Coil insertion device and manufacturing method of stator

Abstract

To properly mount a coil on a stator core at a low cost.SOLUTION: A coil insertion device comprises an inner guide 11 disposed on a coil insertion direction side for inserting a coil 2 into a slot 3a of a stator core 3 and on a radially inner side of the stator core 3, an outer guide 12 disposed on the coil insertion direction side and on a radially outer side of the stator core 3, and a support guide 13 supporting the tip of the coil 2 in the slot 3a. When a plurality of layers of the coil 2 are gradually inserted into the slot 3a in the radial direction through the gap between the inner guide 11 and the outer guide 12, the inner guide 11 moves to the radially inner side each time the coil 2 is inserted into the slot 3a, thereby providing a gap between the inner guide 11 and the outer guide 12 into which a new coil 2 can be inserted, and the support guide 13 supports the tip of the coil 2 inserted into the slot 3a.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a coil insertion device that inserts a coil into a stator core, and a stator manufacturing method. [Background technology]

[0002] In recent years, motors using a stator and a rotor have been used. For example, the stator is formed by inserting segment coils into slots in a cylindrical stator core.

[0003] Patent Document 1 discloses a manufacturing method for a stator in which segment coils are assembled to a stator core while being overlapped in the radial direction of the stator core. Specifically, it discloses that the timing of inserting the coils is staggered to prevent insulation problems if the tip of the core interferes with the insulating paper. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2021-78257 Summary of the Invention [Problem to be solved by the invention]

[0005] In the stator manufacturing method disclosed in Patent Document 1, segment coils are assembled to a stator core in a state where they are overlapped in the radial direction, thereby avoiding insulation failures due to interference between the coils and between the coils and the insulating paper. This is because the coating at the tip of the coil is removed to form peeled parts, and if the coils are not overlapped, the peeled parts may come into contact when assembled to a core with a small gap, causing scratches. More specifically, by overlapping the segment coils in the radial direction before assembling them to a core with a small assembly gap, there are no space constraints, making it easier to avoid interference between the segment coils when overlapping them.

[0006] However, this requires multiple steps, namely overlapping the segments and inserting the overlapped segment coils into the stator core, and requires equipment for each step and time to perform each step, which increases the equipment costs and time costs.

[0007] The present disclosure provides a coil insertion device and a stator manufacturing method that can suitably assemble a coil into a stator core at low cost. [Means for solving the problem]

[0008] The coil insertion device according to the present disclosure is a coil insertion device that inserts coils into slots of a stator core, and includes an inner guide that is arranged on the coil insertion direction side where the coil is inserted into the slot of the stator core and on the radially inside of the stator core, an outer guide that is arranged on the coil insertion direction side and on the radially outside of the stator core, and a support guide that supports the tip of the coil within the slot, and when the coil is inserted into the slot in multiple layers in a radial direction through the gap between the inner guide and the outer guide, the inner guide moves radially inward each time the coil is inserted into the slot, providing a gap between the inner guide and the outer guide into which a new coil can be inserted, and the support guide supports the tip of the coil inserted into the slot. This allows the coils to be inserted into the slots of the stator core in stages while adjusting the position of the coils in each layer.

[0009] Moreover, a stator manufacturing method according to the present disclosure is a stator manufacturing method for manufacturing a stator using a coil insertion device that inserts a coil into a slot of a stator core, the coil insertion device having an inner guide arranged on a coil insertion direction side where the coil is inserted into the slot of the stator core and on the radially inner side of the stator core, an outer guide arranged on the coil insertion direction side and on the radially outer side of the stator core, and a support guide that supports a tip of the coil within the slot, and the method includes the steps of: when the coil is inserted into the slot in stages in multiple layers in the radial direction through a gap between the inner guide and the outer guide, the inner guide moves radially inward each time the coil is inserted into the slot, to provide a gap between the inner guide and the outer guide into which a new coil can be inserted; and, the support guide supports the tip of the coil inserted into the slot. This allows the coils to be inserted into the slots of the stator core in stages while adjusting the position of the coils in each layer. Effect of the Invention

[0010] According to the present disclosure, it is possible to provide a coil insertion device and a stator manufacturing method that can suitably assemble a coil into a stator core at low cost. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a diagram illustrating an example of a configuration of a coil insertion device according to a first embodiment. [Diagram 2] FIG. 2 is a perspective view showing an example of an inner guide according to the first embodiment. [Diagram 3] FIG. 2 is a perspective view showing an example of an outer guide according to the first embodiment. [Figure 4] 1 is a perspective view of a support guide according to a first embodiment, in which the upper end portion is stepped or inclined. FIG. [Diagram 5] 5A to 5C are diagrams showing a procedure for inserting coils into slots according to the first embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] First embodiment Hereinafter, a coil insertion device according to the present embodiment will be described with reference to the drawings. This coil insertion device is a coil insertion device used when inserting a segment coil into a stator core of a stator used in a motor.

[0013] Fig. 1 is a diagram showing an example of the configuration of a coil insertion device 1. The coil insertion device 1 includes an inner guide 11 arranged on the radial inside of a stator core, an outer guide 12 arranged on the radial outside, and a support guide 13 that supports the tip of a coil to be inserted in a slot of the stator core. In the following, the coil insertion device 1 will be described as inserting a coil 2, which is a segment coil, into a slot 3a of a cylindrically formed stator core 3 (see Fig. 4). The coil insertion device 1 will be described as inserting the coil 2 into the slot 3a in order from the radial outside.

[0014] In the following description, the stator core 3 is assumed to be a generally cylindrical shape with its central axis extending in the vertical direction. Furthermore, the coil insertion device 1 is assumed to lower the coil 2 from the upper side of the stator core 3 and insert it into the slot 3a. Therefore, in the following description, the upper side of the stator core 3 is referred to as the coil insertion direction side.

[0015] 2 is a perspective view showing an example of the inner guide 11. The inner guide 11 is disposed radially inside the stator core 3 in the coil insertion direction. In other words, the inner guide 11 is disposed radially inside the stator core 3 above the upper end portion of the stator core 3. The inner guide 11 abuts against the inside of the coil 2 inserted into the stator core 3, thereby adjusting the radial position of the coil 2.

[0016] 3 is a perspective view showing an example of the outer guide 12. The outer guide 12 is disposed radially outward of the stator core 3 in the coil insertion direction. In other words, the outer guide 12 is disposed radially outward of the stator core 3 above the upper end portion of the stator core 3. The outer guide 12 abuts against the outer side of the coil 2 inserted into the stator core 3, thereby adjusting the radial position of the coil 2.

[0017] The support guide 13 is inserted from the lower side of the stator core 3 and disposed in the slot 3a. The upper end of the support guide 13 is in contact with the tip end of the coil 2 in the slot 3a, and serves as an abutment portion that supports the tip end of the coil 2 from below and restrains the tip end of the coil 2.

[0018] Specifically, FIG. 4(a) is a perspective view of the case where the upper end of the support guide 13 is stepped, and shows a state where the coil 2 is in contact with it. FIG. 4(b) is a perspective view of the case where the upper end of the support guide 13 is stepped and the coil is not in contact with it. FIG. 4(c) is a perspective view of the case where the upper end of the support guide 13 is inclined. In this way, the upper end of the support guide 13 may be stepped or inclined, and is arranged so that the outer side in the radial direction is downward. In other words, when the tip of the coil 2 is in contact with the upper end of the support guide 13, a force is applied to the coil 2 to move it radially outward due to the stepped or inclined shape of the support guide 13.

[0019] In addition, insulating paper is provided in the slots 3a of the stator core 3 to insulate the coils 2 from the stator core 3. The support guide 13 has the role of spreading out the insulating paper provided in the slots 3a.

[0020] As shown in FIG. 4(c), the support guide 13 has a predetermined length in the radial direction, and multiple coils 2 arranged continuously in the radial direction can be placed on the support guide 13 at the same time.

[0021] The coil insertion device 1 also has a gripping unit 14 that grips the coil 2 with its lower tip protruding, above the inner guide 11 and the outer guide 12. That is, the gripping unit 14 moves while gripping the coil 2, and guides the coil 2 with the inner guide 11, the outer guide 12, and the support guide 13, thereby moving the coil 2 to an appropriate position in the slot 3a of the stator core 3.

[0022] Next, a description will be given of an example of a procedure for inserting the coils 2 into the slots 3a of the stator core 3 using the coil insertion device 1. Fig. 5(a) to Fig. 5(f) each show a cross-sectional view of the stator core 3 showing the vicinity of one slot 3a when the coil 2 is inserted into the slot 3a of the stator core 3.

[0023] Here, it is assumed that six layers of coils 2 are inserted into slots 3a in the radial direction. The coils 2 are coils 2a, 2b, 2c, 2d, 2e, and 2f in order from the outside in the radial direction. As will be described later, the coils 2a to 2f are inserted into slots 3a in order from the outside in the radial direction. Also, it is assumed that insulating paper is arranged in slots 3a in advance to insulate between the coils 2 and the slots 3a of the stator core 3.

[0024] 5(a), the inner guide 11 and the outer guide 12 are disposed at approximately the same height above the stator core 3. The inner guide 11 is disposed radially inward, i.e., toward the center of the stator core 3, and the outer guide 12 is disposed radially outward from the inner guide 11. Furthermore, the upper part of the support guide 13 is inserted into the slot 3a of the stator core 3 from below.

[0025] The gripping portion 14 pinches the coil 2a while protruding downward, and inserts the coil 2a into the slot 3a by moving downward from above the stator core 3. At this time, the inner guide 11 and the outer guide 12 guide the coil 2a so that it is disposed at the outermost position in the radial direction in the slot 3a.

[0026] In other words, at this time, the inner guide 11 and the outer guide 12 are arranged so that there is a gap that is a distance that allows one coil 2a to be inserted, and the position of this gap is the radially outermost position of the slot 3a.

[0027] As described above, when the coil 2a moves down from above the stator core 3, it is inserted into the gap between the inner guide 11 and the outer guide 12, and is inserted into the slot 3a. The lower end of the coil 2a comes into contact with the upper end of the support guide 13 at the radially outermost part of the slot 3a.

[0028] Next, as shown in FIG. 5(b), the gripping portion 14 pinches the coils 2b and 2c in a downward protruding state, and moves downward from above the stator core, thereby inserting the coils 2b and 2c into the slots 3a.

[0029] More specifically, the inner guide 11 and the outer guide 12 move radially outward once so that the coil 2a is disposed sufficiently radially outward, whereby the coil 2a is guided to a position where it does not interfere with the coils 2b and 2c.

[0030] Thereafter, the inner guide 11 moves radially inward to widen the gap between the inner guide 11 and the coil 2a so that the coils 2b and 2c can be inserted. Thereafter, the coil insertion device 1 moves the coils 2b and 2c held by the holding portion 14 so as to insert them into the gap.

[0031] Therefore, coils 2b and 2c are inserted into slot 3a while being disposed radially inward of coil 2a, with coil 2b adjacent to the radially inner side of coil 2a. At this time, the lower ends of coils 2b and 2c are in contact with the upper end of support guide 13.

[0032] Similarly, as shown in Figure 5(c), coil 2d and coil 2e can be arranged radially inward from coil 2c within slot 3a, and as shown in Figure 5(d), coil 2f can be arranged radially inward from coil 2e.

[0033] Furthermore, as shown in FIG. 5(e), by pushing the upper ends of the coils 2a to 2f downward, the coils 2a to 2f move from a state in which only their lower ends are inserted into the stator core 3 to a state in which they are inserted to a predetermined position.

[0034] 5(f), the support guide 13 moves downward and separates from the coils 2a to 2f. This allows the coils 2a to 2f to move downward without their lower ends coming into contact with the support guide 13 when their upper ends are pushed downward.

[0035] Furthermore, the inner guide 11 and the outer guide 12 are in a state of moving away from the coils 2a to 2f, respectively. That is, the inner guide 11 moves radially inward, and the outer guide 12 moves radially outward, so that the inner guide 11 is away from the coil 2f, and the outer guide 12 is away from the coil 2a. Therefore, when the upper ends of the coils 2a to 2f are pushed downward, the coils 2a to 2f can move downward without being hindered by the inner guide 11 and the outer guide 12.

[0036] From the above, when the coil is inserted radially in multiple layers in stages, the inner guide 11 moves radially inward each time a coil 2 is inserted into the slot 3a, providing a gap between the inner guide 11 and the outer guide 12 into which a new coil 2 can be inserted, and the support guide 13 can support the tip of the coil 2 inserted into the slot 3a.

[0037] This allows the process of overlapping multiple annular coil groups with different diameters, each of which has multiple segment coils aligned on a circumference, to form a coil group overlapped in multiple layers in the radial direction, and the process of inserting the coil group overlapped in multiple layers in the radial direction into a stator core to be performed in a single process, thereby reducing the time and cost required to manufacture a stator.

[0038] The present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit of the present invention. In other words, the above description has been omitted or simplified as appropriate for the purpose of clarity, and a person skilled in the art can easily modify, add, or convert each element of the embodiment within the scope of the present invention. [Explanation of symbols]

[0039] 1 Coil insertion device 2 Coil 3 Stator core 3a Slot 11 Inner Guide 12 Outer guide 13 Support Guide 14 Gripping part

Claims

1. A coil insertion device for inserting a coil into a slot of a stator core, an inner guide disposed on a coil insertion direction side in which the coil is inserted into the slot of the stator core and on a radially inner side of the stator core; an outer guide disposed on the coil insertion direction side and radially outward of the stator core; a support guide for supporting a tip of the coil within the slot; When the coil is inserted into the slot in a radial direction in stages through the gap between the inner guide and the outer guide, the inner guide moves inward in the radial direction each time the coil is inserted into the slot, to provide a gap between the inner guide and the outer guide into which the coil can be newly inserted; The support guide supports a tip end of the coil inserted into the slot. Coil insertion device.

2. The support guide is The contact portion on which the tip of the coil is placed is formed in a stepped shape, and the coil placed on the contact portion is shifted radially outward. The coil insertion device according to claim 1 .

3. The support guide is The contact portion on which the tip of the coil is placed is formed in an inclined shape, and the coil placed on the contact portion is shifted radially outward. The coil insertion device according to claim 1 .

4. The inner guide is When the coil is inserted into the slot, if the coil is disposed in the outermost layer in the radial direction, or if the coil is disposed in the innermost layer, the coil moves radially inward to form the gap into which one layer of coils can be inserted; When the coil is disposed in a layer other than the outermost layer and the innermost layer, the coil is moved radially inward to form the gap into which a plurality of coils can be inserted. The coil insertion device according to any one of claims 1 to 3.

5. A method for manufacturing a stator using a coil insertion device that inserts coils into slots of a stator core, comprising the steps of: The coil insertion device includes: an inner guide disposed on a coil insertion direction side in which the coil is inserted into the slot of the stator core and on a radially inner side of the stator core; an outer guide disposed on the coil insertion direction side and radially outward of the stator core; a support guide for supporting a tip of the coil within the slot; When the coil is inserted into the slot in a radial direction in stages through the gap between the inner guide and the outer guide, a step of: the inner guide moving inward in the radial direction each time the coil is inserted into the slot, thereby providing a gap between the inner guide and the outer guide into which a new coil can be inserted; The support guide supports the tip end of the coil inserted into the slot. Stator manufacturing method.

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