Armature manufacturing method and armature manufacturing device

Abstract

And the armature manufacturing efficiency is improved. In this manufacturing method, a stator (10) is manufactured, the stator (10) having a stator core (12) in which a plurality of slots are formed, and a plurality of segment coils (20), the two leg portions of each segment coil being inserted into each slot, and the plurality of segment coils being arranged in a circular ring shape and overlapping in a multilayer shape in the radial direction of the stator core (12). In the manufacturing method, in an assembly step, an assembly jig (40) in which a plurality of assembly slots are formed is used to overlap the plurality of segment coils (20) in a multilayer shape, and at least one of the width and the length of the assembly slots is set to be larger than the width and the length of the plurality of slots formed in the stator core (12). In the insertion step, a plurality of segment coils (20) stacked in multiple layers are inserted into a plurality of slots of a stator core (12).

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing an armature and a device for manufacturing the armature. Background Art

[0002] Japanese Patent Application Publication No. 2020-182339 discloses an arrangement device that forms ordered coils by arranging multiple segmented coils in a circular ring shape for each layer. Each layer of ordered coils is gripped by a chuck, removed from the arrangement device, combined with other layers of ordered coils, and inserted into slots in a stator core.

[0003] Japanese Patent No. 3975891 discloses a segment coil annular arrangement device, wherein a segment coil insertion portion storing a plurality of segment coils is used to insert a jig that projects sequentially from the inner diameter side, thereby arranging the plurality of segment coils in multiple layers. Summary of the Invention

[0004] Problems to be solved by the invention

[0005] Japanese Patent Application Laid-Open No. 2020-182339 does not disclose a specific method of combining (assembling) the ordered coils of each layer.

[0006] In the prior art disclosed in Japanese Patent No. 3975891, the annular arrangement device itself is not only complicated and bulky, but also takes a lot of time to arrange the segmented coils of a motor. Therefore, there is room for improvement from the perspective of improving manufacturing efficiency.

[0007] The present disclosure has been made in consideration of the above circumstances, and an object thereof is to provide a method for manufacturing an armature and an apparatus for manufacturing an armature that can improve manufacturing efficiency.

[0008] Means used to solve problems

[0009] The present invention discloses a method for manufacturing an armature, comprising: a core having a plurality of slots formed therein; and a plurality of segment coils, wherein two legs of the segment coils are inserted into each slot of the core, the plurality of segment coils being overlapped in multiple layers in a radial direction of the core and arranged in a circular ring shape. The method comprises: an assembling step of overlapping the plurality of segment coils in the multiple layers using an assembling jig having a plurality of aggregation slots formed therein, at least one of a width and a length of the plurality of aggregation slots being set to be larger than the plurality of slots formed in the core; and an inserting step of inserting the plurality of segment coils overlapped in the multiple layers into the plurality of slots formed in the core.

[0010] The armature manufacturing method of the present disclosure includes an arranging step of arranging the plurality of segment coils in an annular shape independently for each of the plurality of layers using a plurality of arranging jigs each having a plurality of arranging grooves.

[0011] In addition, the armature manufacturing method disclosed in the present invention comprises a gripping step in which the plurality of segment coils are gripped by a chuck, and the chuck is a structure capable of being split up and down. In the gripping step, the coil tail end side and the coil front end side of the plurality of segment coils are gripped by the split chuck.

[0012] In addition, in the armature manufacturing method disclosed herein, the plurality of segment coils are gripped by a chuck, and the armature manufacturing method includes a coil re-gripping process. In the coil re-gripping process, the coil tail ends of the plurality of segment coils are gripped and pulled out by the chuck, and then the front ends of the plurality of segment coils are re-gripped.

[0013] In addition, the present invention discloses a method for manufacturing an armature, wherein the armature comprises: a core having a plurality of slots formed therein; and a plurality of segment coils, wherein two legs of the segment coils are inserted into each slot of the core, and the plurality of segment coils are overlapped in multiple layers in a radial direction of the core and arranged in an annular shape. The method also comprises a re-grasping step of grasping the plurality of segment coils arranged in an annular shape using a clamp using a grasping chuck and removing them from the clamp, then placing the leg tips of the plurality of segment coils against a base, moving the grasping chuck relative to the plurality of segment coils toward the leg tips, and re-grasping the plurality of segment coils using the grasping chuck.

[0014] The present invention discloses an apparatus for manufacturing an armature, comprising: a core formed with a plurality of slots; and a plurality of segment coils, wherein two legs of the segment coils are inserted into each slot of the core, the plurality of segment coils being overlapped in multiple layers in a radial direction of the core and arranged in a circular ring shape. The apparatus for manufacturing the armature comprises: an assembling device having an assembling jig for overlapping the plurality of segment coils in the multiple layers, the assembling jig having a plurality of assembly slots, at least one of the width and length of the plurality of assembly slots being set to be larger than the plurality of slots formed in the core; and an inserting device for inserting the plurality of segment coils overlapped in the multiple layers into the plurality of slots formed in the core.

[0015] Furthermore, the armature manufacturing apparatus of the present disclosure includes an aligning device that independently arranges the plurality of segment coils in a ring shape for each of the plurality of layers using a plurality of aligning jigs each having a plurality of aligning grooves.

[0016] Furthermore, the armature manufacturing apparatus of the present disclosure includes a chuck having a structure capable of being divided into upper and lower parts and gripping the coil tail end sides and the coil front end sides of the plurality of segment coils.

[0017] Effects of the Invention

[0018] According to the method for manufacturing an armature disclosed herein, since the assembly step and the insertion step can be performed in parallel, the manufacturing time can be shortened and the manufacturing efficiency can be improved.

[0019] Furthermore, according to the method for manufacturing an armature of the present disclosure, since the arrangement step, the assembly step, and the insertion step can be performed in parallel, the manufacturing time can be shortened and the manufacturing efficiency can be improved.

[0020] In addition, according to the manufacturing method of the armature disclosed in the present invention, since there is a grasping process of grasping the coil tail end side and the coil front end side of the multiple segmented coils by a chuck that can be divided into upper and lower parts, the positions of the leg tips of the multiple segmented coils are stable. Therefore, when the multiple segmented coils are inserted into the slots of other clamps or cores, the leg tips can be easily aligned with the slots, thereby improving manufacturing efficiency.

[0021] Furthermore, according to the armature manufacturing method disclosed herein, the positions of the leg tips of the plurality of segment coils are stabilized by the re-grasping process. Therefore, when the plurality of segment coils are inserted into other jigs or slots of a core, the leg tips can be easily aligned with the slots, thereby improving manufacturing efficiency.

[0022] According to the armature manufacturing method disclosed herein, the positions of the leg tips of the plurality of segment coils are stabilized by the re-grasping process. Therefore, when the plurality of segment coils are inserted into other jigs or slots of a core, the leg tips are easily aligned with the slots, thereby improving manufacturing efficiency.

[0023] According to the armature manufacturing apparatus disclosed herein, since the collecting device and the inserting device can be operated in parallel, the manufacturing time can be shortened and the manufacturing efficiency can be improved.

[0024] Furthermore, according to the armature manufacturing apparatus disclosed herein, since the arranging apparatus, the collecting apparatus, and the inserting apparatus can be operated in parallel, the manufacturing time can be shortened and the manufacturing efficiency can be improved.

[0025] In addition, according to the armature manufacturing device disclosed in the present invention, the positions of the leg tips of the multiple segmented coils are stabilized by the chuck having a structure that can be divided into upper and lower parts and gripping the coil tail end side and coil front end side of the multiple segmented coils. Therefore, when the multiple segmented coils are inserted into the slots of another fixture or core, the leg tips can be easily aligned with the slots, thereby improving manufacturing efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a perspective view showing a stator manufactured by the armature manufacturing method according to the embodiment.

[0027] Figure 2 This is a front view of the segment coils included in the stator.

[0028] Figure 3 It is an explanatory diagram for explaining the method for manufacturing the armature according to the embodiment.

[0029] Figure 4 It is a cross-sectional view showing an assembly jig serving as a jig for segment coils according to the embodiment.

[0030] Figure 5 It is a top view showing the upper portion of the collecting jig.

[0031] Figure 6 is with Figure 5 The cross-sectional view corresponding to the F6-F6 line.

[0032] Figure 7A This is a first cross-sectional view for explaining a state when a segment coil is pulled out from an alignment jig using a gripping chuck, which is a segment coil chuck according to an embodiment.

[0033] Figure 7B This is a second cross-sectional view for explaining the state when the segment coil is pulled out from the alignment jig by the gripping chuck.

[0034] Figure 7C This is a third cross-sectional view for explaining the state when the segment coil is pulled out from the alignment jig by the gripping chuck.

[0035] Figure 8 is a cross-sectional view showing a first comparative example.

[0036] Figure 9A This is a first cross-sectional view for explaining the re-gripping step in the method for manufacturing the armature according to the embodiment.

[0037] Figure 9B This is a second cross-sectional view for explaining the re-grasping process.

[0038] Figure 9C This is a third sectional view for explaining the re-grasping step. DETAILED DESCRIPTION

[0039] Below, refer to Figures 1 to 9C In the drawings, some reference numerals may be omitted for easier viewing. Figure 1 1 shows a stator 10 manufactured by the armature manufacturing method of this embodiment in a perspective view. The stator 10 includes a stator core 12 and a plurality of segment coils 20. The stator 10 constitutes a three-phase AC rotating electrical machine together with a rotor (not shown), for example.

[0040] The stator core 12 is formed into a cylindrical shape by laminating multiple electromagnetic steel sheets. The stator core 12 includes a yoke 14, a plurality of teeth 16, and a plurality of slots 18. The teeth 16 and slots 18 are arranged alternately in the circumferential direction on the inner circumference of the stator core 12. The slots 18 are open on both sides in the axial direction and radially inward.

[0041] like Figure 2As shown, for example, segment coil 20 is formed from a rectangular cross-sectional flat wire made of copper or the like, formed into a generally U-shaped shape. Segment coil 20 includes a pair of legs 22 (not shown) extending parallel to each other, and a coil tail 24 connecting one end of each leg 22. The portion of segment coil 20 other than the distal ends (leg tips) of the pair of legs 22 is covered with an insulating film.

[0042] A pair of legs 22 are inserted from one axial side into separate slots 18 spaced apart in the circumferential direction of the stator core 12. An insulating member (not shown) (here, insulating paper) is sandwiched between each leg 22 and the stator core 12. Coil tails 24 are positioned outside the slots 18 on one axial side of the stator core 12, circumferentially connecting the base ends of the pair of legs 22. Multiple segment coils 20 are stacked in multiple layers (here, three layers) radially of the stator core 12 and arranged in a circular ring shape. The tip of each leg 22 of each segment coil 20 protrudes from the end surface on the other axial side of the stator core 12, is twisted, and then joined to the tip of the leg 22 of another segment coil 20.

[0043] A plurality of segment coils 20 are collectively inserted into the slots of the stator core in a state of being assembled in multiple layers using the manufacturing method and manufacturing apparatus described below. In this embodiment, three layers of segment coils 20 are formed.

[0044] Furthermore, in this embodiment, segment coils 20 are formed from flat wires made of metal wires with a rectangular cross-section. However, this is not limiting. Segment coils may also be formed from flat wires with a rectangular cross-section made of multiple bare wires. Furthermore, in this embodiment, the tips of the legs 22 of segment coils 20 are joined to the tips of the legs 22 of other segment coils 20. However, this is not limiting. Segment coils 20 may also be electrically joined to other segment coils 20 within slots 18 of stator core 12. Furthermore, in this embodiment, stator core 12 is formed from laminated steel plates. However, this is not limiting. At least a portion of stator core 12 may also be formed from a powder core.

[0045] Figure 3 An explanatory diagram illustrating the armature manufacturing method of this embodiment is shown. This armature manufacturing method includes an arrangement step, an assembly step, and an insertion step. In the arrangement step, multiple (here, three) arrangement jigs 30, each formed with a plurality of arrangement slots (not shown), are used to independently arrange the plurality of segment coils 20 in a circular ring shape in each of multiple (here, three) layers. In this arrangement step, the legs 22 of the plurality of segment coils 20 are sequentially inserted into the arrangement slots of the arrangement jig 30, one by one, staggered in the circumferential direction of the slots. Each leg 22 is inserted into the slots once, forming a layer.

[0046] In the assembly process, a segment coil assembly jig 40 (see FIG. 4 ) is used, which is a jig for segment coils having a plurality of assembly slots 44 formed therein. Figures 4 to 6 ), the plurality of segment coils 20 arranged in each of the plurality of layers as described above are stacked in multiple layers. In this assembly step, for example, the segment coils 20 of each layer are sequentially inserted into assembly slots 44 of an assembly jig 40 from the outermost layer, and stacked in layers. This results in a state where the plurality of segment coils 20 are assembled together and can be collectively inserted into stator core 12.

[0047] In the insertion process, the plurality of segment coils 20 stacked in multiple layers as described above are collectively inserted into the plurality of slots 18 formed in the stator core 12. At this time, for example, a jig is provided on the upper surface of the stator core 12 to guide the tips of the legs 22 of the segment coils 20. This allows the segment coils 20 to be stably inserted into the stator core 12. Figure 3 , the segment coil 20 , the arranging jig 30 , the collecting jig 40 , and the stator core 12 are schematically illustrated.

[0048] As described above, by dividing the process into an arrangement step, an assembly step, and an insertion step, parallel operations are possible, shortening the overall machine operation time per workpiece. In particular, in the arrangement step, by arranging each layer of segment coils 20 in parallel, manufacturing time can be significantly shortened compared to arranging each layer of segment coils 20 sequentially. Furthermore, to further improve manufacturing time efficiency, for example, by separating the gripping chucks that grip multiple segment coils 20 during the transition from the arrangement step to the assembly step from the gripping chucks that grip multiple segment coils 20 during the transition from the assembly step to the insertion step, parallel operations can be achieved, making it easier to align the gripping chuck shape with the annular shape of the segment coils 20 in each step.

[0049] like Figure 4 As shown, the assembly jig 40 used in the assembly process has an upper portion 42 formed in an annular shape and a lower portion 48 formed in a disc shape. The upper portion 42 and the lower portion 48 are arranged coaxially and supported by a plurality of support columns 56 (see FIG. Figures 7A to 7C ;exist Figure 4 Figure omitted) are connected to each other.

[0050] like Figure 5 and Figure 6 As shown, the upper portion 42 is formed with a plurality of slots, namely, collective slots 44, into which the legs 22 of the plurality of segment coils 20 are inserted. The lower ends of the legs 22 of the plurality of segment coils 20 inserted into the collective slots 44 abut against the lower portion 48. Figure 5 and Figure 6 In the figure, reference numeral 46 is a fastening hole for fastening the fixing support 56 .

[0051] At least one of the width and length (here, both) of collecting slots 44 is set to be larger than slots 18 formed in stator core 12. Specifically, collecting slots 44 are wider than slots 18 with insulating paper inserted, thereby easing the accuracy of leg tips when inserting leg portions 22 of segment coils 20 into collecting jig 40.

[0052] Thus, compared to directly inserting leg portions 22 of segment coils 20 into stator core 12, temporarily assembling them in assembly jig 40 makes the insertion operation easier. Furthermore, when inserting each layer of segment coils 20 into assembly jig 40 sequentially from the outermost layer, segment coils 20 in the earlier inserted layer can be easily prevented from interfering with later inserted segment coils 20.

[0053] In addition, if Figure 5 and Figure 6 As shown, collecting slot 44 of collecting jig 40 has a tapered portion 44A that tapers toward its upper opening. This tapered portion 44A guides legs 22 of segment coil 20 into collecting slot 44 , further easing the accuracy of leg tips when inserting legs 22 of segment coil 20 into collecting jig 40 .

[0054] Furthermore, while the present embodiment is described using an example having an arrangement step, an assembly step, and an insertion step, the present invention is not limited to this. For example, the arrangement step can be omitted, and multiple segment coils 20 can be directly inserted into assembly jig 40. Even in this case, the assembly step and the insertion step can be performed in parallel, thereby reducing manufacturing time. Furthermore, since the assembly step uses assembly jig 40 having assembly slots 44 that are larger in width or length than slots 18 formed in stator core 12, the assembly process can be performed at a higher speed, compared to conventional devices that operate at a lower speed when high precision is required, thereby reducing manufacturing time.

[0055] Figures 7A to 7C , a segment coil chuck, or gripping chuck 66, is shown for gripping a plurality of segment coils 20 arranged in an annular shape. As an example, gripping chuck 66 is divided into an upper gripping portion 68U and a lower gripping portion 68L. Upper gripping portion 68U grips the plurality of segment coils 20 from both the inner and outer circumferences. Lower gripping portion 68L is disposed below upper gripping portion 68U and grips the plurality of segment coils 20 from both the inner and outer circumferences. The gripping chuck 66 also includes a relative movement mechanism 70 for vertically moving upper gripping portion 68U and lower gripping portion 68L relative to each other. The gripping chuck 66 is moved by a handling device, such as a robot manipulator (not shown), to perform the gripping process.

[0056] Upper gripper 68U and lower gripper 68L include an inner circumference-side chuck 72 that contacts the plurality of segment coils 20 from the inner circumference, and an outer circumference-side chuck 74 that contacts the plurality of segment coils 20 from the outer circumference. Outer circumference-side chuck 74 includes, for example, a drive source such as an air cylinder that presses the plurality of segment coils 20 toward inner circumference-side chuck 72. Relative movement mechanism 70 includes a drive source such as an air cylinder that moves upper gripper 68U and lower gripper 68L relative to each other in the vertical direction.

[0057] In the gripping chuck 66 of the above structure, for example Figure 7A As shown, when the plurality of segment coils 20 are pulled out from the arrangement jig 30, the upper gripping portion 68U and the lower gripping portion 68L are close to each other, and the upper portion (the coil tail end side) of the plurality of segment coils 20 is gripped by the upper gripping portion 68U. Figure 7B As shown, the upper gripping portion 68U is raised relative to the lower gripping portion 68L so that the lower portions (the coil front ends) of the plurality of segment coils 20 are arranged at the height of the lower gripping portion 68L. Figure 7C As shown, lower gripping portion 68L grips the lower portions of multiple segment coils 20, and in this state, gripping chuck 66 is raised as a whole. This allows multiple segment coils 20 to be removed from alignment jig 30. The same procedure is also followed when removing multiple segment coils 20 from assembly jig 40.

[0058] As described above, the lower portions (leg tips) of the plurality of segment coils 20 pulled out are gripped by lower gripping portion 68L of gripping chuck 66, thereby improving the positioning accuracy of the leg tips. As a result, leg portions 22 of segment coils 20 can be easily inserted into stator core 12, thereby improving the manufacturing efficiency of stator 10. Furthermore, if the coils are not that long, it is not a problem to grip the coil tail end side of segment coil 20 with one gripping portion 68 of gripping chuck 67. However, in such cases, Figure 8 When the total length of the segment coil 20 is particularly long, as in the comparative example shown, the segment coil 20 tends to tilt. In this case, the lack of a device to restrict the position of the leg tips makes the position of the leg tips unstable. Consequently, when assembling or inserting multiple segment coils 20, it becomes difficult for the leg tips to align with the slots of the jig or core, complicating workpiece production. In contrast, in the gripping chuck 66 described above, the leg tips of the multiple segment coils 20 are gripped by the lower gripping portion 68L, stabilizing the leg tip position. This makes it easier for the leg tips to align with the slots during assembly or insertion, simplifying workpiece production and reducing the number of defective products.

[0059] In addition, if Figures 9A to 9CAs shown, even when the total length of the segment coil 20 is particularly long and the gripping chuck 67 has only one gripping portion 68, by performing a re-gripping process, the leg tip accuracy can be improved to the same degree as when the gripping chuck 66 is used. In this re-gripping process, after the plurality of segment coils 20 are removed from the jig by the gripping chuck 67, as shown in FIG. Figure 9A As shown, the lower ends (leg tips) of the plurality of segment coils 20 are placed against a base 76. Then, as shown in FIG. Figure 9B As shown in FIG. 1 , the gripping portion 68 is slightly loosened to deflect the gripping portion 68 toward the leg tips of the plurality of segmented coils 20. Figure 9C As shown, the plurality of segment coils 20 are re-grasped by the gripping portion 68. Thus, since the positions of the leg tips of the plurality of segment coils 20 are stable, the leg tips can be easily aligned with the grooves when assembled or inserted, making it easier to manufacture the workpiece.

[0060] Furthermore, in the above-mentioned embodiment, the case of manufacturing a stator has been described, but the present disclosure can also be applied to manufacturing a rotor.

[0061] In addition, the present disclosure can be implemented with various modifications without departing from the scope of the present disclosure. In addition, the scope of rights of the present disclosure is of course not limited to the above-mentioned embodiments.

[0062] In addition, the disclosure of Japanese Patent Application No. 2023-019286 filed on February 10, 2023 is incorporated herein by reference in its entirety. All documents, patent applications, and technical standards described in this specification are incorporated herein by reference to the same extent as if each individual document, patent application, or technical standard was specifically and individually indicated to be incorporated by reference.

Claims

1. A method for manufacturing an armature, wherein: The armature has: a core formed with a plurality of slots; and a plurality of segment coils, wherein two legs of the segment coils are inserted into the slots of the core, and the plurality of segment coils are overlapped in multiple layers in the radial direction of the core and arranged in a circular ring shape. The manufacturing method of the armature comprises: an assembling step of stacking the plurality of segment coils into the multi-layered shape using an assembling jig having a plurality of assembling slots formed therein, wherein at least one of a width and a length of the plurality of assembling slots is set to be larger than a plurality of slots formed in the core; as well as The inserting step inserts the plurality of segment coils stacked in the plurality of layers into the plurality of slots formed in the core.

2. The method for manufacturing an armature according to claim 1, wherein: The method includes an arranging step of arranging the plurality of segment coils in an annular shape independently for each of the plurality of layers using a plurality of arranging jigs each having a plurality of arranging grooves.

3. The method for manufacturing an armature according to claim 1, wherein: The plurality of segmented coils are gripped by a chuck, The armature manufacturing method includes a gripping step, wherein the chuck is structured to be split up and down, and in the gripping step, the coil tail end side and the coil front end side of the plurality of segment coils are gripped by the split chuck.

4. The method for manufacturing an armature according to claim 1, wherein: The plurality of segmented coils are gripped by a chuck, The armature manufacturing method includes a coil re-grasping step in which the coil tail ends of the plurality of segment coils are grasped and pulled out by the chuck, and then the front ends of the plurality of segment coils are re-grasped.

5. A method for manufacturing an armature, wherein: The armature has: a core formed with a plurality of slots; and a plurality of segment coils, wherein two legs of the segment coils are inserted into the slots of the core, and the plurality of segment coils are overlapped in multiple layers in the radial direction of the core and arranged in a circular ring shape. The manufacturing method of the armature comprises: In the re-grasping process, a plurality of segmented coils arranged in a circular shape using a clamp are grasped by a grasping chuck and pulled out from the clamp. Thereafter, the leg tips of the plurality of segmented coils are placed against a base, and the grasping chuck is moved relative to the plurality of segmented coils toward the leg tips, and the plurality of segmented coils are re-grasped by the grasping chuck.

6. An armature manufacturing device, wherein: The armature has: a core formed with a plurality of slots; and a plurality of segment coils, wherein two legs of the segment coils are inserted into the slots of the core, and the plurality of segment coils are overlapped in multiple layers in the radial direction of the core and arranged in a circular ring shape. The armature manufacturing device comprises: an assembling device comprising an assembling jig for overlapping the plurality of segment coils into the multi-layered shape, the assembling jig having a plurality of assembling slots, at least one of a width and a length of the plurality of assembling slots being set to be larger than a plurality of slots formed in the core; and An inserting device inserts the plurality of segment coils stacked in the plurality of layers into the plurality of slots formed in the core.

7. The armature manufacturing device according to claim 6, characterized in that: An arranging device is provided for arranging the plurality of segment coils in a circular shape independently for each of the plurality of layers using a plurality of arranging jigs each formed with a plurality of arranging grooves.

8. The armature manufacturing device according to claim 6, characterized in that A chuck is provided. The chuck is a structure that can be divided into upper and lower parts and grasps the coil tail end side and the coil front end side of the plurality of segment coils.

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