Stator manufacturing apparatus and stator manufacturing method

Abstract

An apparatus for manufacturing a stator according to the present disclosure comprises: a mounting table on which a stator provided with a stator core and a plurality of segment coils is mounted, the stator core being provided with a plurality of slots into which the plurality of segment coils are inserted; a lifting mechanism that lifts and lowers the mounting table; a torsion jig disposed above the mounting table and including an insertion portion into which a tip portion of the segment coil exposed to an upper portion of the stator core can be inserted; a torsion mechanism that rotates the torsion jig; and a separation jig, which is disposed between the mounting table and the torsion jig, and which presses the stator in a direction away from the torsion jig, said stator having been subjected to torsion processing by rotating the torsion mechanism in a state in which the tip part is inserted into the insertion part. And the segmented coil is separated from the torsion clamp.

Description

Technical Field

[0001] The present disclosure relates to a stator manufacturing device and a stator manufacturing method. Background Art

[0002] As coils for stators of rotating electrical machines including motors, generators, etc., there are known coils in which a plurality of segment coils formed by processing a straight wire into a substantially U-shape are inserted into a plurality of slots arranged along the circumferential direction of the stator. In stators including such segment coils, it has been conventionally performed to twist the top ends of the free ends of the segment coils and then to electrically connect them by welding or the like (for example, see International Publication No. 2019 / 093515).

[0003] International Publication No. 2019 / 093515 describes a processing device that, after inserting the top end of a segment coil into an insertion hole or an insertion groove formed in a torsion jig, rotates the torsion jig left and right, wherein the torsion jig is disposed on the upper portion of a stator placed on a workbench. Summary of the invention

[0004] Problems to be solved by the invention

[0005] As in the processing device described in International Publication No. 2019 / 093515, in a device that performs twisting processing using a twisting clamp provided on the upper part of the stator, during the twisting action, a portion of the segmented coil may sometimes get stuck (or sink into) the insertion hole or insertion groove of the twisting clamp, or the gap between multiple twisting clamps. If such a sticking occurs, even if the workbench on which the stator is placed is lowered after the twisting process is completed, the segmented coil and the twisting clamp will not be separated, so the stator may become suspended from the twisting clamp. If the stator becomes suspended from the twisting clamp, not only will the stator be unable to be transported to the subsequent process, but also the stator may fall if the stuck state is accidentally released, and the stator itself or the device may be damaged.

[0006] In view of the above-mentioned problems, an object of the present invention is to provide a stator manufacturing apparatus and a stator manufacturing method capable of reliably separating a segment coil from a twisting jig.

[0007] Solutions for solving problems

[0008] In order to achieve the above-mentioned object, a stator manufacturing device of a first scheme of the present disclosure includes: a mounting table on which a stator including a stator core and a plurality of segment coils is mounted, wherein the stator core has a plurality of slots, and the plurality of segment coils are respectively inserted into the slots; a lifting mechanism that raises and lowers the mounting table; a twisting jig that is arranged above the mounting table and has an insertion portion into which a top end portion of the segment coil exposed at an upper portion of the stator core can be inserted; a twisting mechanism that rotates the twisting jig; and a separation jig that is arranged between the mounting table and the twisting jig and presses the stator, after the segment coils have been twisted by rotating the twisting mechanism with the top end portion inserted in the insertion portion, in a direction away from the twisting jig, so that the segment coils are separated from the twisting jig.

[0009] In the stator manufacturing apparatus described above, the stator is pressed in a direction away from the twisting jig by the separation jig, and the two members can be reliably separated even when the segment coil is caught in the insertion portion of the twisting jig.

[0010] As for the stator manufacturing device of the second scheme of the present disclosure, in the stator manufacturing device of the first scheme of the present disclosure, the separation fixture includes: a separation fixture body, which is arranged between the mounting table and the torsion fixture; and a fixture moving mechanism, which moves the separation fixture body in the upward and downward directions. The fixture moving mechanism lowers the separation fixture body as the lifting mechanism descends, thereby the separation fixture body presses the stator core to separate the segmented coil from the torsion fixture.

[0011] In the stator manufacturing device as described above, the separation jig can be lowered independently, so the stator can be easily pressed in a direction away from the twisting jig. In addition, the force with which the separation jig presses the stator core can be relatively easily varied.

[0012] As for the stator manufacturing device of the third scheme of the present disclosure, in the stator manufacturing device of the first scheme of the present disclosure, the separation fixture includes: a separation fixture body, which is arranged between the mounting table and the torsion fixture; and a connecting mechanism, which connects the separation fixture body to the mounting table, and before the mounting table is lowered by the lifting mechanism, the connecting mechanism is connected to the mounting table, and the separation fixture body is lowered as the lifting mechanism is lowered, thereby the separation fixture body presses the stator core to separate the segmented coil from the torsion fixture.

[0013] In the stator manufacturing apparatus described above, the separation jig operates in conjunction with the mounting table, so that the stator can be pressed in a direction away from the twisting jig as the mounting table descends.

[0014] As for the stator manufacturing device of the fourth scheme of the present disclosure, in the stator manufacturing device of any one of the first scheme to the third scheme of the present disclosure, the separation fixture is a flanging support unit, and the flanging support unit includes: an annular base member; a flanging support, which is arranged on the base member and inserted between the segmented coils exposed at the upper part of the stator core to support the insulating paper inserted into the slot; and an advance and retreat mechanism, which makes the flanging support move forward and backward in a direction close to or away from the axis of the base member.

[0015] In the stator manufacturing apparatus as described above, the cuff support unit for protecting the insulating paper can be used as a separation jig, so the number of parts of the apparatus can be reduced.

[0016] With regard to the stator manufacturing device of the fifth aspect of the present disclosure, in the stator manufacturing device of the fourth aspect of the present disclosure, when the stator placed on the mounting table is raised by the lifting mechanism, a portion of the base member abuts against the upper surface of the stator core.

[0017] In the stator manufacturing apparatus as described above, stress on the burring support member, particularly in the up-down direction, can be suppressed.

[0018] As for the stator manufacturing device of the sixth embodiment of the present disclosure, in the stator manufacturing device of any one of the first to fifth embodiments of the present disclosure, it also includes a rotating clamp holder, which is arranged between the torsion mechanism and the separation clamp, and includes multiple supporting parts that can respectively support multiple torsion clamps.

[0019] In the stator manufacturing apparatus described above, various twist jigs are supported by the support portion, whereby the twist jig connected to the twist mechanism can be easily changed by rotating the jig holder.

[0020] The stator manufacturing method of the seventh scheme of the present disclosure includes the following steps: placing a stator including a stator core and a plurality of segment coils on a mounting table, wherein the stator core has a plurality of slots, and the plurality of segment coils are respectively inserted into the slots; disposing a twisting jig above the mounting table, wherein the twisting jig has an insertion portion into which the top end portions of the segment coils of the stator mounted on the mounting table, which are exposed from the top of the stator core, can be inserted; raising the mounting table to insert at least a part of the top end portions of the segment coils into the insertion portion; rotating the twisting jig to twist the top end portions of the segment coils; and lowering the mounting table and actuating a separation jig disposed between the mounting table and the twisting jig to press the stator in a direction away from the twisting jig, thereby separating the segment coils from the twisting jig.

[0021] In the above-described method for manufacturing a stator, the stator is pressed in a direction away from the twist jig using the separation jig, so that both members can be reliably separated even when the segment coil is caught in the insertion portion of the twist jig.

[0022] Effects of the Invention

[0023] According to the stator manufacturing apparatus and the stator manufacturing method of the present disclosure, the segment coil can be reliably separated from the twisting jig. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a plan view showing an example of a stator before twisting.

[0025] Figure 2 yes Figure 1 A schematic front view of the stator is shown.

[0026] Figure 3 This is a schematic explanatory diagram showing an example of a stator manufacturing apparatus according to an embodiment of the present disclosure.

[0027] Figure 4 It is shown in cross section Figure 3 This is an enlarged view of a main part of a part of an example of a twisting jig used in a stator manufacturing device shown.

[0028] Figure 5 It is shown Figure 3 FIG. 1 is a plan view of an example of a jig holder used in a stator manufacturing apparatus shown.

[0029] Fig. 6A It means in Figure 3 A plan view of an example of a flange support unit used in a stator manufacturing device is shown.

[0030] Figure 6B is along Fig. 6A An enlarged cross-sectional view of the BB line.

[0031] Figure 7 is a diagram showing the relationship between the flange support and the segmented coil. Figure 2 This is a cross-sectional view of the main parts when the area corresponding to the A-A line is cut.

[0032] Figure 8 This is a schematic explanatory diagram showing a modified example of the stator manufacturing apparatus according to the embodiment of the present disclosure.

[0033] Fig. 9 This is a flowchart showing an example of a method for manufacturing a stator according to an embodiment of the present disclosure.

[0034] Fig. 10A Yes means Figure 3 The diagram is an explanatory diagram of the operating state of the stator manufacturing device shown.

[0035] Fig. 10B Yes means Figure 3 The diagram is an explanatory diagram of the operating state of the stator manufacturing device shown.

[0036] Fig. 10C Yes means Figure 3 The diagram is an explanatory diagram of the operating state of the stator manufacturing device shown.

[0037] Fig.11A Yes means Figure 3 The diagram is an explanatory diagram of the operating state of the stator manufacturing device shown.

[0038] Fig. 11B Yes means Figure 3 The diagram is an explanatory diagram of the operating state of the stator manufacturing device shown.

[0039] Fig. 11C Yes means Figure 3 The diagram is an explanatory diagram of the operating state of the stator manufacturing device shown. DETAILED DESCRIPTION

[0040] This application is based on Japanese Patent Application No. 2022-125057 filed in Japan on August 4, 2022, the contents of which constitute a part of this application as the contents of this application.

[0041] In addition, the present disclosure should be more fully understood through the following detailed description. Through the following detailed description, the further application scope of the present application should become clear. However, the detailed description and specific examples are preferred embodiments of the present disclosure and are recorded only for the purpose of illustration. This is because, according to the detailed description, various changes and modifications are obvious to those skilled in the art within the spirit and scope of the present disclosure.

[0042] The applicant does not intend to dedicate any of the described embodiments to the public, and portions of the disclosed changes and alternatives that may not be literally included in the claims are also intended to be part of the invention under the doctrine of equivalents.

[0043] Hereinafter, various embodiments for implementing the present disclosure will be described with reference to the accompanying drawings. It should be noted that, below, the scope required for the description to achieve the purpose of the present disclosure is schematically shown, and the scope required for the description of the corresponding part of the present disclosure is mainly described, and the omitted description is the content known based on the known technology. In addition, the same or similar figure marks are marked for the components that are identical or equivalent to each other in the figures, and repeated descriptions are omitted. Moreover, for the same components in a single figure, sometimes only a part of them is marked with figure marks, and the assignment of figure marks to other identical components is omitted.

[0044] First, before describing a manufacturing apparatus and a manufacturing method of a stator according to the present embodiment, a stator 1 to be twisted in the present embodiment will be briefly described.

[0045] Figure 1 1 is a top view showing an example of a stator before twisting. Figure 2 yes Figure 1 The schematic front view of the stator is shown in FIG. Figure 2 In order to facilitate understanding of the structure, the top portion of several segmented coils 4 is omitted. Figure 1 and Figure 2 As shown, the stator 1 used in the manufacturing device and manufacturing method of the stator of the present embodiment includes: a stator core 2 including a plurality of slots 3; and a segment coil 4 inserted into the slots 3. It should be noted that, here, as the stator 1, a stator of an inner rotor type motor is shown as an example, but it can also be a stator of an outer rotor type motor instead.

[0046] The stator core 2 can be composed of an annular, more specifically, a roughly cylindrical conductor having a central hole 2A formed in the central portion thereof. The stator core 2 includes an annular yoke and teeth protruding from the inner circumferential surface of the yoke, and can be composed of a magnetic body, specifically, an electromagnetic steel plate. The stator core 2 can be, for example, a component formed by stacking a plurality of (e.g., tens to hundreds of) disc-shaped core pieces composed of relatively thin plate-like bodies of about 0.2 mm to 0.5 mm along its central axis CA. In addition, the stator core 2 can also be a component formed by combining so-called split cores that are divided into a plurality of parts in the circumferential direction. It should be noted that, hereinafter, the direction along the central axis CA is sometimes referred to as simply the "axial direction". In addition, it is assumed that Figure 2 The upper end surface of the stator core 2 in FIG. 2 is referred to as an upper surface 2B, and similarly, the lower end surface is referred to as a lower surface 2C.

[0047] The slot 3 may be formed by a slot formed on the inner circumferential surface of the stator core 2 at a predetermined interval along the circumferential direction of the stator core 2 and extending in the axial direction. The slot 3 is provided with a plurality of segment coils 4 inserted therein, and may be provided with insulating paper 5 for insulating the inserted plurality of segment coils 4 from the inner wall of the slot 3. It should be noted that other insulating members such as an insulator and varnish may be used instead of the insulating paper 5. In addition, the slot 3 does not need to extend parallel to the axial direction, and may be formed as an oblique slot.

[0048] The segment coil 4 may be formed of a substantially U-shaped metal wire having a pair of legs 4A, 4A extending substantially parallel to each other at a distance and a bent portion 4B connecting the ends of the pair of legs 4A, 4A on one side thereof that are adjacent to each other. The segment coil 4 may have a connection portion 4C electrically connected to the ends of other segment coils 4, etc., at the ends of the pair of legs 4A, 4A that are not connected to the bent portion 4B. The connection portion 4C may be joined to the other connection portion 4C by welding or the like. In addition, the example in which the wire used for the segment coil 4 is a flat wire is shown, but a round wire or the like may also be used.

[0049] The segment coil 4 having the above structure is sometimes called a hairpin coil. In addition, the segment coil in the present disclosure is not limited to the above structure as long as it is formed by electrically connecting a plurality of segment coils to form a coil wound and mounted on the stator core 2. Moreover, the surface of the segment coil 4 may be covered with an insulating film such as enamel. In addition, in the present embodiment, the stator 1 in which six legs 4A are inserted in a row in each slot 3 along a direction intersecting the axial direction is exemplified.

[0050] Segment coil 4 can be inserted into slot 3 from the opening on the lower surface 2C side in the axial direction so that most of its pair of leg portions 4A, 4A are accommodated in slot 3. Figure 1 and Figure 2 In the stator 1 shown, an example is shown in which six leg portions 4A are inserted into one slot. The connection portion 4C of the segment coil 4 thus inserted and a portion of the leg portion 4A adjacent to the connection portion 4C are exposed outside the slot 3 from the opening on the upper surface 2B side of the stator core 2. In the stator manufacturing device 10 and the stator manufacturing method of the present embodiment, the portion of the segment coil 4 exposed outside the slot 3 from the opening on the upper surface 2B side of the stator core 2 (hereinafter, this portion is referred to as "top end portion 4D") is twisted. It should be noted that, in order to facilitate the twisting process, it is preferable that the top end portion 4D of the segment coil 4 is previously subjected to a process of widening the interval between the top end portions 4D of the segment coils 4 inserted into the common slot 3.

[0051] <Stator manufacturing equipment>

[0052] Next, a stator manufacturing apparatus 10 according to the present embodiment is described, which is capable of twisting the top end portion 4D of the segment coil 4 of the stator 1. It should be noted that, in the following description, an example is given of a case where the stator 1 is used as an object to be processed, but the structure of the stator 1 to be processed is not limited to the above structure.

[0053] Figure 3 1 is a schematic diagram showing an example of a stator manufacturing apparatus according to an embodiment of the present disclosure. Figure 3 As shown in FIG. 1 , the stator manufacturing device 10 of the present embodiment includes a mounting table 20, a lifting mechanism 30, a twisting fixture 40, a twisting mechanism 50, and a cuff supporter unit 60 as an example of a separation fixture. These components can be arranged in a housing 11. It should be noted that in the following description, Figure 3 The X direction shown is assumed to be the left-right direction, the Y direction is assumed to be the front-back direction, and the Z direction is assumed to be the up-down direction for explanation. Figure 3 In the figure, a part of the structure is shown in a simplified manner.

[0054] In addition, the stator manufacturing device 10 of the present embodiment may further include a control device 12 for controlling the entire device including the above-mentioned components. The control device 12 may be a device for controlling the actions of various components of the stator manufacturing device 10 described later. The control device 12 may be a sequencer, a computer, etc. As a computer constituting the control device 12, a computer including at least a processor, a volatile and non-volatile memory, and a communication interface may be used.

[0055] The loading table 20 is a table on which the stator 1 can be placed. Specifically, the loading table 20 may include: a flat loading table body 21; a positioning member 22, which positions the stator 1 placed on the loading table body 21; and a conveying roller 23, which supports the lower surface of the loading table body 21 and is configured to convey the loading table body 21 in one direction (for example, the front-to-back direction). The loading table body 21 may be a so-called tray for moving to various devices when manufacturing the stator 1. The loading table body 21 can be conveyed to any position by the conveying roller 23. Therefore, replacement of the stator 1, etc. becomes easy. In addition, as Figure 3 As shown, stator 1 is placed on mounting table main body 21 such that distal end portion 4D of segment coil 4 is located upward.

[0056] In the above-mentioned structure, positioning member 22 may be a member for positioning stator 1 in the horizontal direction when stator 1 is placed on mounting table body 21. Specifically, positioning member 22 may be provided to surround at least a portion of bent portion 4B of segment coil 4 and the vicinity of lower surface 2C of stator core 2 of stator 1 placed on mounting table body 21.

[0057] Here, it should be noted that the stator 1 placed on the mounting table 20 is positioned in the horizontal direction as described above, but is not fixed to the mounting table 20. If the stator 1 is not fixed to the mounting table 20 but is simply placed on the mounting table 20 as described above, the replacement operation of the stator 1 becomes easier than when the stator 1 is fixed to the mounting table 20, and the manufacturing efficiency can be improved.

[0058] The lifting mechanism 30 is a mechanism for raising or lowering the mounting table 20. Specifically, the lifting mechanism 30 may include: a lifting actuator 31 that moves in the up-down direction; a push table 32 that is connected to the upper end of the lifting actuator 31 and contacts the lower surface of the mounting table body 21 when the lifting actuator 31 moves; and a guide rod 33 that guides the up-down movement of the push table 32.

[0059] The lifting actuator 31 may be a working mechanism that can move the mounting table 20 up and down together with the stator 1. Various actuators may be used for the lifting actuator 31. Specifically, a ball screw mechanism driven by a servo motor, a linear motor, a single-axis robot, or a hydraulic cylinder connected to a pump may be used.

[0060] The push table 32 can be raised by the lifting actuator 31 to contact the lower surface of the mounting table body 21, and the stator 1 can be moved to the position for twisting. In addition, the end of the guide rod 33 supported by the housing 11 is connected to the appropriate position of the push table 32, such as each corner, so that the push table 32 can move up and down without being tilted in the horizontal direction.

[0061] The twisting jig 40 is a jig disposed above the mounting table 20 and used to perform a twisting process on the top end portion 4D of the segment coil 4. In the present embodiment, in order to perform the above-mentioned twisting process on the stator 1 having six leg portions 4A inserted in each slot 3, an example is given in which three twisting jigs 40-1, 40-2, and 40-3 are selectively used. That is, an example is given in which the top end portions 4D of the six segment coils 4 (leg portions 4A) in each slot 3 are twisted in the clockwise direction and the counterclockwise direction two by two using the three twisting jigs 40-1, 40-2, and 40-3. It should be noted that the number of twisting jigs used for one stator and their shapes can be appropriately changed.

[0062] The three twisting jigs 40-1, 40-2, and 40-3 may also be supported by the jig holder 70 so as to be movable. That is, by selectively connecting the twisting jigs 40-1, 40-2, and 40-3 supported by the jig holder 70 to the twisting mechanism 50, the plurality of top ends 4D can be twisted in sequence. It should be noted that the supporting structure based on the jig holder 70 and the method of changing the twisting jigs 40-1, 40-2, and 40-3 used will be described later.

[0063] Figure 4 It is shown in cross section Figure 3 It should be noted that the above-mentioned torsion jigs 40-1, 40-2, and 40-3 have a common structure except for their size, so in the following description, the torsion jig 40 is described as an example of these torsion jigs.

[0064] like Figure 3 and Figure 4 As shown, the torsion jig 40 can be composed of a cylindrical or columnar component. As described above, the torsion jig 40 can perform a twisting process on the top ends 4D of two segmented coils 4 in the six legs 4A inserted into each slot 3. The torsion jig 40 can include an outer crown 41 and an inner crown 42 that are roughly cylindrical, that is, roughly crown-shaped, and a slot-shaped or cut-out-shaped insertion portion 43 and an insertion portion 44 for inserting the top ends 4D of the segmented coils 4 are provided at a position opposite to the stator 1 at the lower part of the outer crown 41 and the inner crown 42. The insertion portions 43 and 44 can be formed corresponding to the number and position of the top ends 4D to be twisted, and the wall thickness thereof can be adjusted to be slightly thicker than the wall thickness of the top ends 4D to be twisted along a direction intersecting the axial direction. It should be noted that in Figure 4 In the embodiment, a structure including two crowns is shown as an example of the torsion jig 40, but the number of crowns included in one torsion jig can be changed appropriately.

[0065] The outer crown 41 and the inner crown 42 may be coaxially arranged and independently rotatable along the common axis. Specifically, during the twisting process of the outer crown 41 and the inner crown 42, the two may be rotated in opposite directions. In this way, the top end portion 4D of the segment coil 4 after the twisting process is adjusted to be twisted in the direction (e.g., counterclockwise) opposite to the twisting direction (e.g., clockwise) of the adjacent inner or outer top end portion 4D.

[0066] Preferably, guide rings 45 and 46 are provided on the outer portion of the outer crown 41 and the inner portion of the inner crown 42, respectively. The guide rings 45 and 46 can prevent the side surfaces of the insertion parts 43 and 44 from accidentally releasing the engagement state with the tip part 4D during the twisting process of the tip part 4D, or from contacting with other adjacent tip parts 4D before or after the twisting process during the twisting process.

[0067] Figure 5 It means in Figure 3 A top view of an example of a jig holder used in a stator manufacturing device shown in FIG. The jig holder 70 can be located between the torsion mechanism 50 and the flange support unit 60 in the vertical direction, and includes a member capable of supporting a plurality of torsion jigs 40-1, 40-2, and 40-3. The jig holder 70 can mainly include a substantially disc-shaped bracket body 71 extending in the horizontal direction and a supporting claw 72 as an example of a supporting portion capable of supporting torsion jigs of various shapes (e.g., torsion jigs 40-1, 40-2, and 40-3).

[0068] The bracket body 71 may be configured to be rotatable along a rotation center 71A extending in the vertical direction. Furthermore, a plurality of, for example, five, support claws 72 disposed around the bracket body 71 at predetermined intervals may each support one torsion jig 40. The support claws 72 that rotate and move with the rotation of the bracket body 71 may be configured to be movable between a use position P1 where the supported torsion jig 40 faces the stator 1 mounted on the mounting table 20 and a setting position P2 where the torsion jig 40 is arbitrarily set by an operator or the like.

[0069] The above-mentioned jig holder 70 can be operated in the following manner: one or more torsion jigs 40 are pre-set on the support claws 72 at the setting position P2 in consideration of the number and arrangement of the segment coils 4 of the stator 1 to be subjected to the torsion process, and the torsion jigs 40 are sequentially moved to the use position P1. Thus, by rotating the jig holder 70, the desired torsion jig 40 can be connected to and disconnected from the torsion mechanism 50, and the operator only needs to set any torsion jig on the support claws 72 at the setting position P2. In other words, most of the replacement work of the torsion jig connected to the torsion mechanism 50 can be automated. It should be noted that in the above-mentioned example, as the jig holder 70, a rotating jig holder having a rotation center 71A is shown as an example, but the present embodiment is not limited thereto. For example, a horizontal conveying jig holder in which the support claws move horizontally can be used instead of the above-mentioned jig holder.

[0070] In addition, Figure 5In the example, the case where the twisting jigs 40-1, 40-2, and 40-3 are supported by three of the five supporting claws 72 provided on the jig holder 70 is shown, but the twisting jig 40 of which shape is supported by which supporting claw 72 can be appropriately changed. Therefore, for example, a twisting jig including six crowns capable of twisting all the segment coils 4 of the stator 1 described above can be supported by one of the supporting claws 72.

[0071] The twisting mechanism 50 is connected to the twisting jig 40, specifically, to one twisting jig 40 disposed at the use position P1 through the jig holder 70, and rotates it. The twisting mechanism 50 may mainly include: a holding arm 51 for holding the twisting jig 40 disposed at the use position P1; and a rotating mechanism 52 for rotating one or more crowns included in the twisting jig 40.

[0072] The gripping arm 51 can grip any position formed on the twisting jig 40, for example, the flange portion 47 formed on the outer periphery of the twisting jig 40. In addition, the rotating mechanism 52 can be formed by a motor or the like, and can have any connection structure that can transmit the rotational force to the outer crown 41 and the inner crown 42 of the twisting jig 40. It should be noted that in the present embodiment, an example is given in which the twisting mechanism 50 does not move in the up-down direction, but a structure that can move the twisting mechanism 50 up-down when the twisting mechanism 50 is rotated, etc., can also be further adopted.

[0073] FIG6 shows Figure 3 FIG6 is a diagram showing an example of a flange support unit used in a stator manufacturing device, FIG6(A) is a top view, and FIG6(B) is an enlarged cross-sectional view obtained by cutting along the BB line of FIG6(A). It should be noted that FIG6(A) shows a protruding state of the flange support 62, and FIG6(B) shows a stored state of the flange support 62 with a solid line, and a protruding state with a dotted line. In addition, in FIG6(B), in order to facilitate the understanding of the action of the flange support 62, a part of it is shown as an end view.

[0074] like Figure 3 As shown in FIG6 , a flange support unit 60 as an example of a separation jig is disposed between the mounting table 20 and the twisting jig 40. The flange support unit 60 may include: a substantially annular base member 61 as an example of a separation jig body; a flange support member 62 disposed on the base member 61; and an advance and retreat mechanism 63 for advancing and retreating the flange support member 62 in a direction close to or away from the axis of the base member 61.

[0075] The base member 61 may include: a flange support member support portion 64 provided with a flange support member 62; and a base body 65 disposed below the flange support member support portion 64 at a predetermined interval. The flange support member support portion 64 may be a plurality of members arranged in a substantially circular shape on the base body 65 so as to support the flange support members 62 respectively. In addition, the base body 65 may have a through hole 65A formed in a substantially central portion thereof through which the segment coil 4 of the stator 1 can pass. Furthermore, one end of a guide cylinder 66 for guiding the vertical movement of the base member 61 may be connected to the base body 65.

[0076] A contact protrusion 64A may be provided at the end of the inner peripheral surface side of each flange support member support portion 64, and the contact protrusion 64A contacts the upper surface 2A of the stator core 2 when the stator 1 placed on the mounting table 20 rises. It is particularly preferred that the contact surface of the contact protrusion 64A and the stator core 2 is located at a distance H1 below the lower surface of the flange support member 62. As a result, the stress generated during the twisting process and the operation of the stator 1, especially the stress in the up-down direction, is not easy to act on the flange support member 62, and damage to the flange support member 62 can be suppressed.

[0077] The flange support 62 may be a member provided in the flange support support portion 64, and capable of supporting the end portion (sometimes referred to as the flange portion) of the insulating paper 5 exposed on the upper surface B of the stator core 2 and inserted into the slot 3. The flange support 62 may be inserted between the segment coils 4 exposed from the upper portion of the stator core 2, more specifically, from the upper surface 2B of the stator core 2 outside the slot 3. In connection therewith, the flange support 62 having the same number as the number of gaps between the segment coils 4, in other words, the same number as the number of teeth of the stator core 2, may be arranged on the base member 61 in a substantially circular manner so as to protrude in the direction in which the through hole 65A is provided along the extension direction of the teeth. The insulating paper 5 is supported by the flange support 62, thereby preventing the insulating paper 5 from being damaged during the twisting process. It should be noted that the flange support 62 may also function as a starting point for the twisting process described later.

[0078] The advance and retreat mechanism 63 may be a mechanism for advancing and retreating the flange support 62 in a direction close to or away from the axis of the base member 61. The advance and retreat mechanism 63 may be configured to mainly include: a swing cam 67, one end of which is rotatably fixed to the base end side of the flange support 62; and a support shaft 68, which supports the swing cam 67 so as to be rotatable. By operating the swing cam 67, the flange support 62 can advance and retreat between a protruding state in which its top end is inserted between the segment coils 4 and a retracted state in which it is retracted on the side of the flange support support portion 64. It should be noted that the structure of the advance and retreat mechanism 63 described above is an example, and other drive mechanisms such as a plunger and a motor may also be used.

[0079] Figure 7 is a diagram showing the relationship between the flange support and the segmented coil. Figure 2 A cross-sectional view of the main parts when the portion corresponding to the A-A line of the embodiment is cut. When the stator 1 placed on the mounting table 20 rises and reaches the position where the flange support unit 60 is provided, and the upper surface 2A of the stator core 2 abuts against the abutment protrusion 64A of the base member 61, the flange support 62 is protruded. The flange support 62 supports one circumferential surface of the adjacent segment coil 4 by inserting its top end into the gap between the segment coils 4.

[0080] In the flange support unit 60 having the above-mentioned structure, the upper surface 2B of the stator core 2 abuts against the abutment protrusion 64A of the base member 61 by the rise of the stator 1, and then the flange support unit 60 can follow the movement of the stator 1 and rise or fall. Therefore, even if the flange support unit 60 does not have a separate moving mechanism for moving it in the up and down direction, the stator 1 can be manufactured. However, as a specific scheme for realizing the function as a separation clamp, the flange support unit 60 of the present embodiment adopts a clamp moving mechanism 80 that can move the base member 61 in the up and down direction (or only in the downward direction) on the basis of the above-mentioned structure. The clamp moving mechanism 80 can be of any structure as long as it can move the flange support unit 60 alone in the up and down direction. In the present embodiment, as Figure 3 1 and 2 , an example is shown in which a mechanism connected to the guide cylinder 66 and capable of controlling the movement of the piston rod of the guide cylinder 66 is adopted.

[0081] As described above, jig moving mechanism 80 is an example of a structure for realizing the function of flange support unit 60 as a separation jig. Therefore, jig moving mechanism 80 can function to press stator 1, after segment coil 4 has been twisted by the operation of twist jig 40 or the like, in a direction away from twist jig 40, specifically, in a downward direction. Specifically, after the twisting process, jig moving mechanism 80 is operated as lifting mechanism 30 descends to lower base member 61, thereby pressing upper surface 2B of stator core 2 by contact protrusion 64A of base member 61.

[0082] Thus, in stator manufacturing apparatus 10 of the present embodiment, by using flange support unit 60 functioning as a separation jig, segment coil 4 after the twisting process is completed can be separated from twisting jig 40. Thus, even if a portion of segment coil 4 is caught in the insertion portion of twisting jig 40 or a gap adjacent to the insertion portion during the twisting process, segment coil 4 can be reliably separated from twisting jig 40 at the timing when stage 20 is lowered.

[0083] Furthermore, by adopting the jig moving mechanism 80, the force of the flange support unit 60 pressing the stator 1 in the direction away from the twist jig 40 can be easily changed by adjusting the output of the jig moving mechanism 80. Furthermore, by monitoring the output of the jig moving mechanism 80, it is possible to infer whether the segment coil 4 is stuck in the gap of the twist jig 40.

[0084] In the stator manufacturing apparatus 10 of the present embodiment described above, an example of a structure in which segment coil 4 and twisting jig 40 are separated by lowering base member 61 using jig moving mechanism 80 is shown. However, the separation method is not limited to using jig moving mechanism 80. Therefore, a stator manufacturing apparatus 10A as a modified example of the stator manufacturing apparatus 10 described above will be described below.

[0085] <Modification>

[0086] Figure 8 1 is a schematic diagram showing a modified example of a stator manufacturing device according to an embodiment of the present disclosure. Figure 8 As shown in FIG. 1 , except for a part of the structure of the flange support unit 60A as an example of the separation jig, the stator manufacturing device 10A of this modified example is the same as the stator manufacturing device 10 described above. Therefore, only the points of the stator manufacturing device 10A of this modified example that are different from the stator manufacturing device 10 will be described below, and for the same structures as the stator manufacturing device 10, the description of the stator manufacturing device 10 described above will be used, and the description thereof will be omitted.

[0087] The flanging support unit 60A of the stator manufacturing device 10A is the same as the above-mentioned flanging support unit 60 in that it has a base member 61, a flanging support 62, and an advance and retreat mechanism 63. On the other hand, in the flanging support unit 60A, a connection mechanism 90 extending toward the mounting table 20 is formed on the lower surface of the base member 61 instead of the connection fixture moving mechanism 80. In connection with this, the guide cylinder 66 in the flanging support unit 60A can be set so that its movement is not separately controlled, but only the movement of the base member 61 in the up-down direction is guided.

[0088] The connection mechanism 90 may include: arms 91 extending from a plurality of locations on the lower surface of the base member 61 toward the mounting table 20; and connection hooks 92 provided at the top of each arm 91 and capable of connecting to the mounting table 20. Preferably, the length of the arm 91 is adjusted in consideration of the axial length of the stator core 2, etc. In addition, the connection hook 92 may be connected to and disconnected from a part of the mounting table 20 at any timing, and its specific structure is not particularly limited, and may be a connection structure other than a hook.

[0089] The connection mechanism 90 including the above-mentioned structure can be connected to the mounting platform 20 when the mounting platform 20 on which the stator 1 is mounted moves upward by the lifting mechanism 30 and the upper surface 2B of the stator core 2 abuts against the abutting protrusion 64A of the flange support unit 60A. Specifically, the mounting platform 20 and the flange support unit 60A can be connected by operating the connection hook 92 so that the connection hook 92 is locked to the edge of the mounting platform 20.

[0090] When the mounting table 20 and the flanging support unit 60A are connected by the connection mechanism 90, the flanging support unit 60A moves in the vertical direction following the movement of the mounting table 20. Therefore, after the twisting process is performed by the twisting jig 40, when the lowering operation of the lifting mechanism 30 is started, the flanging support unit 60A is lowered together with the mounting table 20. As a result, the base member 61 of the flanging support unit 60A presses the upper surface 2B of the stator core 2. Therefore, in the stator manufacturing device 10A of the present modified example, the segment coil 4 can also be reliably separated from the twisting jig 40.

[0091] Furthermore, when the above-described coupling mechanism 90 is employed, it is not necessary to separately control the descending timing of the burring support unit 60 as the separation jig, and thus the separation jig can be realized with a simple structure.

[0092] In the above-mentioned stator manufacturing devices 10 and 10A, the segment coil 4 can be reliably separated from the torsion jig 40 by lowering the separation jig (specifically, the flanging support unit 60 and the flanging support unit 60A) together with the stage 20 after the torsion processing of the stator 1. On the other hand, as a separation jig disclosed in the present invention, any separation jig can be used as long as it can press the stator 1 after the torsion processing, and is not limited to the above-mentioned separation jig. Specifically, as a separation jig, for example, a cam member that functions in a manner of pressing in a direction of separation from each other can be provided between the flanging support unit 60 and the torsion jig 40, and between the flanging support unit 60 and the stator core 2, and the cam member is operated corresponding to the timing of the descent of the stage 20. In addition, in the present embodiment and the modified example, the case where the separation jigs are both composed of the flanging support units 60 and 60A is shown as an example, but the separation jig can also be provided as a member different from the flanging support unit 60.

[0093] <Manufacturing method of stator>

[0094] Next, a method for manufacturing a stator according to an embodiment of the present disclosure is described. In the present embodiment, a method for manufacturing the above-mentioned stator 1 using the above-mentioned stator manufacturing device 10 as a device for executing the stator manufacturing method is described as an example. However, it should be clearly understood that the manufacturing method of the present disclosure is not limited to the implementation based on the above-mentioned manufacturing device 10, and a stator having a structure different from the above-mentioned stator 1 can also be manufactured. It should be noted that the description of the effects shown below also serves as a description of the effects of the stator manufacturing device 10 according to the present embodiment.

[0095] In addition, the stator manufacturing method described below can be implemented by, for example, operating various components of the stator manufacturing device 10 based on a prescribed instruction from a computer of the control device 12 included in the stator manufacturing device 10. Therefore, the stator manufacturing method of the present embodiment can be provided in the form of a program such as software including instructions for causing a processor of the computer constituting the above-mentioned control device 12 to execute prescribed actions, in the form of a non-transitory recording medium storing the program, or in the form of an application program provided via a network or the like.

[0096] Fig. 9 FIG. 10 and FIG. 11 are flowcharts showing an example of a method for manufacturing a stator according to an embodiment of the present disclosure. Figure 3 It should be noted that in FIG10 and FIG11, for easy understanding of the working state, the illustration of components other than the main working parts such as the housing 11 and the guide rod 33 is omitted.

[0097] like Fig. 9 As shown, in the manufacturing method of the stator of the present embodiment, first, the stator 1 to be subjected to twisting is placed on the mounting table 20 (step S1). The stator 1 placed on the mounting table 20 is positioned by the positioning member 22 so that its central axis CA is coaxial with the axis of the twisting mechanism 50 and the center of the flange support unit 60 (see FIG. Fig. 10A ).

[0098] When the stator 1 is placed on the mounting table 20, a twisting jig 40 for twisting the stator 1 is selected and connected to the twisting mechanism 50 (step S2. Fig. 10B The selected torsion fixture 40 is connected to the fixture holder 70 (it should be noted that Fig. 10B The substrate (not shown) is transported to the use position P1, thereby being arranged at a position where it can be connected to the twisting mechanism 50. It should be noted that the order of step S1 and step S2 is not limited to the above order.

[0099] When the twisting fixture 40 is connected to the twisting mechanism 50, the lifting mechanism 30 is then activated. Fig. 10B As shown by arrow A1, the mounting table 20 starts to rise (step S3), so that the upper surface 2B of the stator core 2 of the stator 1 on the mounting table 20 abuts against the abutment protrusion 64A of the base member 61 of the flange support unit 60 (step S4. Fig. 10C ).

[0100] In the state where upper surface 2B of stator core 2 abuts against abutment protrusion 64A of base member 61, advancing and retracting mechanism 63 is operated, thereby displacing flange support member 62 from the stored state to the protruding state (step S5). Since protruding flange support member 62 supports the periphery of top end portion 4D of segment coil 4 together with insulating paper 5, the portion supported by flange support member 62 can serve as a starting point (or fulcrum) during the twisting process described later.

[0101] When the upper surface 2B of the stator core 2 abuts against the abutment protrusion 64A of the base member 61, the fixture moving mechanism 80 is activated, and the flange support unit 60 is controlled to move along with the movement of the mounting table 20. Fig. 10C As shown by arrow A2, stator 1 rises with the movement of stage 20. When stator 1 further rises with the rise of elevating mechanism 30 and jig moving mechanism 80, at least a portion of tip portion 4D of segment coil 4 is inserted into the insertion portion of twist jig 40 (step S6). When tip portion 4D of segment coil 4 is inserted into the insertion portion of twist jig 40, elevating mechanism 30 and jig moving mechanism 80 are temporarily stopped.

[0102] Twisting jig 40 selected in step S2 may be, for example, a jig capable of twisting all six segment coils 4 inserted into slots 3 of stator 1. In this case, twisting jig 40 may include six crowns that can rotate concentrically, and each crown may include an insertion portion into which a portion of top end portion 4D of segment coil 4 can be inserted. Here, as for top end portion 4D of segment coil 4, it is sufficient that a portion of top end portion 4D that becomes connection portion 4C is inserted into the insertion portion. Accordingly, the length of the insertion portion of twisting jig 40 or the rising position of stage 20 may be adjusted.

[0103] When the insertion of the distal end portion 4D of the segment coil 4 into the insertion portion of the twisting jig 40 is completed, the twisting mechanism 50 is rotated, whereby each crown of the twisting jig 40 is rotated in the clockwise direction and the counterclockwise direction (step S7. Fig.11A ). After the end portion is inserted into the insertion portion of each crown, the top end portion 4D of the segmented coil is twisted by the rotation of each crown. Fig.11AAs shown by arrows A3 and A4, if the lifting mechanism 30 and the clamp moving mechanism 80 are further raised along with the twisting action of each crown, it is possible to suppress the elongation and breakage of the segment coil 4, which is preferable.

[0104] When the rotation of each crown of twist jig 40 is completed, top end portion 4D of segment coil 4 is disengaged from the insertion portion, thereby separating the two. At this time, in the stator manufacturing method of the present embodiment, in order to reliably separate twist jig 40 from segment coil 4, as shown in FIG. Fig. 11B As shown by arrows A5 and A6, both the mounting platform 20 and the flange support unit 60 are lowered (step S8). The lowering of the mounting platform 20 can be achieved by the lifting mechanism 30, and the lowering of the flange support unit 60 can be achieved by the fixture moving mechanism 80.

[0105] As described above, when the flange support unit 60 is lowered as the mounting table 20 is lowered, the base member 61 of the flange support unit 60 is lowered, so that the contact protrusion 64A of the base member 61 presses the upper surface 2B of the stator core 2 downward. Thus, the weight of the stator 1 and the pressing force from the flange support unit 60 act to separate the segment coil 4 from the twist jig 40. Therefore, even if a part of the segment coil 4 is caught in the gap of the twist jig 40, for example, the segment coil 4 can be reliably separated from the twist jig 40.

[0106] When the segment coil 4 is separated from the twisting jig 40 by the lowering of the stage 20 and the flanging support unit 60A, it is determined whether the twisting process has been completed (step S9). For example, when the segment coil 4 that has not been twisted is left on the stator 1 (no in step S9), after the twisting jig 40 connected to the twisting mechanism 50 is replaced with a twisting jig that can perform the twisting process on the segment coil 4 that has not been twisted (step S10), the process returns to step S2. When the twisting process has been completed (yes in step S10), the flanging support 62 is set to the storage state and the flanging support unit 60 is separated from the stator 1, and the stage 20 is lowered onto the conveying roller 23, and the stator 1 is conveyed to the next process (for example, the welding process of the connection part 4C).

[0107] In the above-mentioned stator manufacturing method, an example of implementing the method using the stator manufacturing device 10 is described, but the method may be implemented using other devices, such as the stator manufacturing device 10A. In this case, a step of fixing the flange support unit 60 to the mounting table 20 using the connecting mechanism 90 (for example, after step S4) may be adopted instead of the lowering action of the flange support unit 60 by the fixture moving mechanism 80.

[0108] As described above, in the stator manufacturing apparatus and manufacturing method of the present embodiment, segment coil 4 can be reliably separated from twisting jig 40 by using a separation jig that presses the stator 1 after the twisting process in a direction away from twisting jig 40. In addition, by using the separation jig, a series of twisting processes can be performed without fixing stator 1 to mounting table 20, so that a manufacturing apparatus and manufacturing method with a high manufacturing yield can be provided.

[0109] The present disclosure is not limited to the above-mentioned embodiments, and various changes can be made to implement within the scope of the main purpose of the present disclosure. Moreover, all these changes are included in the technical ideas of the present disclosure. In addition, in the present disclosure, as long as no contradiction occurs, each component can have only one or more than two.

[0110] All documents, including publications, patent applications, and patents, cited in this specification are individually indicated and incorporated herein by reference, and all of the contents of the documents are incorporated herein by reference to the same extent as described herein.

[0111] Regarding the use of nouns and the same indicators used in association with the description of the present disclosure (especially in association with the following claims), as long as it is not specifically stated in this specification or there is no obvious contradiction with the context, it is interpreted as covering one and more parties. Regarding the terms "have", "have", "include" and "include", as long as it is not specifically stated, it is interpreted as an open term (i.e., "including but not limited to..."). Regarding the specific description of the numerical range in this specification, as long as it is not specifically stated in this specification, it is only intended to serve as a shorthand method for referring to each value within the range one by one, and each value is introduced into the specification as if it is listed one by one in this specification. Regarding all methods described in this specification, as long as it is not specifically stated in this specification or there is no obvious contradiction with the context, it can be carried out in all appropriate orders. Regarding all examples or exemplary expressions used in this specification (such as "etc."), as long as there is no special claim, it is only intended to better illustrate the present disclosure, not to set a limitation on the scope of the present disclosure. Any expression in the specification is not interpreted as representing an element not recorded in the claims as an indispensable element in the implementation of the present disclosure.

[0112] In this specification, including the best mode known to the inventor for implementing the present disclosure, the preferred embodiments of the present invention are described. For those skilled in the art, as long as the above description is read, the deformation of these preferred implementation methods should be known. The inventor expects that the skilled person will appropriately apply such deformation, and it is expected that the present disclosure will be implemented in a method other than that specifically described in this specification. Therefore, as allowed in the applicable law, the present disclosure includes all modifications and equivalents of the contents recorded in the claims attached to this specification. Moreover, as long as it is not particularly pointed out in this specification or there is no obvious contradiction with the context, any combination of the above elements in all deformations is included in the present disclosure.

Claims

1. A stator manufacturing device, comprising: The stator having a stator core and a plurality of segmented coils is placed on the mounting table, wherein: The stator core has a plurality of slots, and the plurality of segment coils are respectively inserted into the slots; A lifting mechanism to raise and lower the loading platform; a twisting jig disposed above the mounting table and having an insertion portion into which a top end portion of the segment coil exposed above the stator core can be inserted; A torsion mechanism to rotate the torsion fixture; as well as A separation jig is disposed between the mounting table and the twisting jig, and presses the stator, after the segment coil has been twisted by rotating the twisting mechanism with the distal end portion inserted in the insertion portion, in a direction away from the twisting jig, so as to separate the segment coil from the twisting jig.

2. The stator manufacturing device according to claim 1, wherein: The separation fixture comprises: a separation fixture body, which is arranged between the mounting table and the torsion fixture; and a fixture moving mechanism, which moves the separation fixture body in the upward and downward directions. The fixture moving mechanism lowers the separation fixture body as the lifting mechanism descends, thereby the separation fixture body presses the stator core to separate the segment coil from the torsion fixture.

3. The stator manufacturing device according to claim 1, wherein: The separation fixture comprises: a separation fixture main body, which is arranged between the mounting table and the torsion fixture; and a connecting mechanism, which connects the separation fixture main body to the mounting table. Before the mounting table is lowered by the lifting mechanism, the connecting mechanism is connected to the mounting table, and the separation fixture main body is lowered as the lifting mechanism is lowered, so that the separation fixture main body presses the stator core to separate the segment coil from the torsion fixture.

4. The stator manufacturing device according to any one of claims 1 to 3, wherein: The separation fixture is a flange support unit, which includes: an annular base member; a flange support member, which is arranged on the base member and inserted between the segmented coils exposed at the upper part of the stator core to support the insulating paper inserted into the slot; and an advance and retreat mechanism, which enables the flange support member to advance and retreat in a direction close to or away from the axis of the base member.

5. The stator manufacturing device according to claim 4, wherein: When the stator placed on the mounting table is raised by the lifting mechanism, a portion of the base member comes into contact with the upper surface of the stator core.

6. The stator manufacturing device according to claim 1, further comprising: The rotating jig holder is disposed between the twisting mechanism and the separation jig and includes a plurality of support portions capable of supporting a plurality of the twisting jigs, respectively.

7. A method for manufacturing a stator, comprising the following steps: A stator having a stator core and a plurality of segmented coils is placed on a mounting table, wherein: The stator core has a plurality of slots, and the plurality of segment coils are respectively inserted into the slots; disposing a twisting jig above the mounting table, wherein the twisting jig includes an insertion portion into which a tip portion of the segment coil of the stator mounted on the mounting table and exposed above the stator core can be inserted; raising the mounting table to insert at least a portion of the top end portion of the segment coil into the insertion portion; rotating the twisting jig to twist the top end portion of the segment coil; and The mounting table is lowered and a separation jig disposed between the mounting table and the twist jig is operated to press the stator in a direction away from the twist jig, thereby separating the segment coil from the twist jig.

Images