Winding method and winding device

Abstract

To provide a method for making a device for winding a wire around a linearly developed T-shaped connected core compact and for simplifying the operation of the device.SOLUTION: While drawing out a winding 28 from a nozzle 29, a stator winding 5 of a first slot is wound around teeth 9 of a T-shaped connection core 2. Then, by tilting the T-shaped connection core 2 toward the winding side, the end of the stator winding 5 is drawn through a notch 21a of the T-shaped connection core 2 to the opposite winding side of a first electrical insulator assembly 3. Then, by moving the nozzle 29 in the longitudinal direction of the first electrical insulator assembly 3, a winding (crossover wire) 28 is drawn to the opposite winding side of the first electrical insulator assembly 3. By raising the first electrical insulator assembly 3, the end of the winding (crossover wire) 28 is drawn through a notch 21b of the first electrical insulator assembly 3 to the winding side. Then, the winding 28 is wound around the other teeth 9 of the T-shaped connection core 2 to form the stator winding 5 of a second slot.SELECTED DRAWING: Figure 10

Description

[Technical Field]

[0001] The present invention relates to a method and apparatus for winding a coupled core. [Background technology]

[0002] Electric motors (concentrated winding motors) are known that have a stator and a rotor, and in which the stator windings are wound around the teeth of the stator core that constitutes the stator. In concentrated winding motors, the stator windings are wound around the teeth via insulators (electrical insulator assemblies).

[0003] Known methods for winding a stator winding around the teeth of a stator core include the nozzle winding method and the flyer method. As shown in Figure 1(b) of Patent Document 1 below, the nozzle winding method involves moving the nozzle up and down and back and forth while drawing out the stator winding from the tip of the nozzle for each tooth of the stator core, and rotating the stator core to move the nozzle around the teeth and wind the stator winding around the teeth. As shown in Figure 1(a) of Patent Document 1 below, the flyer involves rotating the flyer at high speed and moving back and forth while drawing out the stator winding from the tip of each tooth of the stator core, to wind the stator winding around the teeth.

[0004] However, in the method described in Patent Document 1, the stator core is closed in an annular shape, which narrows the spaces (slots) between the teeth of the stator core, limiting the range of the stator winding winding operation by the nozzles and flyers that move relatively within the slots, making it impossible to increase the number of turns of the stator winding around the teeth.

[0005] Therefore, a method has been proposed in which the stator core is expanded linearly, widening the slots between the teeth, and then winding the stator winding around each tooth. For example, Figure 1 of Patent Document 2 below illustrates how the stator winding is wound using a nozzle around each tooth of an expanded core in a linearly expanded state. With an expanded core, it is easy to ensure winding space for the stator winding, which improves the space factor within the stator winding slot and enables high output with the same volume. This also has the advantage of reducing the amount of magnets containing heavy rare earth elements used. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 2019-22449 [Patent Document 2] Japanese Patent Application Laid-Open No. 2000-83357 Summary of the Invention [Problem to be solved by the invention]

[0007] In this type of concentrated winding motor, the stator windings of the same phase wound around each tooth of the expanding core are connected in series via crossover wires. For example, paragraphs

[0185] to

[0222] and Figures 36 and 38 of the above-mentioned Patent Document 1 describe an example in which crossover wires are arranged within inner transverse lines, outer transverse lines, inner lines, and outer lines formed in an electrical insulator assembly to connect the stator windings of the same phase. As described above, to arrange the crossover wires within each line formed in the electrical insulator assembly, as shown in Patent Documents 1 and 2, this cannot be achieved by simply tilting the nozzle when winding the stator winding around each tooth. Instead, the nozzle must be erected vertically, and the stator winding drawn from the nozzle tip must be arranged within each line to form a crossover wire. In other words, in addition to the up-and-down, left-and-right, and forward-and-back movement of the nozzle described in Patent Document 2, complex operations are required: erecting the nozzle, moving the up-and-down nozzle tip into each line, and then arranging the crossover wire within each line.

[0008] Such complex nozzle operation requires more sophisticated control, which increases the cost of the device, and also causes the device to become larger because the vertical dimension of the device must be increased due to the need to erect the nozzle.

[0009] The present invention has been made to solve these problems, and provides a small, inexpensive winding method and winding device that can wind the stator winding around the teeth and install the jumper wires with simple operations. [Means for solving the problem]

[0010] The invention of claim 1 relates to a stator for an electric motor in which straight T-shaped connected cores to which electrical insulator assemblies are attached are fastened together in a circular ring shape. The straight T-shaped connected core has a winding side where the stator winding is wound around the teeth via the electrical insulator assembly by inserting a winding lead-out portion into a slot between the teeth of the T-shaped connected core and wrapping around the teeth, and a counter-winding side located opposite the winding side. The winding method for the straight T-shaped connected core to which an electrical insulator assembly is attached, which draws the winding in the longitudinal direction of the counter-winding side, includes the steps of winding the stator winding around the teeth of the T-shaped connected core and pulling the winding end of the stator winding out of the notch in the electrical insulator assembly to the counter-winding side of the electrical insulator assembly by tilting the T-shaped connected core toward the winding side.

[0011] The invention of claim 2 relates to a stator for an electric motor in which straight T-shaped connected cores to which electrical insulator assemblies are attached are fastened together in a circular ring shape. The straight T-shaped connected core has a winding side where the stator winding is wound around the teeth via the electrical insulator assembly by inserting a winding lead-out portion into a slot between the teeth of the T-shaped connected core and wrapping around the teeth, and a counter-winding side located opposite the winding side. The winding method for the straight T-shaped connected core to which an electrical insulator assembly is attached, which draws the winding in the longitudinal direction of the counter-winding side, includes the steps of winding the stator winding around the teeth of the T-shaped connected core and tilting the T-shaped connected core to the counter-winding side, thereby drawing the winding end of the stator winding through the notch in the electrical insulator assembly to the counter-winding side of the electrical insulator assembly.

[0012] The invention of claim 3 is characterized in that the winding end of the stator winding drawn out to the anti-winding side of the electrical insulator assembly of claim 1 or claim 2 is drawn in the longitudinal direction of the anti-winding side of the electrical insulator assembly by moving the winding draw-out portion along the longitudinal direction of the linear T-shaped connected core, or by moving the linear T-shaped connected core in its longitudinal direction.

[0013] The invention described in claim 4 is characterized in that the winding is routed in the longitudinal direction of the anti-winding side of the electrical insulator assembly described in claim 3, sandwiching the winding around a protrusion provided on the anti-winding side of the electrical insulator assembly.

[0014] The invention described in claim 5 is characterized in that by raising the linear T-shaped connected core tilted toward the winding side or the anti-winding side described in claim 3, the end of the winding routed toward the anti-winding side of the electrical insulator assembly is pulled into the winding side of the electrical insulator assembly through the notch in the electrical insulator assembly.

[0015] The invention of claim 6 is characterized in that the notch of claim 5 is a stepped portion having stepped surfaces, and these stepped surfaces are used to pull the winding end of the stator winding of each phase from the winding side to the anti-winding side of the electrical insulator assembly, and pull the end of the winding that has been pulled to the anti-winding side from the anti-winding side to the winding side of the electrical insulator assembly.

[0016] The invention of claim 7 is characterized in that, in a three-phase winding electric motor, the winding lead-out portion of claim 6 is formed by winding the stator windings of each phase one at a time, or two phases at a time, or all three phases together, around the teeth of the straight T-shaped connection core, and then the straight T-shaped connection core is tilted toward the winding side or the anti-winding side to pull out the winding end of the stator winding to the anti-winding side of the electrical insulator assembly, and the winding lead-out portion is moved in the longitudinal direction of the anti-winding side of the electrical insulator assembly, or the straight T-shaped connection core is moved in its longitudinal direction to pull the winding in the longitudinal direction of the anti-winding side of the electrical insulator assembly, and the straight T-shaped connection core in the tilted state toward the winding side or the anti-winding side is raised to pull in the end of the winding from the anti-winding side to the winding side of the electrical insulator assembly.

[0017] The invention of claim 8 is a winding device comprising: a rotation mechanism that holds and rotates a straight T-shaped couple core to which an electrical insulator assembly is attached; and a winding lead-out moving mechanism that winds a stator winding around the teeth of the straight T-shaped couple core via the electrical insulator assembly and moves the straight T-side couple core in the longitudinal direction on the opposite winding side of the electrical insulator assembly, or a couple core moving mechanism that moves the straight T-shaped couple core in its longitudinal direction. [Effects of the Invention]

[0018] According to the inventions of claims 1 and 2, the winding end of the stator winding can be drawn out to the opposite winding side of the electrical insulator assembly without operating the winding draw-out portion.

[0019] According to the invention of claim 3, the winding (crossover wire) can be routed on the opposite winding side of the electrical insulator assembly with a simple operation.

[0020] According to the invention as set forth in claim 4, it is possible to ensure a necessary insulation distance between the windings (crossover wires) of each phase.

[0021] According to the invention of claim 5, the end of the winding (crossover wire) can be pulled into the winding side of the electrical insulator assembly without operating the winding pull-out portion.

[0022] According to the invention of claim 6, when the winding end of the stator winding of each phase or the end of the winding (crossover wire) is passed between the winding side and the anti-winding side of the electrical insulator assembly, the necessary insulation distance can be secured between the windings of each phase and the wiring can be arranged in an orderly manner.

[0023] According to the invention of claim 7, it is possible to increase the degree of freedom in each of the operations of winding the stator winding around the teeth, pulling the end of the stator winding to the opposite winding side of the electrical insulator assembly, routing the windings (crossover wires) of each phase on the opposite winding side, and pulling the end of the windings (crossover wires) to the winding side. In particular, when these operations are performed for three phases at once, it is possible to shorten the work time and improve efficiency.

[0024] According to the invention of claim 8, the winding of the stator winding around the teeth, the pulling out of the electrical insulator assembly at the end of the stator winding to the opposite winding side, the routing of the windings (crossover wires) of each phase on the opposite winding side, and the pulling in of the ends of the windings (crossover wires) to the winding side can be realized with a simple device configuration. [Brief explanation of the drawings]

[0025] [Figure 1] FIG. 2 is a perspective view showing a stator according to the present invention. [Figure 2] FIG. 2 is an enlarged plan view showing a portion of the stator according to the present invention. [Figure 3]3 is an enlarged perspective view showing a part of a T-shaped connecting core according to the present invention. FIG. [Figure 4] 1 is a perspective view showing a state in which the T-shaped connecting core according to the present invention is linearly developed and both ends are gripped. FIG. [Figure 5] 1 is a perspective view showing a state in which a linear T-shaped connecting core according to the present invention is rotated. FIG. [Figure 6] 1 is a perspective view of a portion of a straight T-shaped connecting core according to the present invention, viewed from the first electrical insulator assembly side. FIG. [Figure 7] 1 is a perspective view showing a state in which a stator winding is started to be wound around a straight T-shaped connected core according to the present invention from the first electrical insulator assembly side. FIG. [Figure 8] 10 is a perspective view showing the state in the middle of winding a stator winding around a straight T-shaped connected core according to the present invention from the first electrical insulator assembly side. FIG. [Figure 9] 10 is a perspective view showing a state in which one slot of stator winding has been wound around a straight T-shaped connected core according to the present invention, starting from the first electrical insulator assembly side. FIG. [Figure 10] FIG. 2 is a perspective view showing a state in which the winding end of the stator winding is pulled out to the opposite winding side of the first electrical insulator assembly according to the present invention. [Figure 11] FIG. 10 is a perspective view showing how a winding (crossover wire) is routed on the opposite winding side of the first electrical insulator assembly according to the present invention. [Figure 12] FIG. 10 is a perspective view showing a state in which an end of a winding (crossover wire) is pulled into the winding side of the first electrical insulator assembly according to the present invention. [Figure 13] 10 is a perspective view showing the state in which the stator winding for the second slot is started to be wound around the straight T-shaped connected core according to the present invention from the first electrical insulator assembly side. FIG. [Figure 14] 10 is a perspective view showing the state in the middle of winding the stator winding for the second slot around the straight T-shaped connected core according to the present invention from the first electrical insulator assembly side. FIG. [Figure 15] 1 is a perspective view showing how three phases are collectively wound around a straight T-shaped connected core according to the present invention from the first electrical insulator assembly side. FIG. [Figure 16] 1 is a perspective view of a portion of a straight T-shaped connecting core according to the present invention, viewed from the side of a second electrical insulator assembly. FIG. [Figure 17] 10 is a perspective view showing a state in which the stator winding is started to be wound around the straight T-shaped connected core according to the present invention from the second electrical insulator assembly side. FIG. [Figure 18] 10 is a perspective view showing the state in which a stator winding is being wound around a straight T-shaped connected core according to the present invention from the second electrical insulator assembly side. FIG. [Figure 19] 10 is a perspective view showing a state in which one slot of stator winding has been wound around the straight T-shaped connected core according to the present invention from the second electrical insulator assembly side. FIG. [Figure 20] FIG. 2 is a perspective view showing a state in which the winding end of the stator winding is pulled out to the opposite winding side of the first electrical insulator assembly according to the present invention. [Figure 21] FIG. 1 is a perspective view showing how a winding (crossover wire) is routed on the opposite winding side of a first electrical insulator assembly according to the present invention. [Figure 22] FIG. 10 is a perspective view showing the state in which the end of a winding (crossover wire) is pulled into the winding side of the first electrical insulator assembly according to the present invention. [Figure 23] 10 is a perspective view showing the state in which the stator winding for the second slot is started to be wound around the straight T-shaped connected core according to the present invention from the second electrical insulator assembly side. FIG. [Figure 24] 10 is a perspective view showing the state in which the stator winding for the second slot is being wound around the straight T-shaped connected core according to the present invention from the second electrical insulator assembly side. FIG. [Figure 25] FIG. 10 is a perspective view illustrating how three phases are wound together from the second electrical insulator assembly side of the straight T-shaped connected core according to the present invention. [Figure 26] FIG. 10 is a perspective view showing another method of routing a winding (crossover wire) on the opposite winding side of the first electrical insulator assembly according to the present invention. [Figure 27]FIG. 10 is a perspective view showing how a winding (crossover wire) is routed around the winding side of the first electrical insulator assembly according to the present invention by yet another method. [Figure 28] FIG. 2 is a plan view showing a stator according to the present invention. [Figure 29] FIG. 10 is a perspective view showing how a stator winding is wound starting from the first electrical insulator assembly side of a straight T-shaped connected core in a conventional manner. [Figure 30] FIG. 10 is a perspective view showing the state in the process of winding a stator winding from the first electrical insulator assembly side of a straight T-shaped connected core in a conventional manner. [Figure 31] FIG. 10 is a perspective view showing a state in which the stator winding for the first slot has been wound from the first electrical insulator assembly side of a straight T-shaped connected core in a conventional manner. [Figure 32] FIG. 1 is a perspective view showing a state in which the winding end of a stator winding is pulled out to the opposite winding side of an electrical insulator assembly in a conventional manner. [Figure 33] FIG. 1 is a perspective view showing how a winding (crossover wire) is routed to the winding side of an electrical insulator assembly in a conventional manner, as viewed from the winding side. [Figure 34] FIG. 1 is a perspective view showing how a winding (crossover wire) is routed to the opposite winding side of an electrical insulator assembly in a conventional manner, as seen from the opposite winding side. [Figure 35] FIG. 1 is a perspective view showing a state in which an end of a winding (crossover wire) is pulled into the winding side of an electrical insulator assembly in a conventional manner. [Figure 36] FIG. 10 is a perspective view showing how the stator winding for the second slot begins to be wound from the first electrical insulator assembly side of the straight T-shaped connected core in a conventional method. [Figure 37] FIG. 10 is a perspective view showing the state in the middle of winding the stator winding for the second slot from the first electrical insulator assembly side of the straight T-shaped connected core in the conventional method. [Figure 38] FIG. 10 is a perspective view showing how the stator winding starts to be wound from the second electrical insulator assembly side of the straight T-shaped connecting core in the conventional method. [Figure 39]FIG. 10 is a perspective view showing the state in the process of winding a stator winding from the second electrical insulator assembly side of a straight T-shaped connected core in a conventional manner. [Figure 40] FIG. 10 is a perspective view showing a state in which the stator winding for the first slot has been wound from the second electrical insulator assembly side of the straight T-shaped connected core in the conventional method. [Figure 41] FIG. 1 is a perspective view showing a conventional method in which a winding (crossover wire) is routed to the opposite winding side of an electrical insulator assembly, as viewed from the winding side. [Figure 42] FIG. 1 is a perspective view showing a state in which an end of a winding (crossover wire) is pulled into the winding side of an electrical insulator assembly in a conventional manner. [Figure 43] FIG. 10 is a perspective view showing a state in which a winding is hooked onto a stepped portion of a first electrical insulator assembly of a straight T-shaped connecting core in a conventional manner. [Figure 44] FIG. 10 is a perspective view showing how the stator winding for the second slot begins to be wound from the second electrical insulator assembly side of the straight T-shaped connected core in the conventional method. DETAILED DESCRIPTION OF THE INVENTION

[0026] Hereinafter, an embodiment of the present invention will be described with reference to FIGS. 1 to 28. In this specification, the extension direction of the axis P of the stator (see FIG. 1) is referred to as the "axial direction." The axis P of the stator corresponds to the rotation center line of the rotor when the rotor is arranged to be rotatable relative to the stator. Furthermore, the circumferential direction centered on the axis P when viewed in a cross section perpendicular to the "axial direction" from one side of the axial direction is referred to as the "circumferential direction." The extension direction of a line passing through the axis P when viewed in a cross section perpendicular to the "axial direction" from one side of the axial direction is referred to as the "radial direction." The term "radially inner" refers to the radial direction toward the axis P when viewed in a cross section perpendicular to the "axial direction," and the term "radially outer" refers to the opposite side of the axis P along the "radial direction" when viewed in a cross section perpendicular to the "axial direction."

[0027] It should be noted that the terms "axial direction," "circumferential direction," and "radial direction" used with respect to the electrical insulator assemblies (first electrical insulator assembly, second electrical insulator assembly) correspond to the "axial direction," "circumferential direction," and "radial direction" of the stator when the electrical insulator assemblies are attached to a T-shaped connecting core (described later) and formed into a ring shape.

[0028] FIG. 1 is a perspective view of a stator 1 according to the present invention. The stator 1 of the present invention is composed of a T-shaped coupler core (T-shaped coupler core) 2, a first electrical insulator assembly 3, a second electrical insulator assembly 4, and a stator winding 5. In the stator 1 according to this embodiment, the first electrical insulator assembly 3 and the second electrical insulator assembly 4 sandwich the T-shaped coupler core 2 from one axial side and the other axial side of the T-shaped coupler core 2, thereby concealing some of the teeth and yoke of the T-shaped coupler core 2, which will be described later. The T-shaped coupler core 2 is formed by laminating electromagnetic steel sheets. The T-shaped coupler core 2 has a coupler end face 2A on one axial side and a coupler end face 2B on the other axial side. As shown in FIG. 2, the T-shaped coupler core 2 has a yoke 6, multiple teeth 7, and multiple slots 8 when viewed from one axial side.

[0029] The yoke 6 extends in the circumferential direction by connecting adjacent yokes 6 with thin-walled portions 6a, and in this embodiment, is formed in an annular shape. A plurality of teeth 7 are spaced apart along the circumferential direction of the yoke 6 and extend radially inward from the inner periphery of the yoke 6. Each tooth 7 comprises a tooth base 9 extending radially inward from the yoke 6 and a tooth tip portion 10 extending circumferentially at the tip of the tooth base 9. The tooth tip portion 10 has a tooth tip inner circumferential surface 10a on the radially inner side, which forms a coupled core inner space 11 (see FIG. 1 ). A rotor is rotatably disposed within the coupled core inner space 11. Various known rotor configurations can be used as the rotor. The stator 1 and the rotor disposed within the coupled core inner space 11 constitute an electric motor.

[0030] A slot 8 is defined by the yoke 6 and the teeth 7 adjacent to it in the circumferential direction. The slot 8 is defined by the inner wall surface (yoke inner wall surface) 6b of the yoke 6, the side surface (tooth base side surface) 9b of the tooth base portion 9 of the adjacent tooth 7, and the outer wall surface (tooth tip outer wall surface) 10b of the tooth tip portion 10. A slot opening 12 communicating with the slot 8 is formed between the tooth tip portions 10 of adjacent teeth 7. A first electrical insulator assembly 3 and a second electrical insulator assembly 4 are attached to the T-shaped couple core 2. The first electrical insulator assembly 3 and the second electrical insulator assembly 4 are arranged on both axial sides of the T-shaped couple core 2. The first electrical insulator assembly 3 is arranged on a couple core end face 2A on one axial side of the T-shaped couple core 2, and the second electrical insulator assembly 4 is arranged on a couple core end face 2B on the other axial side. The first electrical insulator assembly 3 and the second electrical insulator assembly 4 are formed from a resin having insulating properties.

[0031] As shown in FIG. 3 , the electrical insulator assembly 3 includes an outer wall portion 13 extending from the yoke 6 of the 2 on one axial side, an outer wall portion inner surface 13a forming the radially inner side of the outer wall portion 13, an inner wall portion 14 extending from one axial side of the tooth tip portion 10, an inner wall portion outer surface 14a forming the radially outer side of the inner wall portion 14, and a connecting portion 15 integrally connecting the outer wall portion 13 and the inner wall portion 14. The outer wall portion 13 extends in the circumferential and axial directions, and the inner wall portion 14 is disposed radially inward from the outer wall portion 13 and extends in the circumferential and axial directions. The connecting portion 15 extends in the circumferential, axial, and radial directions, has an opening on the other axial side, and has a U-shaped vertical cross section. The end face of the outer wall portion 13 on the other axial side and the end face of the opening of the connecting portion 15 form a continuous, flush plane.

[0032] As shown in Fig. 3, the electrical insulator assembly 4 is composed of an outer wall portion 16 extending from the yoke 6 of the T-shaped connecting core 2 on the other axial side, an outer wall portion inner surface 16a forming the radially inner side of the outer wall portion 16, an inner wall portion 17 extending from the other axial side of the tooth tip portion 10, an inner wall portion outer surface 17a forming the radially outer side of the inner wall portion 17, and a connecting portion 18 integrally connecting the outer wall portion 16 and the inner wall portion 17. The outer wall portion 16 extends in the circumferential and axial directions, and the inner wall portion 17 is disposed radially inward of the outer wall portion 16 and extends in the circumferential and axial directions. The connecting portion 18 extends in the circumferential, axial, and radial directions, has an opening on one axial side, and has a U-shaped vertical cross section. The other axial end face of the outer wall inner surface 16a and the opening end face of the connecting portion 18 form the same continuous plane.

[0033] The other axial side of the outer wall portion 13 of the first electrical insulator assembly 3 and one axial side of the outer wall portion 16 of the second electrical insulator assembly 4 have mating portions 13b, 16b formed in a stepped relationship, and the outer wall portion 13 of the first electrical insulator assembly 3 and the outer wall portion 16 of the second electrical insulator assembly 4 are mated using these mating portions 13b, 16b. Furthermore, the other axial side of the inner wall portion 14 of the first electrical insulator assembly 3 and one axial side of the inner wall portion 17 of the second electrical insulator assembly 4 have mating portions 14b, 17b formed in a stepped relationship, and the inner wall portion 14 of the first electrical insulator assembly 3 and the inner wall portion 17 of the second electrical insulator assembly 4 are mated using these mating portions 14b, 17b. By arranging the first electrical insulator assembly 3 so as to extend on one axial side of the T-shaped connecting core 2 and arranging the second electrical insulator assembly 4 so as to extend on the other axial side, the yoke inner wall surface 6b of the T-shaped connecting core 2 and the tooth base side surface 9b and tooth tip outer wall surface 10b shown in Figure 2 are completely covered by the first and second electrical insulator assemblies 3 and 4.

[0034] As shown in Fig. 3, a pair of step portions 19 having a plurality of (three in Fig. 3) step surfaces 13c to 13f are formed on the outer wall portion 13 of the first electrical insulator assembly 3, and notches 21a, 21b are formed between the pair of step portions 19 and a central portion 20. As shown in Fig. 2, protrusions 22a to 22c that protrude radially outward are formed on each of the step surfaces 13c to 13f, and a step space 23 (see Fig. 3) in which the winding can be routed is formed between the lower surface of the protrusion 22a and the step surface 13a.

[0035] The stator winding 5 is formed by winding a wire around the teeth 9 of the T-shaped connected core 2, the connecting portions 15 of the first electrical insulator assembly 3, and the connecting portions 18 of the second electrical insulator assembly 4, with the first electrical insulator assembly 3 and the second electrical insulator assembly 4 arranged on the T-shaped connected core 2. The above-mentioned nozzle winding method or flyer method can be used as a method for winding the wire around the teeth 9 and the connecting portions 15, 18. The winding is made of a conductor such as copper or aluminum, and an insulating coating that covers the outer periphery of the conductor.

[0036] In the present invention, when winding the windings around the teeth 9, the T-shaped connected core 2, to which the electrical insulator assemblies 3 and 4 are attached, is opened out in a straight line as shown in Figure 4. By opening the T-shaped connected core 2 in a straight line, the slots 8 between adjacent teeth 9 are widened, ensuring sufficient space for winding the stator winding 5. This improves the space factor of the stator winding 5 in the slots 8.

[0037] FIG. 4 shows an example of a rotation mechanism constituting a winding device of the present invention. The rotation mechanism A (A1, A2) in FIG. 4 has the function of gripping both ends of the linearly extended T-shaped couple core 2 and rotating the T-shaped couple core 2 as shown in FIG. 5. The rotation mechanism A (A1, A2) grips the T-shaped couple core 2 by clamping the couple core end faces 2A and 2B of the T-shaped couple core 2 with a pair of gripping pieces 24a and 24b. The gripping pieces 24a and 24b can clamp the couple core end faces 2A and 2B using a known clamping technique. The pair of gripping pieces 24a and 24b are connected to a rotating shaft 26 via a gripping table 25. By rotating the rotating shaft 26 using a rotation drive unit 27, the T-shaped couple core 2 can be rotated from the state shown in FIG. 4 to the state shown in FIG. 5 and from the state shown in FIG. 5 to the state shown in FIG. 4.

[0038] Next, a method (first embodiment) for winding a wire around a straight T-shaped connected core as shown in Fig. 3 using the winding device of the present invention will be described. Fig. 6 is an enlarged view of a portion of the T-shaped connected core 2 held by the rotation mechanism A (A1, A2) shown in Fig. 4. Note that the rotation mechanism A (A1, A2) is not shown in Fig. 6. In Fig. 6, the first electrical insulator assembly 3 is held by the rotation mechanism A (A1, A2) while positioned on one side (upper side) in the axial direction.

[0039] In this state, the winding 28 is wound around the teeth 9 of the T-shaped connected core 2 via the connecting portion 15 (top surface 15a, right side surface 15b1, left side surface 15b2) of the first electrical insulator assembly 3 and the connecting portion 18 (bottom surface 18a, right side surface 18b1, left side surface 18b2) of the second electrical insulator assembly 4. The winding 28 can be wound using the nozzle method or flyer method, as described above. In this embodiment, the nozzle method will be described as an example. The winding device of the present invention is composed of the rotation mechanism A (A1, A2) described above, a winding lead-out portion such as a nozzle for the nozzle method or a flyer for the flyer method, and a winding lead-out portion movement mechanism that moves the winding lead-out portion to a predetermined position. When winding the winding 28 around the teeth 9 via the connecting portions 15, 18, the winding is performed by pulling out the winding 28 from the tip of the nozzle 29 in a tilted position, and moving the nozzle 29 up and down and back and forth, as shown in FIG. 7 . Specifically, the nozzle 29 descends from above the first electrical insulator assembly 3 toward the upper surface 15a of the connecting portion 15 while pulling out the winding 28, and moves from the right side surface 15b1 of the connecting portion 15 to the right side surface 18b1 of the connecting portion 18 (diagonally downward) in order to wind the winding 28 around the connecting portions 15, 18 near the upper surface 15a.

[0040] 8, the nozzle 29 moves from the lower surface 15a of the connecting portion 15 to the left side surface 18b2 of the connecting portion 18 and around to the left side surface 15b2 of the connecting portion 15, and moves between the adjacent tooth 9. After that, the nozzle 29 moves again from the upper surface 15a of the connecting portion 15 to the right side surface 15b1 of the connecting portion 15 and to the right side surface 18b1 of the connecting portion 18, and the same operation is repeated. By repeating this operation a predetermined number of times, the winding 28 for the first slot is wound around the tooth 9 of the T-shaped connecting core 2 via the connecting portions 15 and 18. When the winding of the winding 28 for the first slot is completed, as shown in FIG. 9, the stator winding 5 is wound around one tooth 9 of the T-shaped connecting core 2 via the connecting portions 15 and 18, and the nozzle 29 is positioned between the adjacent tooth 9 on the side of the stator winding 5 and then stops temporarily.

[0041] Next, by rotating the rotary shaft 26 of the rotary mechanism A (A1, A2) shown in FIG. 5, the T-shaped connected core 2 is tilted toward the winding side (the side on which the stator winding 5 is wound) as shown in FIG. 10. As a result, the winding 28 drawn out from the nozzle 29 is drawn out from the notch 21a between adjacent first electrical insulator assemblies 3 to the counter-winding side (the side opposite the winding side) of the first electrical insulator assemblies 3. At this time, the nozzle 29 remains in its tilted state and does not move, but moves relatively toward the counter-winding side of the first electrical insulator assemblies 3. The winding 28 drawn out to the counter-winding side of the first electrical insulator assemblies 3 is drawn out while abutting against the step surface 13c (see FIG. 3) at the deepest part of the step portion 19 that forms the notch 21a, as shown in FIG. 10.

[0042] Once the nozzle 29 has moved to the anti-winding side of the first electrical insulator assembly 3 as shown in Fig. 10, the nozzle 29 is moved by the winding draw-out portion moving mechanism along the longitudinal direction of the first electrical insulator assembly 3 from the position indicated by the dotted line in Fig. 11 in the direction indicated by the solid line. As a result, the winding 28 drawn out from the nozzle 29 is pulled to the anti-winding side while hooked on the protrusion 22a. Then, once the nozzle 29 has moved to the position of the stepped portion 19 of the notched portion 21b of the fourth first electrical insulator assembly 3 from the right, two apart, the rotary shaft 26 of the rotary mechanism A (A1, A2) shown in Fig. 5 is rotated to raise the T-shaped connected core 2 as shown in Fig. 12.

[0043] As a result, the winding 28 drawn from the nozzle 29 is drawn into the winding side of the first electrical insulator assembly 3 through the notch 21b between adjacent first electrical insulator assemblies 3. At this time, the nozzle 29 remains in its tilted position and does not move, but moves relatively toward the winding side of the first electrical insulator assembly 3. The winding 28 drawn into the winding side is drawn into the winding side of the first electrical insulator assembly 3 while abutting against the step surface 13a (see FIG. 3) at the deepest part of the notch 21b, as shown in FIG. 12. After the winding 28 is drawn into the winding side, the nozzle 29 is moved to the right as shown in FIG. 12, so that the winding 28 is hooked onto the deepest part of the step 19. At this time, the nozzle 29 is positioned slightly above the center between adjacent teeth 9. In this state, the winding 28 is drawn between the step spaces 23 shown in FIG. 3 on the anti-winding side of the first electrical insulator assembly 3 to form a crossover wire.

[0044] 12, the nozzle 29 moves to the side surface 15b1 of the connecting portion 15 of the first electrical insulator assembly 3 and the side surface 18b1 of the second electrical insulator assembly 4, which have the notch 21b through which the winding 28 passes, as shown in FIG. 13. Thereafter, the nozzle 29 moves around the connecting portion 15 of the first electrical insulator assembly 3 and the connecting portion 18 of the second electrical insulator assembly 4 from the side surfaces 15b1 and 18b1, passing through the underside 18a of the second electrical insulator assembly 18, to the opposite side surfaces 18b2 and 15b2, thereby winding the winding 28 around the connecting portions 15 and 18, as shown in FIG.

[0045] Thereafter, the winding 5 moves toward the upper surface 15a of the connecting portion 15, and then moves again toward the side surfaces 15b1, 18b1 of the connecting portions 15, 18, and the same operation is repeated. By repeating this operation a predetermined number of times, the winding 28 of the second slot is wound around the teeth 9 of the T-shaped connecting core 2 via the connecting portions 15, 18. After the winding of the winding 28 of the second slot is completed, the same operation as after the winding of the winding 28 of the first slot is completed is repeated to wind the stator winding 5 around the teeth 9 spaced two apart via the first and second electrical insulator assemblies 3, 4. Thereafter, as shown in FIGS. 4 and 5 , in the case of a T-shaped connecting core 2 having 12 teeth 9, this is repeated until the winding of the winding 28 of the fourth slot is completed, thereby completing the winding of the stator winding 5 of the first phase (for example, U phase).

[0046] After the winding of the stator winding 5 of the first phase (e.g., U phase) is completed, the stator winding 5 of the second phase (e.g., V phase) is wound around the teeth 9 of the T-shaped connecting core 2 shown in Fig. 6 adjacent to the teeth 9 around which the first phase is wound, in the same manner as the winding of the stator winding 5 of the first phase. After the winding of the stator winding 5 of the second phase (e.g., V phase) is completed, the winding 28 forming the stator winding 5 of the second phase is routed through the step space 30 (see Fig. 3) between the protrusions 22a and 22b shown in Fig. 2 on the opposite winding side of the first electrical insulator assembly 3 to form a crossover wire. After the winding of the stator winding 5 of the second phase (e.g., V phase) is completed, the stator winding 5 of the third phase (e.g., W phase) is wound around the teeth 9 of the T-shaped connecting core 2 shown in Fig. 6 adjacent to the teeth 9 around which the second phase is wound, in the same manner as the winding of the stator winding 5 of the second phase. Then, when the winding of the third-phase (e.g., W-phase) stator winding 5 is completed, the winding 28 that forms the third-phase stator winding 5 is routed through the step space 31 (see FIG. 3) between the protrusions 22b and 22c shown in FIG. 2 on the opposite winding side of the first electrical insulator assembly 3 to form a crossover wire. In this way, the three-phase stator windings 5 ​​are wound around the teeth 9 of the T-shaped connecting core 2 via the first and second electrical insulator assemblies 3 and 4.

[0047] 15 shows a case where the windings 28 for the three phases described above are wound together using three nozzles 29. As described above, the winding method of the present invention may wind the windings for each phase one by one, or may wind two phases together, or may wind all three phases together. Regardless of the winding method used, when the three-phase stator winding 5 is wound, the windings 28 for each phase are routed via the protrusions 22a, 22b, and 22c on the opposite winding side of the first electrical insulator assembly 3 to form crossover wires.

[0048] 16 to 25 show another embodiment (embodiment 2) of the present invention. Fig. 16 shows an enlarged view of a portion of the T-shaped connecting core 2 held by the rotation mechanism A (A1, A2) shown in Fig. 4. Note that the rotation mechanism A (A1, A2) is omitted from Fig. 16. Also, in Fig. 16, the second electrical insulator assembly 4 is held by the rotation mechanism A (A1, A2) with the second electrical insulator assembly 4 positioned on one side (upper side) in the axial direction.

[0049] In this state, the winding 28 is wound around the teeth 9 of the T-shaped connected core 2 via the connecting portions 18, 15 of the first and second electrical insulator assemblies 4, 3. In this embodiment, the winding 28 is wound using a nozzle method, but a flyer method may also be used. When winding the winding 28 around the teeth 9 via the connecting portions 18, 15, as shown in FIG. 17 , the winding 28 is wound around the teeth 9 by pulling out the winding 28 from the tip of the nozzle 29 in a tilted position and moving the nozzle 29 up and down and back and forth. Specifically, the nozzle 29 moves down from above the second electrical insulator assembly 4 toward the connecting portion 18 while pulling out the winding 28, and then moves toward the side surfaces 18b2, 15b2 of the connecting portions 18, 15 (diagonally downward) near the connecting portion 18 to wind the winding 28 around the connecting portions 18, 15.

[0050] 18, the nozzle 29 moves around from the bottom surface 15a of the connecting portion 15 to the side surface 15b1, 18b1 on the opposite side of the connecting portion 15. After that, it moves again from the top surface 15a of the connecting portion 18 to the side surface 18b2, 15b2 of the connecting portions 18, 15, and repeats the same operation. By repeating this operation a predetermined number of times, the winding 28 for the first slot is wound around the tooth 9 of the T-shaped connecting core 2 via the connecting portions 18, 15. When the winding of the winding 28 for the first slot is completed, as shown in FIG. 19, the stator winding 5 is wound around one tooth 9 of the T-shaped connecting core 2 via the connecting portions 18, 15, and the nozzle 29 is positioned slightly below and between the adjacent teeth 9 to the side of the stator winding 5, and then stops temporarily.

[0051] Next, by rotating the rotary shaft 23 of the rotating mechanism A (A1, A2), the T-shaped connected core 2 is tilted toward the anti-winding side as shown in FIG. 20. As a result, the winding 28 drawn out from the nozzle 29 is drawn out from the notch 21a of the first electrical insulator assembly 3 toward the anti-winding side of the first electrical insulator assembly 3. At this time, the nozzle 29 remains in its tilted state and does not move, but moves relatively toward the anti-winding side of the first electrical insulator assembly 3. The winding 28 drawn out toward the anti-winding side of the first electrical insulator assembly 3 is drawn out while abutting against the step surface 13c (see FIG. 3) at the deepest part of the step portion 19 that forms the notch 21a, as shown in FIG. 20.

[0052] Once the nozzle 29 has moved to the counter-winding side of the first electrical insulator assembly 3 as shown in Fig. 20, the nozzle 29 is moved along the longitudinal direction of the first electrical insulator assembly 3 from the position indicated by the dotted line in Fig. 21 in the direction indicated by the solid line. As a result, the winding 28 drawn out from the nozzle 29 is drawn to the counter-winding side while being hooked onto the protrusion 22a (see Fig. 2) provided on the counter-winding side of the first electrical insulator assembly 3. Then, once the nozzle 29 has moved to the position of the stepped surface 13c of the notched portion 21b of the fourth first electrical insulator assembly 3 from the right, two apart, the rotary shaft 26 of the rotary mechanism A (A1, A2) is rotated to raise the T-shaped connected core 2 as shown in Fig. 22.

[0053] As a result, the winding 28 drawn out from the nozzle 29 is drawn into the winding side of the first electrical insulator assembly 3 through the cutout 21b between the first electrical insulator assemblies 3. At this time, the nozzle 29 remains in its tilted position and does not move, but moves relatively toward the winding side of the first electrical insulator assembly 3. The winding 28 drawn into the winding side is drawn into the winding side of the first electrical insulator assembly 3 while abutting against the step surface 13c (see FIG. 3) at the deepest part of the step portion 19c that forms the cutout 21b, as shown in FIG. 22. After the winding 28 has been drawn into the winding side, the nozzle 29 is moved to the right as shown in FIG. 22, so that the winding 28 is hooked onto the deepest part of the step portion 19. At this time, the nozzle 29 is positioned slightly below the center between adjacent teeth 9. In this state, the winding 28 is routed through the stepped space 23 shown in FIG. 3 on the opposite winding side of the first electrical insulator assembly 3 to form a crossover wire.

[0054] 22, the nozzle 29 moves to the side surface 15b1 of the connecting portion 15 of the first electrical insulator assembly 3 and the side surface 18b1 of the second electrical insulator assembly 4, which have the notch 21b through which the winding 28 passes, as shown in FIG. 23. Thereafter, the nozzle 29 moves around the connecting portion 15 of the first electrical insulator assembly 3 and the connecting portion 18 of the second electrical insulator assembly 4 from the side surfaces 15b1 and 18b1, passing through the top surface 18a of the second electrical insulator assembly 18, to the opposite side surfaces 18b2 and 15b2, thereby winding the winding 28 around the connecting portions 18 and 15, as shown in FIG.

[0055] Then, the winding 5 moves again from the lower surface 15a of the connecting portion 15 to the side surfaces 15b1, 18b1 of the connecting portions 15, 18, and the same operation is repeated thereafter. By repeating this operation a predetermined number of times, the winding 28 of the second slot is wound around the teeth 9 of the T-shaped connecting core 2 via the connecting portions 18, 15. After the winding of the winding 28 of the second slot is completed, the same operation as after the winding of the winding 28 of the first slot is completed is repeated to wind the stator winding 5 around another tooth 9 spaced two apart via the first and second electrical insulator assemblies 3, 4. Thereafter, for example, in the case of a T-shaped connecting core 2 having 12 teeth 9, this is repeated until the winding of the winding 28 of the fourth slot is completed, thereby completing the winding of the stator winding 5 of the first phase (e.g., U phase).

[0056] After the winding of the stator winding 5 of the first phase (e.g., U phase) is completed, the stator winding 5 of the second phase (e.g., V phase) is wound around the teeth 9 of the T-shaped connection core 2 shown in Fig. 16 adjacent to the teeth 9 around which the first phase is wound, in the same manner as the winding of the stator winding 5 of the first phase. After the winding of the stator winding 5 of the second phase (e.g., V phase) is completed, the winding 28 forming the stator winding 5 of the second phase is routed through the step space 30 between the protrusions 22a and 22b shown in Fig. 2 on the opposite winding side of the first electrical insulator assembly 3 to form a crossover wire. After the winding of the stator winding 5 of the second phase (e.g., V phase) is completed, the stator winding 5 of the third phase (e.g., W phase) is wound around the teeth 9 of the T-shaped connection core 2 shown in Fig. 16 adjacent to the teeth 9 around which the second phase is wound, in the same manner as the winding of the stator winding 5 of the second phase. Then, when the winding of the third-phase (e.g., W-phase) stator winding 5 is completed, the winding 28 that forms the third-phase stator winding 5 is routed through the step space 31 between the protrusions 22b and 22c shown in Figure 2 on the opposite winding side of the first electrical insulator assembly 3 to form a crossover wire. In this way, the three-phase stator winding 5 is wound around the teeth 9 of the T-shaped connecting core 2 via the first and second electrical insulator assemblies 3 and 4.

[0057] 25 shows a case where the windings 28 for the three phases described above are wound together using three nozzles 29. As described above, the winding method of the present invention may wind the windings 28 for each phase one by one, or may wind two phases together, or may wind all three phases together. Regardless of the winding method used, when the three-phase stator winding 5 is wound, the windings 28 for each phase are routed via the protrusions 22a, 22b, and 22c on the opposite winding side of the first electrical insulator assembly 3 to form crossover wires.

[0058] Fig. 26 shows yet another embodiment (Embodiment 3) of the present invention. Fig. 26 shows a winding method for winding 28 in the first embodiment shown in Figs. 6 to 15, but instead of the routing operation of winding (crossover wire) 28 in Fig. 11 (the method of moving nozzle 29 from the dotted line position to the solid line position), the method is realized by moving T-shaped couple core 2 in the direction of the arrow shown in Fig. 26. To perform this method, the winding device for winding 28 is provided with a couple core moving mechanism instead of the aforementioned winding lead-out portion moving mechanism. The couple core moving mechanism can be realized by a configuration in which rotation mechanism A (A1, A2) shown in Figs. 4 and 5 is moved directly in the longitudinal direction of T-shaped couple core 2, but is not limited to this.

[0059] Fig. 27 shows yet another embodiment (Embodiment 4) of the present invention. Fig. 27 shows a fourth embodiment of the winding method for winding 28 according to the second embodiment shown in Figs. 16 to 25, but instead of the routing operation of winding (crossover wire) 28 in Fig. 21 (the method of moving nozzle 29 from the dotted line position to the solid line position), the method is realized by moving T-shaped couple core 2 in the direction of the arrow shown in Fig. 27. To implement this method, the winding device for winding 28 is provided with a couple core moving mechanism instead of the aforementioned winding lead-out portion moving mechanism. The couple core moving mechanism can be realized by a configuration in which rotation mechanism A (A1, A2) shown in Figs. 4 and 5 is moved directly in the longitudinal direction of T-shaped couple core 2, but is not limited to this.

[0060] After winding the wire around the linearly expanded T-shaped connected core 2 as described above, the T-shaped connected core 2 is removed from the rotation mechanism A (A1, A2) of the winding device and its two ends are joined to form the annular stator 1 as shown in FIG. 28. The two ends are joined by overlapping the through hole 32a formed in one end 32 with the through hole 33a formed in the other end 33 and inserting a joining pin into the through holes 32a, 33a. The one end 32 and the other end 33 can be joined by mutually swapping the shapes of the one end 32 and the other end 33 shown in FIG. 28 in terms of the lamination positions of the electromagnetic steel sheets that make up the T-shaped connected core 2. The method for joining the one end 32 and the other end 33 is not limited to this method, and they may be joined by other known joining methods, such as welding. In this way, by winding the stator winding 5 around the T-shaped connected core 2 in a linearly expanded state, it is possible to increase the space factor of the stator winding 5 in the slots 8 when the T-shaped connected core 2 is formed into a ring shape.

[0061] In the present invention, when winding the winding 28 around the T-shaped connected core 2, the T-shaped connected core 2 can be tilted toward the winding side or the anti-winding side, thereby allowing the winding lead-out portions, such as the nozzle 29, to be kept in a tilted state at all times. This eliminates the need to erect the nozzle 29, as described in the prior art, and allows the winding device to be configured in a compact size. This point will be explained using Figures 29 to 37. Note that although the winding of the winding 28 can be performed using the nozzle method or flyer method described above in Figures 29 to 37 as well, the nozzle method will be explained as an example.

[0062] 29 to 37 are hypothetical diagrams illustrating the case where a winding 28 is wound by a conventional method around a T-shaped coupler core 2 to which electrical insulator assemblies 3 and 4 according to the present invention are attached. In the conventional method, the T-shaped coupler core 2 shown in Fig. 29 is fixed so that the first electrical insulator assembly 3 is on one side (upper side) in the axial direction by, for example, gripping the yoke 6 of the T-shaped coupler core 2 with gripping pieces 24a and 24b shown in Fig. 4, but does not include a mechanism (rotation drive unit 27) for rotating the T-shaped coupler core 2 as shown in Fig. 4.

[0063] In the conventional method, the winding 28 is also wound around the teeth 9 of the T-shaped connected core 2 via the connecting portions 15, 18 of the first and second electrical insulator assemblies 3, 4. When winding the winding 28 around the teeth 9 via the connecting portions 15, 18, as shown in Fig. 29, the winding 28 is drawn out from the tip of the tilted nozzle 29 while the nozzle 29 is moved up and down and back and forth. Specifically, the nozzle 29 moves down from above the first electrical insulator assembly 3 toward the connecting portion 15 while drawing out the winding 28, and then moves toward the side surfaces 15b1, 18b1 of the connecting portions 15, 18 (diagonally downward) near the connecting portion 15 to wind the winding 28 around the connecting portions 15, 18.

[0064] 30, the nozzle 29 moves from the lower surface 18a of the connecting portion 18 to the side surfaces 15b2, 18b2 on the opposite side of the connecting portions 18, 15, and moves between the adjacent teeth 9. After that, the nozzle 29 returns from the upper surface 15a of the connecting portion 15 to the side surfaces 15b1, 18b1 of the connecting portions 15, 18, and the same operation is repeated. By repeating this operation a predetermined number of times, the winding 28 for the first slot is wound around the teeth 9 of the T-shaped connecting core 2 via the connecting portions 15, 18. When the winding of the winding 28 for the first slot is completed, as shown in FIG. 31, the stator winding 5 is wound around one tooth 9 of the T-shaped connecting core 2 via the connecting portions 15, 18, and the nozzle 29 is positioned between the adjacent teeth 9 on the side of the stator winding 5 and then stops.

[0065] Next, a winding pull-out portion moving mechanism (not shown) positions the nozzle 29 vertically with the pull-out portion of the winding 28 facing downward, as shown in Figure 32, and moves the nozzle 29 to the opposite winding side of the first electrical insulator assembly 3. As a result, the winding 28 pulled out from the nozzle 29 is pulled out to the opposite winding side of the first electrical insulator assembly 3 through the notch 21a of the first electrical insulator assembly 3. At this time, the T-shaped connecting core 2 remains vertical and does not move. The winding 28 pulled out to the opposite winding side of the first electrical insulator assembly 3 is pulled out to the opposite winding side of the first electrical insulator assembly 3 while abutting against the deepest step surface 13c (see Figure 3) of the step portion 19 that forms the notch 21b, as shown in Figure 32.

[0066] Once the nozzle 29 has moved to the anti-winding side of the first electrical insulator assembly 3 as shown in Fig. 32, the nozzle 29 is moved along the longitudinal direction of the first electrical insulator assembly 3 from the position shown by the dotted line in Fig. 33 to the direction shown by the solid line. As a result, the winding 28 drawn out from the nozzle 29 is pulled to the anti-winding side while being hooked on the protrusion 22a (see Fig. 2). Fig. 34 shows this state as viewed from the anti-winding side of the first electrical insulator assembly 3. As shown in FIG. 34, the nozzle 29 is moved until it reaches the position of the step surface 13c of the notch 21b of the fourth first electrical insulator assembly 3 from the right, two apart, as shown in FIG. 35. Then, a winding pull-out portion moving mechanism (not shown) moves the nozzle 29 in an upright position to the winding side of the first electrical insulator assembly 3, and then, on that winding side, the nozzle 29 is tilted so that the pull-out portion faces the first electrical insulator assembly 3, as shown in FIG.

[0067] As a result, the winding 28 drawn out from the nozzle 29 is drawn into the winding side of the first electrical insulator assembly 3 through the notch 21b between the first electrical insulator assemblies 3. At this time, the T-shaped connected core 2 remains vertical and does not move. The winding 28 drawn into the winding side is drawn into the winding side of the first electrical insulator assembly 3 while abutting against the step surface 13c (see FIG. 3) at the deepest part of the step portion 19 that forms the notch 21b, as shown in FIG. 35. After the winding 28 is drawn into the winding side, the nozzle 29 is moved to the right as shown in FIG. 35 to hook the winding 28 into the deepest part of the step portion 19. At this time, the nozzle 29 is positioned slightly above the center between adjacent teeth 9. In this state, the winding 28 is drawn between the step spaces 23 shown in FIG. 3 on the anti-winding side of the first electrical insulator assembly 3 to form a crossover wire.

[0068] 35, the nozzle 29 moves to the side surface 15b1 of the connecting portion 15 of the first electrical insulator assembly 3 and the side surface 18b1 of the second electrical insulator assembly 4, which have the notch 21b through which the winding 28 passes, as shown in FIG. 36. Thereafter, the nozzle 29 moves around the connecting portion 15 of the first electrical insulator assembly 3 and the connecting portion 18 of the second electrical insulator assembly 4 from the side surfaces 15b1 and 18b1, passing through the underside 18a of the second electrical insulator assembly 18, to the opposite side surfaces 18b2 and 15b2, thereby winding the winding 28 around the connecting portions 15 and 18, as shown in FIG.

[0069] Thereafter, the winding 5 moves toward the upper surface 15a of the connecting portion 15, and then returns to the side surfaces 15b1, 18b1 of the connecting portions 15, 18, and repeats the same operation. By repeating this operation a predetermined number of times, winding of the winding 28 for the second slot is completed around the teeth 9 of the T-shaped connecting core 2 via the connecting portions 15, 18. After winding of the winding 28 for the second slot is completed, the same operation as after winding of the winding 28 for the first slot is completed is repeated to wind the stator winding 5 around another tooth 9 spaced two apart via the first and second electrical insulator assemblies 3, 4. Thereafter, if the T-shaped connecting core 2 has 12 teeth 9, this is repeated until winding of the stator winding 5 for the fourth slot is completed, thereby completing winding of the stator winding 5 for the first phase (for example, U phase).

[0070] After the winding of the stator winding 5 of the first phase (for example, U phase) is completed, the stator winding 5 of the second phase (for example, V phase) is wound around the teeth 9 of the T-shaped connection core 2 shown in Fig. 29 adjacent to the teeth 9 around which the first phase is wound, in the same manner as the winding of the stator winding 5 of the first phase. After the winding of the stator winding 5 of the second phase (for example, V phase) is completed, the winding 28 forming the stator winding 5 of the second phase is routed through the step space 30 between the protrusions 22a and 22b shown in Fig. 2 on the opposite winding side of the first electrical insulator assembly 3, forming a crossover wire. After the winding of the stator winding 5 of the second phase (for example, V phase) is completed, the stator winding 5 of the third phase (for example, W phase) is wound around the teeth 9 of the T-shaped connection core 2 shown in Fig. 29 adjacent to the teeth 9 around which the second phase is wound, in the same manner as the winding of the stator winding 5 of the second phase. Then, when the winding of the third-phase (e.g., W-phase) stator winding 5 is completed, the winding 28 that forms the third-phase stator winding 5 is routed through the step space 31 between the protrusions 22b and 22c shown in Figure 2 on the opposite winding side of the first electrical insulator assembly 3 to form a crossover wire. In the conventional method, the three-phase stator winding 5 is wound around the teeth 9 of the T-shaped connecting core 2 via the first and second electrical insulator assemblies 3 and 4 in this manner.

[0071] That is, when winding a wire around the T-shaped connecting core 2 using the conventional method, the winding lead-out portion, such as a nozzle, must be vertically erected. This requires securing space above the T-shaped connecting core 2 for the winding lead-out portion to be erected, resulting in an increase in the size of the winding device. Furthermore, it is difficult to hook the winding 28 onto the protrusions 22a to 22c (see FIG. 2) on the counter-winding side of the first electrical insulator assembly 3 while the winding lead-out portion, such as a nozzle, is erected, complicating control of the winding lead-out portion. In contrast, the winding method of the present invention does not require the winding lead-out portion, such as a nozzle, to be erected. This eliminates the need to secure space above the T-shaped connecting core 2, allowing for a more compact device. Furthermore, by tilting the T-shaped connecting core 2 toward the winding side or the counter-winding side, the winding 28 can be easily hooked onto the protrusions 22a to 22c (see FIG. 2) on the counter-winding side of the first electrical insulator assembly 3, simplifying control of the winding lead-out portion.

[0072] 38 to 44 are hypothetical diagrams illustrating the case where winding is performed by a conventional method on a T-shaped coupler core 2 with the electrical insulator assemblies 3 and 4 according to the present invention attached from the side of the second electrical insulator assembly 4. In this case, too, the T-shaped coupler core 2 shown in Fig. 38 is fixed by, for example, gripping the yoke 6 with the gripping pieces 24a and 24b shown in Fig. 4, but does not include a mechanism (rotation drive unit 27) for rotating the T-shaped coupler core 2 as shown in Fig. 4.

[0073] In this conventional method, the winding 28 is wound around the teeth 9 of the T-shaped connected core 2 via the connecting portions 18, 15 of the first and second electrical insulator assemblies 4, 3. While the nozzle method is shown as an example of winding the winding 28, a flyer method may also be used. When winding the winding 28 around the teeth 9 via the connecting portions 18, 15, as shown in FIG. 38 , the nozzle 29 is moved up and down and back and forth while the winding 28 is drawn out from the tip of the tilted nozzle 29. Specifically, the nozzle 29 moves down from above the second electrical insulator assembly 4 toward the connecting portion 18 while drawing out the winding 28. The nozzle 29 then moves diagonally downward toward the side surfaces 18b2, 15b2 of the connecting portions 18, 15 attached to the teeth 9 that face the adjacent teeth 9 to wind the winding 28 around the connecting portions 18, 15 near the connecting portions 18.

[0074] 39, the nozzle 29 is moved from the bottom surface 15a of the connecting portion 15 to the side surfaces 15b1, 18b1 on the opposite side of the connecting portions 15, 18. After that, the nozzle 29 is moved from the top surface 18a of the connecting portion 18 back to the side surfaces 18b2, 15b2 of the connecting portion 15, and the same operation is repeated. By repeating this operation a predetermined number of times, the winding 28 for the first slot is wound around the teeth 9 of the T-shaped connecting core 2 via the connecting portions 18, 15. When the winding of the winding 28 for the first slot is completed, as shown in FIG. 40, the stator winding 5 is wound around one tooth 9 of the T-shaped connecting core 2 via the connecting portions 18, 15, and the nozzle 29 is positioned slightly below and between the adjacent teeth 9 to the side of the stator winding 5, and then temporarily stops.

[0075] Next, by operating a winding draw-out mechanism (not shown), the nozzle 29 is raised so that the draw-out portion of the winding 28 faces upward, and is moved to the anti-winding side of the first electrical insulator assembly 3 as shown by the solid line in Figure 41. As a result, the winding 28 drawn out from the nozzle 29 is drawn out to the anti-winding side of the first electrical insulator assembly 3 through the notch 21a of the first electrical insulator assembly 3. At this time, the T-shaped connected core 2 remains vertical and does not move. The winding 28 drawn out to the anti-winding side of the first electrical insulator assembly 3 is drawn out while abutting against the step surface 13c (see Figure 3) at the deepest part of the step portion 19 that forms the notch 21b.

[0076] Once the nozzle 29 has moved to the anti-winding side of the first electrical insulator assembly 3 as shown in FIG. 41 , the nozzle 29 is moved along the longitudinal direction of the first electrical insulator assembly 3 from the position indicated by the solid line in FIG. 41 to the direction indicated by the dotted line. As a result, the winding 28 drawn out from the nozzle 29 is drawn around to the anti-winding side while hooked onto a protrusion 22a (see FIG. 2 ) provided on the anti-winding side of the first electrical insulator assembly 3. Then, once the nozzle 29 has moved to the position of the stepped surface 13c of the notched portion 21b of the fourth first electrical insulator assembly 3 from the right, two apart (the dotted line position in FIG. 41 ), a winding draw-out portion moving mechanism (not shown) is driven to move the nozzle 29 to the winding side of the electrical insulator assembly 3 as shown in FIG. 42. In this state, the winding 28 is drawn around the stepped space 23 shown in FIG. 3 on the anti-winding side of the first electrical insulator assembly 3 to form a crossover wire.

[0077] The winding 28 drawn out from the nozzle 29 is then drawn into the winding side of the first electrical insulator assembly 3 through the cutout 21b of the first electrical insulator assembly 3. At this time, the T-shaped connected core 2 remains upright and does not move. The winding 28 drawn into the winding side is drawn into the winding side of the first electrical insulator assembly 3 while abutting against the step surface 13c at the deepest part of the step portion 19 that forms the cutout 21b, as shown in FIG. 42. After the winding 28 has been drawn into the winding side, the nozzle 29 is moved diagonally upward to the right as shown in FIG. 43, so that the winding 28 is hooked onto the deepest part of the step portion 19. At this time, the nozzle 29 is positioned slightly above the center between adjacent teeth 9.

[0078] After the nozzle 29 has moved to the position shown in FIG. 43, the nozzle 29 moves around the connecting portion 15 of the first electrical insulator assembly 3, which has the notch 21b through which the winding 28 passes, and the connecting portion 18 of the second electrical insulator assembly 4, from the side surfaces 15b1, 18b1 side, past the top surface 18a side of the second electrical insulator assembly 4, to the opposite side surfaces 18b2, 15b2 side, as shown in FIG. 44, thereby winding the winding 28 around the connecting portions 18, 15.

[0079] Thereafter, the winding 5 moves toward the lower surface 15a of the connecting portion 15, and then moves again toward the side surfaces 15b1, 18b1 of the connecting portions 15, 18, and the same operation is repeated. By repeating this operation a predetermined number of times, winding of the winding 28 for the second slot is completed around the teeth 9 of the T-shaped connecting core 2 via the connecting portions 18, 15. After winding of the winding 28 for the second slot is completed, the same operation as after winding of the winding 28 for the first slot is completed is repeated to wind the stator winding 5 around another tooth 9 spaced two apart via the second and first electrical insulator assemblies 4, 3. Thereafter, for example, in the case of a T-shaped connecting core 2 having 12 teeth 9, this is repeated until winding of the winding 28 for the fourth slot is completed, thereby completing winding of the stator winding 5 for the first phase (e.g., U phase).

[0080] After the winding of the stator winding 5 of the first phase (for example, U phase) is completed, the stator winding 5 of the second phase (for example, V phase) is wound around the teeth 9 of the T-shaped connection core 2 shown in Fig. 38 adjacent to the teeth 9 around which the first phase is wound, in the same manner as the winding of the stator winding 5 of the first phase. After the winding of the stator winding 5 of the second phase (for example, V phase) is completed, the winding 28 forming the stator winding 5 of the second phase is routed through the step space 30 between the protrusions 22b and 22c shown in Fig. 2 on the opposite winding side of the first electrical insulator assembly 3 to form a crossover wire. After the winding of the stator winding 5 of the second phase (for example, V phase) is completed, the stator winding 5 of the third phase (for example, W phase) is wound around the teeth 9 of the T-shaped connection core 2 shown in Fig. 38 adjacent to the teeth 9 around which the second phase is wound, in the same manner as the winding of the stator winding 5 of the second phase. Then, when the winding of the third-phase (e.g., W-phase) stator winding 5 is completed, the winding 28 that forms the third-phase stator winding 5 is routed through the step space 31 between the protrusions 22c and 22d shown in Figure 2 on the opposite winding side of the first electrical insulator assembly 3, forming a crossover wire. In this way, in the conventional method, the three-phase stator winding 5 is wound from the second electrical insulator assembly 4 side onto the teeth 9 of the T-shaped connecting core 2 via the second and first electrical insulator assemblies 4 and 3.

[0081] When winding the winding around the T-shaped connecting core 2 from the second electrical insulator assembly 4 side using this conventional method, the winding lead-out portion, such as a nozzle, must be positioned vertically below the T-shaped connecting core 2. This requires securing space below the T-shaped connecting core 2 for the winding lead-out portion to stand upright, resulting in an increased size of the winding device. Alternatively, if the winding lead-out portion cannot be positioned vertically below the T-shaped connecting core 2 as shown in FIG. 41 , winding from the second electrical insulator assembly 4 side is not possible. Furthermore, it is difficult to hook the winding 28 onto the protrusions 22a-22c on the opposite winding side of the first electrical insulator assembly 3 while the winding lead-out portion, such as a nozzle, is positioned upright, which complicates control of the winding lead-out portion. In contrast, the winding method of the present invention does not require the winding lead-out portion, such as a nozzle, to stand upright below the T-shaped connecting core 2. This eliminates the need to secure space below the T-shaped connecting core 2, resulting in a more compact device. Furthermore, by tilting the T-shaped connecting core 2 to the winding side or the anti-winding side, the winding 28 can be easily hooked onto the protrusions 22a to 22c provided on the anti-winding side of the first electrical insulator assembly 3, thereby simplifying the control of the winding lead-out section.

[0082] As described above, the winding method of the present invention allows for a compact winding device. Furthermore, because the windings are wound around the teeth or the windings (crossover wires) are routed by tilting the T-shaped connecting core toward the winding side or the opposite winding side, control of the movement mechanism for the winding lead-out section can be simplified. Furthermore, because the windings (crossover wires) of each phase are routed across the protrusions installed on the opposite winding side of the electrical insulator assembly, the required insulation distance can be reliably secured between the windings (crossover wires) of each phase.

[0083] Furthermore, by raising the T-shaped connecting core from its tilted state, the end of the winding (crossover wire) routed in the longitudinal direction on the anti-winding side of the electrical insulator assembly can be pulled into the winding side through the notch in the electrical insulator assembly, eliminating the need for complicated nozzle operations. Furthermore, when pulling the end of the stator winding from the winding side to the anti-winding side of the electrical insulator assembly or when pulling the end of the winding (crossover wire) from the anti-winding side to the winding side of the electrical insulator assembly, the stepped surface of the stepped portion of the electrical insulator assembly can be used to neatly arrange the windings. Furthermore, because the windings (crossover wires) are routed around the protrusions on the anti-winding side of the electrical insulator assembly, an appropriate insulation distance can be ensured between each winding (crossover wire).

[0084] Furthermore, after the winding lead-out portion winds the windings of each phase one by one, or two or three phases together, around the teeth of the T-shaped connecting core, the T-shaped connecting core is tilted to the winding side or the opposite winding side to lead out the end of the stator winding to the opposite winding side of the electrical insulator assembly, and the winding lead-out portion is moved in the longitudinal direction of the opposite winding side of the electrical insulator assembly, or the T-shaped connecting core is moved in its longitudinal direction to lead the crossover wire to the longitudinal direction of the opposite winding side of the electrical insulator assembly. By rotating the stator winding around the teeth and then standing up the T-shaped connecting core from its tilted state, the end of the crossover wire can be pulled in from the anti-winding side of the electrical insulator assembly to the winding side, which increases the degree of freedom in winding the stator winding around the teeth, pulling the end of the stator winding to the anti-winding side of the electrical insulator assembly, routing the windings (crossover wires) of each phase on the anti-winding side of the electrical insulator assembly, and pulling the end of the winding (crossover wire) to the winding side of the electrical insulator assembly. In particular, when these operations are performed for three phases at once, the entire operation can be completed efficiently in a short time. Furthermore, the above effects can be achieved with a simple device configuration. [Industrial Applicability]

[0085] This can be used when winding wire around the teeth of a linearly developed core. [Explanation of symbols]

[0086] 1 Stator 2 T-shaped connector core 2A, 2B Connected core end face 3 First Electrical Insulator Assembly 4 Second Electrical Insulator Assembly 5 Stator Winding 6 York 6a Thin wall part 6b Inner wall of yoke 7 Teeth base 8 slots 9 Teeth 9b Teeth base side 10 Teeth tip 10a Inner surface of tip of teeth 10b Outer wall surface of tooth tip 11. Space inside the connecting core 12 slot opening 13,16 Exterior wall 13a,16a Inner side of outer wall 13b,16b fitting part 13c~13f Step surface 14,17 Inner wall 14a,17a Inner wall outer surface 14b,17b Fitting part 15,18 Connection part 15a Top surface (bottom surface) 15b1,15b2,18b1,18b2 Side 18a Bottom surface (Top surface) 19 Step 20 Central part 21a, 21b Notch 22a~22c protrusion 23, 30, 31 Step space 24a,24b Grip piece 25 Gripping stand 26 Rotation axis 27 Rotation drive unit 28 windings 29 Nozzle (winding draw-out part) 32 One end (T-shaped connection corner) 33 Other end (T-shaped connection core) 32a, 33a through holes A(A1,A2) Rotation Mechanism P axis

Claims

1. In an electric motor stator having linear T-shaped connected cores attached with electrical insulator assemblies fastened together in a circular ring shape, the linear T-shaped connected core has a winding side where the stator winding is wound around the teeth via the electrical insulator assembly by inserting a winding lead-out portion into a slot between the teeth of the T-shaped connected core and winding around the teeth, and a counter-winding side located opposite the winding side, and a winding method for the linear T-shaped connected core attached with an electrical insulator assembly that draws a winding in the longitudinal direction of the counter-winding side comprises the steps of: winding the stator winding around the teeth of the T-shaped connected core; and pulling out the winding end of the stator winding through a notch in the electrical insulator assembly to the counter-winding side of the electrical insulator assembly by tilting the T-shaped connected core toward the winding side.

2. In an electric motor stator having linear T-shaped connected cores attached with electrical insulator assemblies fastened together in a circular ring shape, the linear T-shaped connected cores have a winding side where the stator winding is wound around the teeth via the electrical insulator assembly by inserting a winding lead-out portion into a slot between the teeth of the T-shaped connected core and winding around the teeth, and a counter-winding side located opposite the winding side, and a winding method for winding the linear T-shaped connected core attached with an electrical insulator assembly that draws a winding in the longitudinal direction of the counter-winding side comprises the steps of: winding the stator winding around the teeth of the T-shaped connected core; and pulling out the winding end of the stator winding through a notch in the electrical insulator assembly to the counter-winding side of the electrical insulator assembly by tilting the T-shaped connected core to the counter-winding side of the electrical insulator assembly.

3. 3. The winding method according to claim 1, wherein the winding end of the stator winding drawn out to the opposite winding side of the electrical insulator assembly is drawn in the longitudinal direction of the opposite winding side of the electrical insulator assembly by moving the winding draw-out portion along the longitudinal direction of the linear T-shaped connected core or by moving the linear T-shaped connected core in its longitudinal direction.

4. 4. The winding method according to claim 3, wherein the winding is routed in the longitudinal direction of the opposite winding side of the electrical insulator assembly, sandwiching the winding around a protrusion provided on the opposite winding side of the electrical insulator assembly.

5. 4. The winding method according to claim 3, wherein the end of the winding routed on the anti-winding side of the electrical insulator assembly is pulled into the winding side of the electrical insulator assembly through the notch in the electrical insulator assembly by raising the linear T-shaped connected core tilted toward the winding side or the anti-winding side.

6. 6. The winding method according to claim 5, wherein the notch is a stepped portion having stepped surfaces, and the stepped surfaces are utilized to pull the winding end of the stator winding of each phase from the winding side to the anti-winding side of the electrical insulator assembly, and pull the end of the winding that has been pulled to the anti-winding side from the anti-winding side to the winding side of the electrical insulator assembly.

7. 7. The winding method according to claim 6, wherein in a three-phase winding electric motor, the winding lead-out portion is formed by winding the stator winding for each phase one by one, or two by two, or all three phases together around the teeth of the straight T-shaped connection core, and then the straight T-shaped connection core is tilted toward the winding side or the anti-winding side to pull out the winding end of the stator winding to the anti-winding side of the electrical insulator assembly, and the winding lead-out portion is moved in the longitudinal direction of the anti-winding side of the electrical insulator assembly, or the straight T-shaped connection core is moved in its longitudinal direction to pull the winding in the longitudinal direction of the anti-winding side of the electrical insulator assembly, and the straight T-shaped connection core tilted toward the winding side or the anti-winding side is raised to pull the end of the winding from the anti-winding side to the winding side of the electrical insulator assembly.

8. a winding device comprising: a rotation mechanism that grips and rotates a straight T-shaped connected core to which an electrical insulator assembly is attached; a winding lead-out portion movement mechanism that winds a stator winding around the teeth of the straight T-shaped connected core via the electrical insulator assembly and moves the straight T-side connected core in the longitudinal direction on the opposite winding side of the electrical insulator assembly; or a connected core movement mechanism that moves the straight T-shaped connected core in its longitudinal direction.

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