with the second bend and extends axially along the stator core. The second end has a second peeled portion from which the coating has been removed.

[0005] In the manufacturing method described in the aforementioned patent document, the first and second stripped portions are held by electrodes. The held first and second stripped portions are electrically bonded by TIG (Tungsten Inert Gas) welding.

[0006] As described in the aforementioned patent document, the first and second stripped portions are electrically bonded by TIG welding. For TIG welding to be performed, the first and second stripped portions need to be long enough to be held by electrodes. This results in a larger stator size, which is undesirable.

[0007] Consider a method of joining the first and second peeled portions using laser welding. In this case, it is no longer necessary to clamp the first and second peeled portions with electrodes. Therefore, compared to the TIG welding method, the length of the first and second peeled portions can be shortened.

[0008] However, when these peel-off sections are short, the heat generated by laser welding can easily be transferred to the coating near the peel-off section. Therefore, the coating becomes hot, which may damage it.

[0009] In the above stator manufacturing method, the heat generated by welding may damage the coating of the section coil. Summary of the Invention

[0010] According to a technical solution of this disclosure, a clamping device is provided, which is configured to hold a first section coil and a second section coil disposed on a stator core. The first section coil and the second section coil are covered with an insulating film. The clamping device is used when a first peeled portion of the first section coil (with the film removed) and a second peeled portion of the second section coil (with the film removed) are joined by laser welding. The clamping device is configured to have a first axis and a second axis, the first axis being arranged along the stator core. The second shaft is configured to extend radially along the stator core. With the first shaft pressed against the second section coil and the second shaft pressed against the first section coil, the first shaft and the second shaft are spaced apart circumferentially along the stator core, such that the first end and the second end are clamped and their positions in the circumferential direction of the stator core are restricted. The first end and the second end are clamped while restricting their positions in the circumferential direction of the stator core.

[0011] According to a technical solution of this disclosure, a method for manufacturing a stator is provided. The stator has a first section coil and a second section coil disposed on a stator core and covered by an insulating film. The manufacturing method includes a positioning step and a welding step. In the positioning step, a clamping device having a first axis and a second axis is moved toward the stator core, pressing the first axis against the film of the second section coil and pressing the second axis against the film of the first section coil, thereby positioning the first section coil and the second section coil axially in the stator core. After the positioning step, the welding step uses laser welding to combine a first peeled portion of the first end of the first section coil, from which the film has been peeled off, with a second peeled portion of the second end of the second section coil, from which the film has been peeled off. Attached Figure Description

[0012] Figure 1 This is a diagram showing a stator manufactured using a clamping device according to one embodiment.

[0013] Figure 2 It means Figure 1 A diagram of a portion of the multiple segmented coils contained in the stator.

[0014] Figure 3 yes Figure 2 Enlarged image.

[0015] Figure 4 This is a three-dimensional view of the clamping device.

[0016] Figure 5 It indicates the released state. Figure 4 A diagram of a part of the clamping device.

[0017] Figure 6 It indicates the clamping state. Figure 4 A diagram of a part of the clamping device.

[0018] Figure 7 This is a schematic diagram showing multiple sections of the coil before the axial positioning of the stator core.

[0019] Figure 8 This is a schematic diagram showing the state of multiple coil sections after the stator core has been positioned axially.

[0020] Figure 9 It indicates the released state. Figure 4 A top view of a part of the clamping device.

[0021] Figure 10 It indicates the clamping state. Figure 4 A top view of a part of the clamping device.

[0022] Figure 11 It is along Figure 9 A sectional view along line 11-11.

[0023] Figure 12 It is along Figure 10 A sectional view along line 12-12. Detailed Implementation

[0024] Hereinafter, a clamping device according to an embodiment and a method for manufacturing a stator using the clamping device will be described with reference to the accompanying drawings.

[0025] <Stator 10 manufactured using clamping device 100>

[0026] Reference Figures 1-3 The stator 10 manufactured using the clamping device 100 will be described below. The central axis of the stator core 20 is indicated by a dashed line. Hereinafter, a cylindrical coordinate system with the central axis of the stator core 20 set as the z-axis will be used. Figure 1 The radius r shown is called the radial direction of the stator core 20. The direction of angle θ is called the circumferential direction of the stator core 20. The direction of the axis z is called the axial direction of the stator core 20. Furthermore, when viewing the stator core 20 from above in the negative direction of the axis z, the two directions along the circumferential direction are called the clockwise direction and the counterclockwise direction when viewed from the axial direction. That is, the counterclockwise direction when viewed from the axial direction is the positive direction in the direction of angle θ, and the clockwise direction when viewed from the axial direction is the negative direction in the direction of angle θ.

[0027] like Figure 1 As shown, the stator 10 has a cylindrical stator core 20 and multiple segment coils 30 housed in the stator core 20.

[0028] The stator core 20 has a plurality of slots 20a arranged at predetermined intervals along the circumference of the stator core 20, and the plurality of slots 20a extend radially along the stator core 20. A plurality of segment coils 30 are respectively disposed in two slots 20a of the plurality of slots 20a.

[0029] Figure 2 express Figure 1 The stator 10 contains a portion of the multiple segment coils 30. Figure 2 The stator core 20 is not shown; only the multiple segment coils 30 arranged in the state of the stator core 20 are indicated. The multiple segment coils 30 include a first segment coil 32, a second segment coil 34, a third segment coil 36, and a fourth segment coil 38. (Example:) Figure 2 As shown, the first section coil 32, the second section coil 34, the third section coil 36, and the fourth section coil 38 are arranged radially along the stator core 20. The first section coil 32 is located on the innermost radial side, and the fourth section coil 38 is located on the outermost radial side.

[0030] The first section coil 32 has a first protrusion 32A that protrudes upward from the slot 20a and extends clockwise when viewed from the axial direction of the stator core 20. The first section coil 32 has a first straight portion 32B that is continuous with the first protrusion 32A and extends axially within the slot 20a along the stator core 20. The first section coil 32 has a first connecting portion 32C that is continuous with the first straight portion 32B and protrudes downward from the slot 20a, extending counterclockwise when viewed from the axial direction of the stator core 20. The first section coil 32 has a first straight portion 32D that is continuous with the first connecting portion 32C and extends axially within the slot 20a along the stator core 20. The first section coil 32 has a first protrusion 32E, which is continuous with the first straight portion 32D and protrudes from the slot 20a, extending in a clockwise direction when viewed from the axial direction of the stator core 20.

[0031] The second section coil 34 has a second protrusion 34A that protrudes upward from the slot 20a and extends counterclockwise when viewed from the axial direction of the stator core 20. The second section coil 34 has a second straight portion 34B that is continuous with the second protrusion 34A and extends axially within the slot 20a along the stator core 20. The second section coil 34 has a second connecting portion 34C that is continuous with the second straight portion 34B and protrudes downward from the slot 20a, extending counterclockwise when viewed from the axial direction of the stator core 20. The second section coil 34 has a second straight portion 34D that is continuous with the second connecting portion 34C and extends axially within the slot 20a along the stator core 20. The second section coil 34 has a second protrusion 34E, which is continuous with the second straight portion 34D and protrudes from the slot 20a, extending in a clockwise direction when viewed from the axial direction of the stator core 20.

[0032] The third section coil 36 has a third protrusion 36A that protrudes upward from the slot 20a and extends counterclockwise when viewed from the axial direction of the stator core 20. The third section coil 36 has a third straight portion 36B that is continuous with the third protrusion 36A and extends axially within the slot 20a along the stator core 20. The third section coil 36 has a third connecting portion 36C that is continuous with the third straight portion 36B and protrudes downward from the slot 20a, extending counterclockwise when viewed from the axial direction of the stator core 20. The third section coil 36 has a third straight portion 36D that is continuous with the third connecting portion 36C and extends axially within the slot 20a along the stator core 20. The third section coil 36 has a third protrusion 36E, which is continuous with the third straight portion 36D and protrudes from the slot 20a, extending in a clockwise direction when viewed from the axial direction of the stator core 20.

[0033] The fourth section coil 38 has a fourth protrusion 38A that protrudes upward from the slot 20a and extends counterclockwise when viewed from the axial direction of the stator core 20. The fourth section coil 38 has a fourth straight portion 38B that is continuous with the fourth protrusion 38A and extends axially within the slot 20a along the stator core 20. The fourth section coil 38 has a fourth connecting portion 38C that is continuous with the fourth straight portion 38B and protrudes downward from the slot 20a, extending counterclockwise when viewed from the axial direction of the stator core 20. The fourth section coil 38 has a fourth straight portion 38D that is continuous with the fourth connecting portion 38C and extends axially within the slot 20a along the stator core 20. The fourth section coil 38 has a fourth protrusion 38E, which is continuous with the fourth straight portion 38D and protrudes from the slot 20a, extending in a counterclockwise direction when viewed from the axial direction of the stator core 20.

[0034] like Figures 1-3 As shown, the first section coil 32 has a first bend 32a and a first end portion 32b. The first bend 32a protrudes from the stator core 20 and extends clockwise when viewed from the axial direction of the stator core 20. The first end portion 32b is continuous with the first bend 32a and extends along the axial direction of the stator core 20. The first bend 32a and the first end portion 32b constitute a first protrusion 32E. The first section coil 32 is covered by an insulating film. The first end portion 32b has a first peeled portion from which the film has been removed.

[0035] The second section coil 34 has a second bend 34a and a second end 34b. The second bend 34a protrudes from the stator core 20 and extends counterclockwise when viewed from the axial direction of the stator core 20. The second end 34b is continuous with the second bend 34a and extends axially along the stator core 20. The second bend 34a and the second end 34b constitute a second protrusion 34A. The second section coil 34 is covered by an insulating film. The second end 34b has a second peeled portion from which the film has been removed. The second section coil 34 has a second bend 34c and a second end 34d. The second bend 34c protrudes from the stator core 20 and extends clockwise when viewed from the axial direction of the stator core 20. The second end 34d is continuous with the second bend 34c and extends axially along the stator core 20. The second curved portion 34c and the second end portion 34d constitute the second protrusion 34E. The second end portion 34d has a second peel portion from which the coating has been peeled off.

[0036] The third section coil 36 has a third bend 36a and a third end 36b. The third bend 36a protrudes from the stator core 20 and extends counterclockwise when viewed from the axial direction of the stator core 20. The third end 36b is continuous with the third bend 36a and extends axially along the stator core 20. The third bend 36a and the third end 36b constitute a third protrusion 36A. The third section coil 36 is covered by an insulating film. The third end 36b has a third peeled portion from which the film has been removed. The third section coil 36 has a third bend 36c and a third end 36d. The third bend 36c protrudes from the stator core 20 and extends clockwise when viewed from the axial direction of the stator core 20. The third end 36d is continuous with the third bend 36c and extends axially along the stator core 20. The third bend 36c and the third end 36d constitute the third protrusion 36E. The third end 36d has a third peeling portion from which the coating has been peeled off.

[0037] The fourth section coil 38 has a fourth bend 38a and a fourth end portion 38b. The fourth bend 38a protrudes from the stator core 20 and extends counterclockwise when viewed from the axial direction of the stator core 20. The fourth end portion 38b is continuous with the fourth bend 38a and extends axially along the stator core 20. The fourth bend 38a and the fourth end portion 38b constitute a fourth protrusion 38A. The fourth section coil 38 is covered by an insulating film. The fourth end portion 38b has a fourth peeled portion from which the film has been removed.

[0038] The first bend 32a, the second bend 34c, and the third bend 36c protrude from the same groove 20a. The first bend 32a, the second bend 34c, and the third bend 36c are arranged radially along the stator core 20 in sequence.

[0039] The second bend 34a, the third bend 36a, and the fourth bend 38a protrude from the same groove 20a. The second bend 34a, the third bend 36a, and the fourth bend 38a are arranged radially along the stator core 20 in sequence.

[0040] The first end 32b, the second end 34b, 34d, the third end 36b, 36d, and the fourth end 38b are arranged radially along the stator core 20, forming a group consisting of multiple ends. For example... Figure 1 As shown, multiple groups consisting of multiple ends are arranged at equal intervals along the circumference of the stator core 20.

[0041] <Overview of clamping device 100>

[0042] like Figure 4As shown, the clamping device 100 includes a support plate 50 with an opening 50a. The opening 50a of the support plate 50 has a shape formed by two lines that are approximately orthogonal to the inner arc connecting the inner arc and the outer arc. The inner arc and the outer arc are concentric and have the same central angle.

[0043] The clamping device 100 includes an arcuate wall 52 extending perpendicularly from the support plate 50. The arcuate wall 52 extends along the inner arc of the opening 50a. That is, the arcuate wall 52 is curved in an arc shape. The arcuate wall 52 has a plurality of support holes 52a for supporting a plurality of shafts 58, which will be described later. The plurality of support holes 52a are arranged in a row.

[0044] The clamping device 100 includes a plurality of posts 54 extending perpendicularly from the support plate 50. The arcuate wall 52 and the plurality of posts 54 extend in the same direction. The plurality of posts 54 are arranged along the outer arcuate side of the opening 50a. Each of the plurality of posts 54 has a support pin 56 for supporting a corresponding shaft 58 (described later). When the support plate 50 is horizontally positioned, the plurality of support holes 52a and the plurality of support pins 56 are at the same height.

[0045] The clamping device 100 includes a plurality of shafts 58. Each shaft 58 is supported by a corresponding support hole 52a and a corresponding support pin 56, enabling rotation. Specifically, the shafts 58, the arm 62 (described later), and the support pin 56 are arranged sequentially, with the support pin 56 supporting the shaft 58 via the arm 62. The plurality of shafts 58 extend radially relative to the center of the inner arc of the opening 50a. The plurality of shafts 58 are arranged at equal intervals along the inner arc of the opening 50a. Each shaft 58 has a plurality of claws 60. Detailed descriptions of the plurality of shafts 58 and the plurality of claws 60 are provided later.

[0046] The clamping device 100 includes multiple arms 62, each fixed relative to a plurality of shafts 58. Each arm 62 extends radially along its corresponding shaft 58. An elongated hole extending along the extending direction of each arm 62 is provided in each arm 62. A rod 66 is connected to the arm 62 in a rotatable manner via a connecting pin 64 that slides through the elongated hole. The rod 66 extends through a hole provided in the support plate 50. When the support plate 50 is horizontally positioned, the rod 66 extends vertically. By moving the rod 66 vertically, the shaft 58 can be rotated about its central axis.

[0047] <The clamping device 100 includes multiple axes 58 and multiple jaws 60>

[0048] Figure 5 express Figure 4 Two adjacent axes 58 are shown among the plurality of axes 58. Hereinafter, these two axes 58 will be referred to as axis 1 58A and axis 2 58B, respectively. Figure 6 Indicates to make Figure 5 The first axis 58A and the second axis 58B are shown rotating around their respective central axes. Furthermore, the first axis 58A and the second axis 58B will be rotated to... Figure 6 The state of the position shown is called the clamping state.

[0049] Regarding each of the plurality of claws 60, the thickness of the peripheral portion of the claw 60 is thinner than the thickness of the central portion of the claw 60. Hereinafter, the plurality of claws 60 provided on the first axis 58A will be referred to as the plurality of first claws 60a, 60b, 60c, 60d, 60e, and 60f (60a to 60f). Hereinafter, the plurality of claws 60 provided on the second axis 58B will be referred to as the plurality of second claws 60a, 60b, 60c, 60d, 60e, and 60f (60a to 60f).

[0050] Multiple first claws 60a to 60f extend radially from the middle portion of the first shaft 58A. The end of the first shaft 58A supported in the support hole 52a, the multiple first claws 60a to 60f, and the base end of the first shaft 58A supported in the support pin 56 are arranged sequentially. First claws 60a, 60c, and 60e extend in the same radial direction of the first shaft 58A and are separated axially within the first shaft 58A. First claws 60b, 60d, and 60f extend in the same radial direction of the first shaft 58A and are separated axially within the first shaft 58A.

[0051] Multiple second claws 60a to 60f extend radially from the middle portion of the second shaft 58B. The end of the second shaft 58B supported by the support hole 52a, the multiple second claws 60a to 60f, and the base end of the second shaft 58B supported by the support pin 56 are arranged sequentially. Second claws 60a, 60c, and 60e extend in the same radial direction of the second shaft 58B and are separated axially within the second shaft 58B. Second claws 60b, 60d, and 60f extend in the same radial direction of the second shaft 58B and are separated axially within the second shaft 58B.

[0052] like Figure 6 As shown, the first claw 60a, the second claw 60b, the first claw 60c, the second claw 60d, the first claw 60e, and the second claw 60f are arranged in sequence. In addition, the second claw 60b is close to the first claw 60c, and the second claw 60d is close to the first claw 60e.

[0053] <Operation of clamping device 100 and manufacturing method of stator 10>

[0054] Explain the operation of the clamping device 100.

[0055] Clamping device 100 is configured in Figure 1 Above the stator core 20 shown. Figure 7 This indicates the state schematically.

[0056] First of all, Figure 7 The state allows the clamping device 100 to approach the stator core 20 so as to clamp each of the multiple groups consisting of multiple ends using the two adjacent shafts 58.

[0057] like Figure 8 As shown, multiple shafts 58 are pressed against multiple segment coils 30. By pressing the multiple shafts 58 against the multiple segment coils 30, the multiple segment coils 30 are positioned axially in the stator core 20. Simultaneously, the multiple segment coils 30 are also positioned circumferentially in the stator core 20. The multiple segment coils 30 positioned using the first shaft 58A and the second shaft 58B will be described below. The multiple shafts 58 have the same shape. The multiple shafts 58 are arranged at equal intervals along the inner arc of the opening 50a. Furthermore, in the manufactured stator 10, multiple groups consisting of multiple ends are arranged at equal intervals along the circumferential direction of the stator core 20. Multiple segment coil units are arranged circumferentially in the stator core 20, and one group consisting of multiple ends belongs to one segment coil unit. For example, the first segment coil 32, the second segment coil 34, the third segment coil 36, and the fourth segment coil 38 constitute one segment coil unit. Therefore, any two adjacent axes 58 among the plurality of axes 58 can perform a clamping operation in the same configuration as the first axis 58A and the second axis 58B. Here, the clamping operation is briefly described. The first end 32b and the second end 34b are clamped by the first jaw 60a and the second jaw 60b. The second end 34d and the third end 36b are clamped by the first jaw 60c and the second jaw 60d. The third end 36d and the fourth end 38b are clamped by the first jaw 60e and the second jaw 60f. Details of the clamping operation will be described later.

[0058] Figure 7 This is a schematic diagram showing the first section coil 32 and the second section coil 34 before they are positioned axially in the stator core 20. Figure 8This is a schematic diagram showing the first section coil 32 and the second section coil 34 after being positioned axially on the stator core 20. Compared to the first section coil 32 after being positioned axially on the stator core 20, the first section coil 32 before being positioned axially on the stator core 20 is separated from the stator core 20 by a greater distance. Compared to the second section coil 34 after being positioned axially on the stator core 20, the second section coil 34 before being positioned axially on the stator core 20 is separated from the stator core 20 by a greater distance. Compared to the third section coil 36 after being positioned axially on the stator core 20, the third section coil 36 before being positioned axially on the stator core 20 is separated from the stator core 20 by a greater distance. Compared to the fourth section coil 38 after it is positioned axially in the stator core 20, the fourth section coil 38 before it is positioned axially in the stator core 20 is separated from the stator core 20 by a greater distance.

[0059] The first shaft 58A and the second shaft 58B are moved toward the stator core 20 such that the first end 32b, the second end 34b, 34d, the third end 36b, 36d, and the fourth end 38b are sandwiched between the first shaft 58A and the second shaft 58B. This presses the first shaft 58A against the second bend 34a, the third bend 36a, and the fourth bend 38a, and presses the second shaft 58B against the first bend 32a, the second bend 34c, and the third bend 36c. This positions the first section coil 32, the second section coil 34, the third section coil 36, and the fourth section coil 38 axially in the stator core 20. In this positioning process, as... Figure 5 as well as Figure 11 As shown, the first claws 60a, 60c, 60e and the second claws 60a, 60c, 60e face the side opposite to the stator core 20. Conversely, the first claws 60b, 60d, 60f and the second claws 60b, 60d, 60f face the stator core 20. During the positioning process, with these claws 60 in their oriented state, the first axis 58A and the second axis 58B are moved toward the stator core 20.

[0060] The first shaft 58A and the second shaft 58B are spaced apart circumferentially in the stator core 20, thereby clamping the first end 32b, the second end 34b, 34d, the third end 36b, 36d, and the fourth end 38b. Therefore, the first shaft 58A and the second shaft 58B can restrict the position of the first end 32b, the second end 34b, 34d, the third end 36b, 36d, and the fourth end 38b in the circumferential direction of the stator core 20.

[0061] Figure 8 as well as Figure 9 This indicates that multiple sections of coil 30 are positioned axially in the stator core 20. For example... Figure 9As shown, the first shaft 58A and the second shaft 58B are configured to extend radially along the stator core 20.

[0062] Next, make multiple axes 58 self- Figure 9 as well as Figure 11 The state shown Figure 10 as well as Figure 12 The state shown is rotated. As described above, multiple shafts 58 can be rotated by moving multiple rods 66 in the vertical direction. Specifically, with multiple segment coils 30 positioned along the axial direction of the stator core 20, the first shaft 58A and the second shaft 58B are rotated about their respective central axes to... Figure 10 as well as Figure 12 The state shown. (As indicated) Figure 10 As shown, the first claw 60a, the first end 32b, the second end 34b, the second claw 60b, the first claw 60c, the second end 34d, the third end 36b, the second claw 60d, the first claw 60e, the third end 36d, the fourth end 38b, and the second claw 60f are arranged as follows. Figure 10 As shown, these elements overlap sequentially in the radial direction of the stator core 20.

[0063] Furthermore, the first claw 60a and the second claw 60b are separated by a predetermined interval in the radial direction of the stator core 20, with the predetermined interval set such that the first end 32b and the second end 34b are clamped by the first claw 60a and the second claw 60b. The first claw 60a abuts against the first end 32b, and the second claw 60b abuts against the second end 34b.

[0064] The first claw 60c and the second claw 60d are separated by a predetermined interval in the radial direction of the stator core 20, and the predetermined interval is set such that the second end 34d and the third end 36b are clamped by the first claw 60c and the second claw 60d. That is, the first claw 60c abuts against the second end 34d, and the second claw 60d abuts against the third end 36b.

[0065] The first claw 60e and the second claw 60f are separated by a predetermined interval in the radial direction of the stator core 20, and the predetermined interval is set such that the third end 36d and the fourth end 38b are clamped by the first claw 60e and the second claw 60f. That is, the first claw 60e abuts against the third end 36d, and the second claw 60f abuts against the fourth end 38b.

[0066] Thus, the clamping device 100 holds the first segment coil 32 and the second segment coil 34 by laser welding to combine the first peeled portion (with the film removed) at the first end 32b with the second peeled portion (with the film removed) at the second end 34b. Furthermore, the clamping device 100 holds the second segment coil 34 and the third segment coil 36 by laser welding to combine the second peeled portion (with the film removed) at the second end 34d with the third peeled portion (with the film removed) at the third end 36b. Additionally, the clamping device 100 holds the third segment coil 36 and the fourth segment coil 38 by laser welding to combine the third peeled portion (with the film removed) at the third end 36d with the fourth peeled portion (with the film removed) at the fourth end 38b.

[0067] Thus, in the manufacturing method of stator 10, a clamping process is performed on stator 10 in a state where multiple segment coils 30 are mounted on stator core 20 and the multiple segment coils 30 are bent so that multiple ends are arranged in groups. That is, a clamping device 100 is mounted on stator 10 in the state where multiple ends are arranged in groups, and pressure is applied to cause the clamping device 100 to rotate and clamp. In the manufacturing method of stator 10, the clamping process is performed by clamping device 100 as described above.

[0068] Next, the welding process is performed while maintaining the clamping posture. That is, the welding process is performed with the first shaft 58A pressed against the second curved portion 34a, the third curved portion 36a, and the fourth curved portion 38a, and the second shaft 58B pressed against the first curved portion 32a, the second curved portion 34c, and the third curved portion 36c. In the welding process, laser welding is used to combine the first peeled portion (with the coating removed) at the first end 32b, held by the first jaw 60a and the second jaw 60b, with the second peeled portion (with the coating removed) at the second end 34b. The first shaft 58A and the second shaft 58B are rotated around their respective central axes to clamp the first end 32b and the second end 34b. Figure 10 as well as Figure 12 As shown, when the first end 32b and the second end 34b are clamped, the first claw 60a and the second claw 60b abut against the film-covered portions of the first end 32b and the second end 34b. With the first claw 60a and the second claw 60b abutting against the film-covered portions of the first end 32b and the second end 34b, a first peeled portion of the first end 32b with the film removed is joined to a second peeled portion of the second end 34b with the film removed by laser welding.

[0069] Furthermore, in the welding process, laser welding is used to combine the second peeled portion (with the coating removed) at the second end 34d, held by the first jaw 60c and the second jaw 60d, with the third peeled portion (with the coating removed) at the third end 36b. When the first shaft 58A and the second shaft 58B are rotated around their respective central axes to hold the second end 34d and the third end 36b, the first jaw 60c and the second jaw 60d abut against the coating portions at the second end 34d and the third end 36b. With the first jaw 60c and the second jaw 60d abutting against the coating portions at the second end 34d and the third end 36b, laser welding is used to combine the second peeled portion (with the coating removed) at the second end 34d with the third peeled portion (with the coating removed) at the third end 36b.

[0070] Furthermore, in the welding process, laser welding is used to combine the third peeled portion (without coating) at the third end 36d, held by the first jaw 60e and the second jaw 60f, with the fourth peeled portion (without coating) at the fourth end 38b. When the first shaft 58A and the second shaft 58B are rotated around their respective central axes to clamp the third end 36d and the fourth end 38b, the first jaw 60e and the second jaw 60f abut against the coating portions at the third end 36d and the fourth end 38b. With the first jaw 60e and the second jaw 60f abutting against the coating portions at the third end 36d and the fourth end 38b, laser welding is used to combine the third peeled portion (without coating) at the third end 36d with the fourth peeled portion (without coating) at the fourth end 38b.

[0071] Similarly, laser welding is performed on all other parts clamped by the clamping device 100.

[0072] Once laser welding of all parts clamped by the clamping device 100 is complete, the clamping device 100 performs a releasing action. That is, it releases the multiple shafts 58 from their original positions. Figure 10 as well as Figure 12 The state shown Figure 9 as well as Figure 11 The state shown is rotated.

[0073] Next, the clamping device 100 is moved to the next part, and the clamping and welding processes are performed in the same way. This is repeated until all parts of the stator core 20 that require welding are completed.

[0074] This allows all the multiple sections of coil 30 at the stator core 20 to be electrically connected.

[0075] <Effects of this implementation method>

[0076] (1) The second shaft 58B contacts the first bend 32a, the second bend 34c, and the third bend 36c, and the first shaft 58A contacts the second bend 34a, the third bend 36a, and the fourth bend 38a. In this contact state, the first section coil 32, the second section coil 34, the third section coil 36, and the fourth section coil 38 are clamped.

[0077] This allows for laser welding of the stripped sections together while holding the first section coil 32, the second section coil 34, the third section coil 36, and the fourth section coil 38.

[0078] The second shaft 58B contacts the first bend 32a, the second bend 34c, and the third bend 36c, while the first shaft 58A contacts the second bend 34a, the third bend 36a, and the fourth bend 38a. Therefore, heat generated by laser welding can escape from the first bend 32a, the second bend 34a, 34c, the third bend 36a, 36c, and the fourth bend 38a to the first shaft 58A and the second shaft 58B. Consequently, the possibility of heat generated by welding damaging the coating of the first section coil 32, the second section coil 34, the third section coil 36, and the fourth section coil 38 can be reduced.

[0079] (2) The first segment coil 32, the second segment coil 34, the third segment coil 36 and the fourth segment coil 38 can be positioned in the radial direction of the stator core 20 using the first claw 60a, 60c, 60e and the second claw 60b, 60d, 60f.

[0080] (3) The coating at the first end 32b and the coating at the second end 34b are held by the first claw 60a and the second claw 60b. The coating at the second end 34d and the coating at the third end 36b are held by the first claw 60c and the second claw 60d. The coating at the third end 36d and the coating at the fourth end 38b are held by the first claw 60e and the second claw 60f. Therefore, heat generated by laser welding can escape from the first claw 60a, 60c, 60e and the second claw 60b, 60d, 60f to the first shaft 58A and the second shaft 58B. Therefore, the possibility that heat generated by welding may damage the coating of the first section coil 32, the second section coil 34, the third section coil 36 and the fourth section coil 38 can be further reduced.

[0081] (4) In the clamping process described above, the first shaft 58A and the second shaft 58B are rotated around their respective central axes until the first claw 60a, the first end 32b, the second end 34b, and the second claw 60b overlap radially in the stator core 20. Therefore, the periphery of the first claw 60a abuts against the first end 32b, and then the center of the first claw 60a abuts against the first end 32b. Similarly, the periphery of the second claw 60b abuts against the second end 34b, and then the center of the second claw 60b abuts against the second end 34b. Positioning can be achieved by slowly moving the first end 32b and the second end 34b radially in the stator core 20. This is particularly effective in structures that clamp multiple parts simultaneously, as described in the above embodiment. That is, by moving many segment coils 30 together little by little to gradually adjust their positions, the many segment coils 30 as a whole are easily and well aligned in a balanced manner.

[0082] (5) It can simultaneously clamp multiple parts arranged radially along the stator core 20.

[0083] (6) It can simultaneously clamp multiple parts arranged circumferentially along the stator core 20.

[0084] (7) By moving rod 66 along its axial direction, shaft 58 can be rotated around its central axis. That is, by moving rod 66 along its axial direction, clamping action can be achieved.

[0085] (8) In the positioning process, the clamping device 100 is brought close to the stator core 20, thereby using multiple shafts 58 to clamp multiple ends. In the positioning process, such as Figure 5 as well as Figure 11 As shown, the first claws 60b, 60d, 60f and the second claws 60b, 60d, 60f face downwards, while the first claws 60a, 60c, 60e and the second claws 60a, 60c, 60e face upwards. Figure 12 This indicates the orientation of the first claw (60a-60f) and the second claw (60a-60f) towards a direction orthogonal to the axial direction of the stator core 20. In the positioning process, compared to... Figure 12 When the clamping device 100 is brought close to the stator core 20 in the shown state, interference between the first claw 60a-60f and the second claw 60a-60f and the multiple section coils 30 is less likely to occur. As a result, the possibility of the first claw 60a-60f and the second claw 60a-60f damaging multiple stripping portions is reduced.

[0086] This embodiment can be implemented in the following modified ways. This embodiment and the following modifications can be implemented in combination with each other within the scope of technical inconsistency.

[0087] In the above embodiment, the clamping device 100 has a plurality of shafts 58. The number of shafts 58 can be appropriately varied. It is sufficient that the number of shafts 58 is two or more.

[0088] Alternatively, multiple shafts 58 can be arranged in a circle around the entire circumference of the stator core 20, thereby enabling all ends to be clamped in a single clamping operation.

[0089] In the above embodiment, the first end 32b, the second end 34b, 34d, the third end 36b, 36d, and the fourth end 38b are arranged radially along the stator core 20, forming a group of six ends. However, this is merely an example. The number of ends forming a group can be appropriately varied.

[0090] In the above embodiment, each of the multiple shafts 58 has a multiple claws 60. The number of the multiple claws 60 can be appropriately varied. For example, it is also possible for the first shaft 58A to have only the first claw 60a and the second shaft 58B to have only the second claw 60b.

[0091] In the above embodiment, the first shaft 58A and the second shaft 58B are rotated around their respective central axes to clamp the first end 32b and the second end 34b. When clamping the first end 32b and the second end 34b, the first claw 60a and the second claw 60b abut against the coated portions of the first end 32b and the second end 34b. Alternatively, the first claw 60a and the second claw 60b may abut only against the uncoated portions of the first end 32b and the second end 34b. Similarly, the first claw 60c and the second claw 60d may abut only against the uncoated portions of the second end 34d and the third end 36b. Alternatively, the first claw 60e and the second claw 60f may abut only against the uncoated portions of the third end 36d and the fourth end 38b.

[0092] In the above embodiment, for each of the plurality of claws 60, the thickness of the peripheral portion of the claw 60 is thinner than the thickness of the central portion of the claw 60. Alternatively, the thickness of the peripheral portion of the claw 60 may be the same as the thickness of the central portion of the claw 60. It is also possible that a portion of the peripheral portion of the claw 60 is thinner than the thickness of the central portion of the claw 60. The thickness of the claw 60 may vary continuously or in stages.

[0093] In the above embodiments, Figure 11 The left side of the second claw 60b abuts against the second end 34b before the right side of the second claw 60b. In the above embodiment, the thickness of the peripheral portion of the second claw 60b is thinner than the thickness of the central portion of the second claw 60b. Alternatively, it can be made... Figure 11The left side of the second claw 60b is thinner than the right side of the second claw 60b. That is, the leading side of the claw 60 can also be thinner than the trailing side of the claw 60. The leading side of the claw 60 refers to the part of the claw 60 that first approaches the end, and the trailing side of the claw 60 refers to the part that later approaches the end.

[0094] ·exist Figures 1-3 In the embodiment shown above, viewed from above the stator core 20, the first section coil 32 has a first curved portion 32a protruding from the stator core 20 and extending clockwise when viewed from the axial direction of the stator core 20. Alternatively, viewed from above the stator core 20, the first section coil 32 may have a first curved portion 32a protruding from the stator core 20 and extending counterclockwise when viewed from the axial direction of the stator core 20. In this case, viewed from above the stator core 20, the second curved portion 34c and the third curved portion 36c protrude from the stator core 20 and extend counterclockwise when viewed from the axial direction of the stator core 20. Viewed from above the stator core 20, the second curved portion 34a, the third curved portion 36a, and the fourth curved portion 38a protrude from the stator core 20 and extend clockwise when viewed from the axial direction of the stator core 20.

Claims

1. A clamping device configured to hold a first section of coil and a second section of coil disposed on a stator core, wherein, The first section coil and the second section coil are covered with an insulating film. When the first peeled portion of the first section coil (with the film removed) and the second peeled portion of the second section coil (with the film removed) are joined by laser welding, the clamping device is used. The clamping device is configured to have a first axis and a second axis. The first shaft is configured to extend radially along the stator core. The second shaft is configured to extend radially along the stator core. With the first shaft pressed against the second section coil and the second shaft pressed against the first section coil, the first shaft and the second shaft are spaced apart circumferentially along the stator core, such that they clamp the first end and the second end, thus restricting the position of the first end and the second end in the circumferential direction of the stator core. The first end and the second end are clamped while restricting their positions in the circumferential direction of the stator core; The clamping device also includes a first jaw and a second jaw. The first claw extends radially from the middle portion of the first axis. The second claw extends radially from the middle portion of the second axis. The first claw and the second claw are separated by a predetermined interval in the radial direction of the stator core. The predetermined interval is set in such a way that, when viewed in the axial direction of the stator core, the first end and the second end are clamped by the first and the second claws when the first claw and the second claw overlap radially along the stator core.

2. The clamping device according to claim 1, wherein, The clamping device is configured such that the first claw and the second claw abut against the film portions at the first end and the second end, thereby holding the first segment coil and the second segment coil.

3. The clamping device according to claim 1 or 2, wherein, The clamping device is configured such that the first jaw abuts against the first end, and the second jaw abuts against the second end, thereby holding the first section coil and the second section coil. The thickness of the peripheral portion of the first claw is thinner than the thickness of the central portion of the first claw, and the thickness of the peripheral portion of the second claw is thinner than the thickness of the central portion of the second claw.

4. The clamping device according to claim 1 or 2, wherein, The first section of the coil has a first bend and a first end portion. The first bend protrudes from the stator core and extends clockwise when viewed from the axial direction of the stator core. The first end portion is continuous with the first bend and extends along the axial direction of the stator core. The second section of the coil has a second bend and a second end portion. The second bend protrudes from the stator core and extends counterclockwise when viewed from the axial direction of the stator core. The second end portion is continuous with the second bend and extends along the axial direction of the stator core. The second section of the coil has another second bend and another second end, the second bend protruding from the stator core and extending clockwise when viewed from the axial direction of the stator core, the second end being continuous with the second bend and extending axially along the stator core. The third section of the coil has a third bend and a third end. The third bend protrudes from the stator core and extends counterclockwise when viewed from the axial direction of the stator core. The third end is continuous with the third bend and extends axially along the stator core. The third section of the coil is covered by an insulating film. The clamping device is configured to hold the second segment coil and the third segment coil by laser welding together a second peeled portion at the other second end, from which the coating has been peeled off, and a third peeled portion at the third end, from which the coating has been peeled off. The first claw is one of two first claws that extend in the same radial direction on the first shaft and are separated in the axial direction on the first shaft. The second claw is one of two second claws that extend in the same radial direction on the second axis and are separated in the axial direction on the second axis. With the two first claws, the two second claws, the first end, the second end, the other second end, and the third end overlapping radially along the stator core, the first end, the second end, the other second end, and the third end are clamped by the two first claws and the two second claws.

5. The clamping device according to claim 1 or 2, wherein, The first segment coil and the second segment coil constitute a segment coil unit. The segment coil unit is one of two segment coil units arranged circumferentially along the stator core, such that the first stripped portion and the second stripped portion overlap radially in the stator core. The clamping device has a third axis and a third jaw. The third shaft is configured to extend radially along the stator core. The third claw extends radially from the middle portion of the third axis. Viewed axially from the stator core, the first axis, the second axis, and the third axis are arranged in a counterclockwise direction. The second axis has another second claw. When the first end and the second end in one of the two segmented coil units are held by the first claw and the second claw, in the other of the two segmented coil units, the first end and the second end are held by the other second claw and the third claw.

6. The clamping device according to claim 1 or 2, wherein, The clamping device includes a first arm, a first rod, a second arm, and a second rod. The first arm is fixed to the first shaft and extends radially along the first shaft, and is provided with a first elongated hole extending along the extension direction of the first arm. The first rod is connected to the first arm in a rotatable manner via a first connecting pin that can slide in the first elongated hole. The second arm is fixed to the second shaft and extends radially along the second shaft, and is provided with a second elongated hole extending along the extension direction of the second arm. The second rod is connected to the second arm in a rotatable manner by means of a second connecting pin that can slide in the second elongated hole.

7. A method for manufacturing a stator, said stator having a first section coil and a second section coil disposed in a stator core and covered by an insulating film, wherein, The manufacturing method includes a positioning process and a welding process. In the positioning process, a clamping device having a first axis and a second axis is moved toward the stator core, pressing the first axis against the coating of the second section coil and pressing the second axis against the coating of the first section coil, thereby positioning the first section coil and the second section coil axially in the stator core. The welding process, following the positioning process, involves using laser welding to combine the first peeled portion (with the film removed) at the first end of the first section coil with the second peeled portion (with the film removed) at the second end of the second section coil. The first section of the coil has a first bend and a first end portion. The first bend protrudes from the stator core and extends clockwise when viewed from the axial direction of the stator core. The first end portion is continuous with the first bend and extends along the axial direction of the stator core. The second section of the coil has a second bend and a second end portion. The second bend protrudes from the stator core and extends counterclockwise when viewed from the axial direction of the stator core. The second end portion is continuous with the second bend and extends along the axial direction of the stator core. The clamping device further includes a first jaw and a second jaw, the first jaw extending radially from the middle portion of the first axis along the first axis, and the second jaw extending radially from the middle portion of the second axis along the second axis. The positioning process includes the following actions: with the first shaft and the second shaft extending radially along the stator core and sandwiching the first end and the second end, the first shaft is pressed against the second bent portion and the second shaft is pressed against the first bent portion, thereby restricting the position of the first end and the second end in the circumferential direction of the stator core. The manufacturing method further includes a clamping step, in which the first shaft and the second shaft are rotated about their respective central axes to a position where the first jaw, the first end, the second end, and the second jaw overlap radially on the stator core, thereby clamping the first end and the second end using the first jaw and the second jaw. In the positioning process, with the first claw facing the side opposite to the stator core and the second claw facing the stator core, the first axis and the second axis are moved toward the stator core.

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