Annularization assembly apparatus of split core unit, and manufacturing method of stator core

Abstract

To provide an annularization assembly apparatus for split core units, and a manufacturing method of a stator core capable of reducing the number of motions required when annularizing, and enabling general motions.SOLUTION: An annularization assembly apparatus 10 according to an embodiment is an apparatus for assembling and annularizing a plurality of split core units 8 having: a plurality of split cores 2 arranged in a circumferential direction with a predetermined space apart; an insulator 3 connected by an annular member 7 to integrate the plurality of split cores 2; and coils 4 each wound around the respective split cores 2. The apparatus has an assembly unit 11 capable of opening the split core units 8 by gripping the same from radially outside, and assembling and annularizing the opened split core units 8.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates to an apparatus for assembling divided core units into annular shapes and a method for manufacturing a stator core. [Background technology]

[0002] Conventionally, it is known to manufacture a stator core by assembling a plurality of split cores in an annular shape. For example, in Patent Document 1, when assembling a split core unit in which a plurality of split cores are connected by an annular member, the split core units are sequentially placed on a dedicated support jig using a device, and the split core units placed on the support jig are expanded from the radially inner side to the radially outer side using a dedicated expansion jig, and the resulting gap is used to assemble the last split core unit. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2021-191036 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in conventional methods, the first of multiple split core units that are assembled in sequence must be placed on a dedicated support jig, which requires the device to operate. This increases the number of times the device must operate, which can worsen the cycle time, or it can require the device to have multiple units in order to improve the cycle time, which can lead to increased costs.

[0005] In addition, although the orientation of the split core unit needs to be limited to prevent the expansion jig from coming into contact with the annular member, it is anticipated that there will be requests to change the orientation of the split core unit and assemble it depending on the process order, or to assemble split core units with different stack thicknesses, inner diameters, or outer shapes.

[0006] The present disclosure has been made in consideration of the above circumstances, and its purpose is to provide a split core unit annular assembly device and a stator core manufacturing method that can reduce the number of operations required for annularization and enable versatile operation. [Means for solving the problem]

[0007] The split core unit annular assembly device according to the embodiment assembles and annularizes a plurality of split core units (8) each having a plurality of split cores (2) arranged at a predetermined interval in the circumferential direction, an insulator (3) connected by an annular member (7) to unite the plurality of split cores, and a coil (4) wound around each of the split cores, and is equipped with an assembly unit (11) that can grasp and expand the split core units from the radial outside and assembles the expanded split core units into an annular shape.

[0008] In addition, the manufacturing method of the stator core (1) according to the embodiment is a method of assembling and forming into a ring a plurality of split core units (8) each having a plurality of split cores (2) arranged at predetermined intervals in the circumferential direction, an insulator (3) connected by an annular member (7) to integrate the plurality of split cores, and a coil (4) wound around each of the split cores, and includes a step (S2) of grasping the split core units from the radially outside, a step (S4) of expanding the grasped split core units radially outward, and a step (S6) of assembling and forming into a ring the expanded split core units. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a diagram illustrating a configuration of a stator core according to an embodiment. [Figure 2] Schematic diagrams showing examples of the shapes of split cores [Figure 3] FIG. 1 is a diagram illustrating a configuration example of a divided core unit; [Figure 4] FIG. 10 is a diagram illustrating an example of an assembly mode of the split core unit; [Figure 5] FIG. 1 is a diagram showing a schematic configuration example of a circular assembly device; [Figure 6] Diagram 1 explaining the operation of the circular assembly device [Figure 7] Diagram 2 explaining the operation of the circular assembly device [Figure 8] A diagram showing the manufacturing process of the stator core [Figure 9] 1A and 1B are diagrams illustrating the split core unit in an expanded state and an assembled state; DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, an embodiment will be described with reference to the drawings. As shown in FIG. 1, a stator core 1 includes a plurality of split cores 2 arranged in an annular shape. In this embodiment, the stator core 1 has 12 split cores 2 arranged circumferentially at 30-degree intervals, and these split cores 2 are connected in an annular shape. Note that the number of split cores 2 provided in the stator core 1 is an example and is not limited to this. Hereinafter, the direction perpendicular to the paper surface in FIG. 1 will be referred to as the axial direction, and the state viewed from the axial direction will be referred to as the plan view. Furthermore, since the axial direction basically aligns with the top-bottom direction in the manufacturing process described below, the direction along the axial direction will also be referred to as the up-down direction.

[0011] As shown in plan and perspective views in FIG. 2, each split core 2 has a back yoke 21 that forms the outer edge of the stator core 1, and teeth 22 that protrude from the back yoke 21 radially inward of the stator core 1. Positioning grooves 23 are formed in the radially outer surface of the back yoke 21. The height of the split core 2 in the perspective view corresponds to the stack thickness. This split core 2 is arranged so that an end face 21a in the circumferential direction of the back yoke 21 is connected, or abuts, with an end face of another adjacent split core 2, as indicated by the dashed line. Note that the shape of the split core 2 shown in FIG. 2 is an example and is not limited to this.

[0012] 3, each split core 2 is fitted with an insulator 3 and a coil 4 wound around the tooth 22 via the insulator 3. As shown in side view, the insulator 3 includes four upper covers 5 attached to the upper side of the split core 2 and covering roughly the upper half of the teeth 22 and the upper end surface of the back yoke 21, and four lower covers 6 attached to the lower side of the split core 2 and covering roughly the lower half of the teeth 22 and the lower end surface of the back yoke 21. For ease of explanation, the split core 2 located on the near side is not shown in the side view, and only a partial cross section taken along line AA in plan view and a see-through view of the coil 4 from line B are shown.

[0013] The upper covers 5 are individually attached to the split cores 2, and are formed so that their radially inner end portions 51 protrude in the axial direction more than their radially outer end portions 52. In contrast, the lower cover 6 is connected to the annular member 7, and is formed so that their radially inner end portions 61, which are connected to the annular member 7, protrude in the axial direction more than their radially outer end portions 62. The upper cover 5 and the lower cover 6 are formed to have a size that does not protrude circumferentially from the back yoke 21.

[0014] Then, split cores 2 are placed on the four lower covers 6, and upper covers 5 are attached to each split core 2, thereby attaching insulators 3 to the split cores 2. In this state, coils 4 are wound around the teeth 22 to form one split core unit 8. At this time, the insulators 3 and lower covers 6 are connected by annular members 7, so the attached multiple split cores 2 become one unit.

[0015] In this embodiment, the stator core 1 is formed by arranging three split core units 8 in an annular shape. In the following description, for convenience, the split core units 8 will be referred to as split core unit 8A, split core unit 8B, and split core unit 8C, but the designations A to C will not be used to describe the contents common to all the split core units 8.

[0016] While the split core units 8 have roughly the same shape in a plan view, they differ in core height (H) from the top surface of the annular member 7 to the bottom end of the split core 2 in a side view. Specifically, assuming that the thickness (ΔH) of the annular member 7 of each split core unit 8 is constant, and the core height (HA) of split core unit 8A is used as the reference, the core height (HB) of split core unit 8B is HA-ΔH, and the core height (HC) of split core unit 8C is HA-2×ΔH. Note that if the thickness (ΔH) of the annular member 7 differs, the core height (H) will also differ accordingly.

[0017] Therefore, by first placing split core unit 8A in a predetermined position, then assembling split core unit 8B coaxially so that the annular members 7 overlap from above, and then assembling split core unit 8C coaxially so that the annular members 7 overlap from above, the stator core 1 is completed in a state in which the axial positions of each split core 2 match, as shown in the side view of the completed stage in Figure 4, which will be described later. Note that the positions of the split cores 2 also match if split core unit 8C is placed first, split core unit 8B is assembled coaxially so that the annular members 7 overlap from above, and then split core unit 8A is assembled coaxially so that the annular members 7 overlap from above.

[0018] Here, the assembly of the split core units 8 and the problems with the conventional method will be described with reference to Fig. 4. When manufacturing the stator core 1, in this embodiment, three split core units 8A, 8B, and 8C are assembled in a ring shape in order. Specifically, as shown in Fig. 4 as a preparation stage, first, two split core units 8A and 8B are assembled. Hereinafter, for convenience, the state in which the split core units 8A and 8B are assembled, that is, the stage before the final split core unit 8C is assembled, will be referred to as a semi-finished core 9.

[0019] Thereafter, the remaining split core units 8C are assembled as shown in the final assembly stage, resulting in the completed stator core 1 in which the split cores 2 are adjacent to each other in the circumferential direction as shown in the plan and side views.

[0020] Now, each split core 2 is formed to a size that allows it to be connected to other split cores 2 adjacent in the circumferential direction when arranged in an annular shape. Therefore, the space (S) for assembling the last split core unit 8C in the semi-finished core 9 is approximately the same size as each split core 2 of the split core unit 8C. In this case, when attempting to insert the split core 2 into the space (S) from the axial direction to assembling the split core unit 8C, there is a possibility that the split core 2 will come into contact with the split core 2 on the semi-finished core 9 side.

[0021] Therefore, in the conventional method, the semi-finished core 9 is expanded from its inner periphery toward its outer periphery, and the position of the split core 2 is shifted radially outward to enlarge the space (S), making it possible to assemble the split core units 8C without contact. On the other hand, when the split core units 8 are connected by the annular member 7, an expansion jig must be inserted from the opposite side of the annular member 7 to expand the semi-finished core 9 from the inner periphery, so the orientation and order in which the split core units 8 are assembled are fixed.

[0022] Furthermore, in the conventional method, all split core units 8 are placed on a dedicated support jig by a device in order to accurately position each split core unit 8 relative to the expansion jig, which tends to require a large number of operations. For example, in the conventional method, at least four operations are required: placing split core unit 8A, assembling split core unit 8B, assembling split core unit 8C, and removing the split core units after assembly. Furthermore, the increased number of operations required by the device can result in a worsening cycle time or require the use of multiple machines to improve the cycle time, which can lead to increased costs.

[0023] It is also expected that versatility will be required, such as being able to change the orientation of the split core units 8 depending on the process order or the layout of the production line, being able to adjust the amount of expansion or gripping position during assembly, and being able to assemble split core units 8 with different stacking thicknesses, inner diameters or outer shapes using the same equipment. However, in conventional methods, the orientation of the split core units 8 was fixed because the semi-finished core 9 was expanded from the inner periphery side using an expansion jig.

[0024] Therefore, in this embodiment, in order to reduce the number of operations required for assembly and to achieve versatility, a circular assembly device 10 shown in schematic form in Figure 5 is used. In this circular assembly device 10, the operation and amount of operation of each part of an assembly unit 11 are controlled by a control unit (not shown) configured by a microcomputer or the like.

[0025] The details of the circularization assembling device 10 will be described below, but the structures and mechanisms for operating the circularization assembling device 10 described below and shown in the drawings are examples and are not limited to these, and other structures and mechanisms may be adopted, strength supplementary members not shown may be provided, or the device may be housed in a housing or the like as a dustproof measure. Also, in Fig. 5, to make the structure easier to understand, general mechanisms are labeled on the right side of the illustration, and detailed symbols for each part are labeled on the left side of the illustration.

[0026] The annular assembly device 10 is capable of radially outwardly expanding the split core unit 8 to be assembled last among the multiple split core units 8 that make up the stator core 1, and includes an assembly unit 11 that assembles the expanded split core units 8 to form an annular shape. The annular assembly device 10 also includes four assembly units 11, the same number as the number of split cores 2 provided in each split core unit 8.

[0027] The assembly units 11 are arranged at four equal positions in the circumferential direction about a central axis (CL) that coincides with the center of the completed stator core 1. For ease of explanation, Fig. 5 shows the assembly units 11 arranged in the left-right direction, and omits the assembly units 11 arranged at the back and front of the page.

[0028] The assembly unit 11 includes a chuck portion 12 that can hold the split core unit 8 from the radial outside and the split core 2 by clamping it from both axial ends, and a rotation mechanism portion 13 that can rotate the chuck portion 12 so that the side opposite the annular member 7 opens.

[0029] The chuck unit 12 includes a fixed chuck 122 fixed to the lower end of a base member 121 and a movable chuck 125, the distance between which is variable as a result of a feed screw 124 rotated by a servo motor 123. The chuck unit 12 abuts the upper surface of the fixed chuck 122 against the radially outer lower end of the split core 2. By moving the movable chuck 125 in this state, the chuck unit 12 clamps both axial ends of the split core 2 from the radially outer side, as shown in FIG. 5 as a clamping state. In this embodiment, the chuck unit 12 indirectly clamps the split core 2 by clamping the upper cover 5 and the lower cover 6 of the insulator 3. Hereinafter, for convenience, the state in which the split core unit 8 is clamped without being opened, as shown in FIG. 5, will be referred to as the clamping state.

[0030] The rotation mechanism 13 includes an L-shaped angle member 131 that is rotatable around a predetermined rotation center (J) and fixed to the chuck 12, a cam follower 132 attached to the upper end of the angle member 131, a cam plate 133 that has a contact surface with which the cam follower 132 comes into contact, and a spring member 134 that presses the cam follower 132 against the cam plate 133.

[0031] Cam plate 133 has a normal contact surface 133a with which cam follower 132 comes into contact when chuck portion 12 is axially aligned, a first inclined surface 133b inclined radially inward from the upper end of normal contact surface 133a, and a second inclined surface 133c inclined radially outward from the lower end of normal contact surface 133a. This cam plate 133 moves up and down when servo motor 136 fixed to swivel base member 135 rotates lead screw 137. Furthermore, when cam plate 133 moves up and down, cam follower 132 is biased toward cam plate 133 by spring member 134, so cam plate 133 is always in contact with cam plate 133.

[0032] The turning mechanism 13 can turn the chuck 12 at a desired angle by moving the cam plate 133 up and down. Specifically, when the cam plate 133 moves downward, the cam follower 132 is pushed radially inward by the first inclined surface 133b, causing the angle member 131 to turn around the turning center (J), as shown in FIG. 6 . As a result, the chuck 12, which is fixed to the angle member 131, also turns so that its lower end expands radially outward. The turning angle (α), i.e., the inclination of the chuck 12, can be set to any angle within a range of, for example, approximately 2 to 5 degrees by adjusting the position of the cam plate 133 with the servo motor 136. However, the range of the inclination of the chuck 12 is not limited to 2 to 5 degrees. Note that while FIG. 6 shows the operation of two assembly units 11, one on the left and one on the right, other assembly units 11 (not shown) also operate in the same manner.

[0033] On the other hand, when the cam plate 133 moves upward, the cam follower 132 is pressed toward the second inclined surface 133c by the spring member 134, as shown in FIG. 7, causing the angle member 131 to pivot about the pivot center (J). As a result, the base member 121 fixed to the angle member 131 also pivots, and the chuck unit 12 also pivots so that its upper end expands radially outward. The pivot angle (β) at this time can also be set to any angle within a range of, for example, approximately 2 to 5 degrees by adjusting the position of the cam plate 133 with the servo motor 136. However, the tilt range of the chuck unit 12 is not limited to 2 to 5 degrees. Also, while FIG. 7 shows the operation of the two assembly units 11 on the left and right sides of the figure, other assembly units 11 (not shown) also operate in the same manner.

[0034] Which end side is expanded can be switched depending on the gripping state of the split core unit 8. Specifically, when the split core unit 8 is gripped with the annular member 7 positioned upward as shown in Fig. 6, the upper end side can be expanded, and when the split core unit 8 is gripped with the annular member 7 positioned downward as shown in Fig. 7, the lower end side can be expanded.

[0035] The annular assembly device 10 also includes a radial movement mechanism 14 that operates in conjunction with the rotation of the chuck 12 by the rotation mechanism 13 and is capable of moving the assembly unit 11 in the radial direction. In this radial movement mechanism 14, a servo motor 142 fixed to a radial base member 141 rotates a feed screw 143 to move a nut 144, thereby moving the entire assembly unit 11, including the chuck 12 and the rotation mechanism 13, radially outward or radially inward.

[0036] For example, when the lower end of the chuck portion 12 is rotated so as to open as shown in Fig. 6, the chuck portion 12 rotates around the rotation center (J), which is located at a position away from the split core unit 8. Therefore, when the chuck portion 12 is rotated, the connection portion of the annular member 7 with the split core 2 is pulled radially outward, which may result in damage to the annular member 7.

[0037] Therefore, the radial movement mechanism 14 operates in conjunction with the rotation of the chuck 12. Specifically, the radial movement mechanism 14 moves the chuck 12 and the rotation mechanism 13 radially inward so that the outer diameter (X1) of the annular member 7 when the chuck 12 is rotated matches the outer diameter (X0) of the annular member 7 when no load is applied, as shown in Fig. 5. This reduces the load applied to the connection portion of the annular member 7 with the lower cover 6 when the chuck 12 is rotated.

[0038] 7, when the upper end side of the chuck portion 12 is rotated so as to expand, the connection portion of the annular member 7 with the divided core 2 may be pressed radially inward and damaged. Therefore, the radial movement mechanism 14 moves the chuck portion 12 and the rotation mechanism 13 radially outward in conjunction with the rotation of the chuck portion 12, thereby making the outer diameter (X2) of the annular member 7 when the chuck portion 12 is rotated equal to the outer diameter (X1) in the gripped state shown in FIG. 5, thereby reducing the load applied to the annular member 7.

[0039] The radial movement mechanism 14 also moves the chuck 12 along the radial direction when gripping the split core unit 8. Specifically, when gripping the split core unit 8, the radial movement mechanism 14 moves the chuck 12 radially outward from each split core 2 to be gripped as shown by the filled-in arrows in the gripping stage of Fig. 5, and also moves the chuck 12 radially inward to a position where the split core 2 can be gripped.

[0040] The assembly unit 11 configured as described above is supported as a whole by an axial movement mechanism 15 so as to be movable up and down. In this axial movement mechanism 15, a servo motor 152 fixed to an apparatus base member 151 rotates a feed screw 153, thereby moving the radial base member 141 up and down. Therefore, the annular assembling device 10 can move the assembly unit 11 up and down when gripping or assembling the split core units 8. Note that, to make it easier to grip or assembling the split core units 8, a rotation mechanism that supports each assembly unit 11 so as to be rotatable about a central axis (CL) may also be provided.

[0041] Next, the operation and effect of the annular assembly device 10 configured as described above and the method for manufacturing the stator core 1 using the same will be described in comparison with conventional methods. In addition, the following will be described using an example in accordance with this embodiment in which the stator core 1 is manufactured by assembling three split core units 8A, 8B, and 8C in a predetermined order. However, the number of split core units 8 to be assembled is not limited to three.

[0042] When manufacturing the stator core 1, first, a semi-finished core 9 is prepared (S1) as shown in Fig. 8. The semi-finished core 9 is in a state in which the split core unit 8A and the split core unit 8B are assembled as shown in Fig. 4, and in step S1, although not shown, the split core unit 8B is assembled to the split core unit 8A that has been transported on, for example, a transport tray. This is because, when the annular assembly device 10 is used, no special support jig is required as in conventional methods, and it is sufficient that the split core unit 8A is positioned.

[0043] In this embodiment, the placement on the transport tray is performed in a separate process, and in step S1, the annular assembly device 10 is used to assemble the split core unit 8B. Therefore, the number of device operations for preparing the semi-finished core 9 is reduced compared to the conventional method described above. Note that if the preparation of the semi-finished core 9 is performed in a separate process, the number of operations of the annular assembly device 10 can be further reduced.

[0044] When preparation of the semi-finished core 9 is complete, the annular assembly device 10 grips the split core unit 8C to be assembled last (S2) and moves the split core unit 8C to an assembly start position (S2). At this time, the annular assembly device 10 grips each of the split cores 2 of the split core unit 8 from the radially outer side with the chuck portion 12 with the annular member 7 facing upward, as shown in FIG. 5, for example. In other words, the chuck portion 12 grips the split core 2 at a position that does not interfere with the inner peripheral side of the split core 2. The assembly start position is preset, for example, above the semi-finished core 9 and where the annular members 7 are coaxial, in the example of FIG. 6.

[0045] Next, the annular assembly device 10 rotates the chuck portion 12 to expand the lower end side of the split core unit 8C opposite the annular member 7, while moving the assembly unit 11 radially inward to move the chuck portion 12 inward, thereby reducing the load on the annular member 7 (S4). Note that the cycle time can be shortened by simultaneously performing the operation of moving to the assembly start position in step S3 and the operation of expanding and reducing the load in step S4.

[0046] When the split core unit 8C is expanded, each split core 2 of the split core unit 8C is positioned radially outward of each split core 2 of the semi-finished core 9, as shown in Fig. 9, which shows the positional relationship in a plan view in the expanded state. Furthermore, if the width between the radially inner ends of each split core 2 of the semi-finished core 9 is W1 and the width between the radially outer ends of each split core 2 of the semi-finished core 9 is W2, W2 is larger than W1. Note that, for the sake of explanation, the gaps between the split cores 2 are intentionally enlarged in Fig. 9.

[0047] This allows the split cores 2 of the split core unit 8C to be inserted axially into the space (S) without enlarging the space (S) as in the conventional method. In other words, contact with the split cores 2 of the semi-finished core 9 can be avoided when the assembly unit 11 is lowered. Furthermore, in this state, when the split cores 2 are to be connected as described below, the split cores 2 can be easily moved radially inward.

[0048] Therefore, the annular assembly device 10 lowers the assembly unit 11 in the axial direction to move the split core unit 8C in the expanded state to a predetermined assembly position (S5). Although not shown, in the cases of Figures 6 and 7, the assembly position is preset to a position where the annular member 7 of the split core unit 8C overlaps the annular member 7 on the semi-finished core 9 from above. Note that it is also possible to configure the device so that contact with the annular member 7 on the semi-finished core 9 can be detected and the split core unit 8C is lowered until it comes into contact with the annular member 7 on the semi-finished core 9.

[0049] Next, the annular assembly device 10 releases the rotation of the chuck portion 12 and assembles the split core unit 8 (S6). At this time, the annular assembly device 10 moves the cam plate 133 in the opposite direction from the direction of expansion, and also moves the assembly unit 11 in the opposite direction from the direction of expansion. This reduces the load on the annular member 7, and inserts each split core 2 of the split core unit 8C radially inward from the outside into the space portion (S) on the semi-finished core 9 side, as shown in FIG. 9 as the assembled state, and the split cores 2 are connected together in an annular shape as a whole. In other words, the stator core 1 is completed.

[0050] Thereafter, the annular assembly device 10 unchucks the split core units 8, i.e., finishes gripping them (S7), moves the chuck portions 12 radially outward to avoid contact with the stator core 1, and then moves the assembly unit 11 to a predetermined initial position (S8). This initial position is set in advance to a position where the assembly unit 11 will not come into contact with the completed stator core 1.

[0051] This completes the series of annular forming steps in the manufacture of the stator core 1. The completed stator core 1 can be transported to the next step, for example, on a transport tray, without necessarily requiring the operation of the annular forming assembling device 10. This eliminates the need for an operation to remove the completed stator core 1 as in the conventional method, and allows for a reduction in the number of operations.

[0052] In this way, the annular assembly device 10 manufactures the stator core 1 by grasping the split core unit 8 that is to be assembled last from the radial outside and spreading it out while assembling it, thereby annularizing the multiple split core units 8.

[0053] When the annular member 7 is located on the lower side as illustrated in Figure 7, the split core unit 8C and the split core unit 8B are assembled to prepare the semi-finished core 9, and finally the split core unit 8A is assembled. Although the rotation direction of the split core 2 and the radial movement direction during the rotation operation are opposite to those described above, the manufacturing process can be similar.

[0054] According to the embodiment described above, the following effects can be obtained. The annular assembly device 10 is a device that assembles and annularizes a plurality of split core units 8, each having a plurality of split cores 2 arranged at predetermined intervals in the circumferential direction and an insulator 3 that is connected by an annular member 7 to unite the plurality of split cores 2, and is equipped with an assembly unit 11 that can grasp and expand the split core units 8 from the radial outside and assembles the expanded split core units 8 into annular shapes.

[0055] By adopting such a configuration, the annular assembly device 10 does not need to use a dedicated support jig to expand the split core unit 8 from the radially inner side, and the operation of placing it on the support jig is no longer necessary, thereby reducing the number of operations.In addition, since the number of operations is reduced, the cycle time is improved, eliminating the need for multiple machines, thereby minimizing capital investment.

[0056] Furthermore, since the annular assembly device 10 grips the split core units 8 from the radially outer side, it does not interfere with the annular member 7, and the orientation in which the split core units 8 are gripped can be changed. It can also grip and assemble split core units 8 with different stacking thicknesses, inner diameters, or outer shapes, making it versatile. Therefore, it is possible to reduce the number of operations required for annular assembly and enable versatile operations.

[0057] The assembly unit 11 also includes a chuck 12 that can grip the split core unit 8 from the radial outside so as to sandwich the split cores 2 from both axial ends, and a turning mechanism 13 that can rotate the chuck 12 so that the side opposite the annular member 7 expands. This allows the gripped split core unit 8 to expand by rotating each split core 2. At this time, by configuring the cam plate 133 to move using a servo motor 136 as in the embodiment, the inclination of the split cores 2 when expanded can be adjusted as desired.

[0058] Furthermore, the turning mechanism 13 can expand either the upper or lower side of the split core 2 when the split core 2 is gripped, which is the side opposite the annular member 7. This allows the split core unit 8 to be assembled regardless of the orientation of the split core unit 8, that is, regardless of whether the annular member 7 is on the upper or lower side when gripped.

[0059] The annular assembly device 10 also includes a radial movement mechanism 14 that can move the assembly unit 11 radially in conjunction with the rotation of the chuck 12 by the rotation mechanism 13. This reduces the load on the annular member 7 even when the split core 2 rotates and expands around a rotation center (J) spaced apart from the split core unit 8.

[0060] Furthermore, the radial movement mechanism 14 of the annular assembly device 10 can move the position of the chuck 12 when gripping the split core unit 8 to a position radially outward of the split core 2 to be gripped. This makes it possible to easily grip the split core unit 8 from the radially outer side.

[0061] The manufacturing method of the stator core 1 is a method of assembling and forming into an annular shape a plurality of split core units 8, each having a plurality of split cores 2 arranged at predetermined intervals in the circumferential direction and an insulator 3 connected by annular members 7 to unite the plurality of split cores 2, and includes a step (S2) of gripping the split core units 8 from the radially outer side, a step (S4) of expanding the gripped split core units 8 radially outward, and a step (S6) of assembling the expanded split core units 8 into an annular shape. This manufacturing method can also achieve various effects similar to those of the annular shape assembling device 10 described above, such as reducing the number of operations required for assembly and providing versatility.

[0062] In the embodiment, an example has been shown in which the stator core 1 is formed by three split core units 8 each having four split cores 2, but when m is an integer of 2 or greater and n is an integer of 2 or greater, m split core units 8 may each have n split cores 2 and m×n split cores 2 connected in a ring shape. Note that in the embodiment, m=3 and n=4, but this means that other numbers are also possible.

[0063] Alternatively, m split core units 8 may be provided with different numbers of split cores 2, and the split cores 2 may be ultimately connected in a ring shape. In this case, although the embodiment shows an example in which all of the assembly units 11 are operated simultaneously, it is also possible to operate, for example, two assembly units 11 arranged diagonally opposite each other.

[0064] In the embodiment, a configuration in which the chuck portion 12 is rotated via the angle member 131 has been exemplified, but a configuration in which a cam follower 132 is provided at the upper end of the base member 121 and the chuck portion 12 is rotated directly may also be adopted. Also, a configuration in which the chuck portion 12 is rotated using a motor or a feed screw without providing the cam follower 132 or the cam plate 133 may also be adopted.

[0065] Also, instead of the spring member 134, a pressing mechanism that presses the angle member 131 toward the cam plate 133 using a motor, a feed screw, or the like may be employed. Also, a configuration may be adopted in which something other than the spring member 134 is employed as a biasing member that biases the angle member 131 toward the cam plate 133.

[0066] In the embodiment, a configuration in which a servo motor or a feed screw is used to move the movable part has been exemplified, but other moving mechanisms may also be employed to move the movable part.

[0067] The control unit and the method described herein may be implemented by a special-purpose computer configured by configuring a processor and memory programmed to perform one or more functions embodied in a computer program. Alternatively, the control unit and the method described herein may be implemented by a special-purpose computer configured by configuring a processor with one or more dedicated hardware logic circuits. Alternatively, the control unit and the method described herein may be implemented by one or more special-purpose computers configured by combining a processor and memory programmed to perform one or more functions with a processor configured with one or more hardware logic circuits. Furthermore, the computer program may be stored as instructions executed by a computer on a computer-readable non-transitory tangible storage medium. [Explanation of symbols]

[0068] In the drawings, 1 indicates a stator core, 2 indicates a split core, 3 indicates an insulator, 4 indicates a coil, 7 indicates an annular member, 8, 8A, 8B, and 8C indicate split core units, 10 indicates an annular assembly device, 11 indicates an assembly unit, 12 indicates a chuck portion, 13 indicates a rotation mechanism portion, 14 indicates a radial movement mechanism portion, and 15 indicates an axial movement mechanism portion.

Claims

1. The coil assembly is formed into a ring by assembling a plurality of split core units (8, 8A, 8B, 8C) each having a plurality of split cores (2) arranged at predetermined intervals in the circumferential direction, an insulator (3) connected by an annular member (7) to integrate the plurality of split cores, and a coil (4) wound around each of the split cores, The split core unit annular assembly device includes an assembly unit (11) that can grasp and expand the split core units from the radial outside and assembles the expanded split core units into an annular shape.

2. The assembly unit includes: a chuck portion (12) capable of gripping the split core unit from the radially outer side so as to sandwich the split core; 2. The split core unit annular assembly device according to claim 1, further comprising a turning mechanism (13) that turns the chuck portion so that the side opposite to the annular member opens.

3. 3. The split core unit annular assembly device according to claim 2, wherein the rotating mechanism is capable of expanding either the upper or lower side of the split core when gripping the split core, the side being opposite the annular member.

4. 3. The divided core unit annular assembly device according to claim 2, further comprising a radial movement mechanism (14) capable of moving the assembly unit in the radial direction in conjunction with the rotation of the chuck portion by the rotation mechanism.

5. The split core unit annular assembly device according to claim 4, wherein the radial movement mechanism is capable of moving the position of the chuck portion when gripping the split core unit to a position radially outside the split core to be gripped.

6. A method for assembling and annularizing a plurality of split core units (8, 8A, 8B, 8C) each having a plurality of split cores (2) arranged at predetermined intervals in the circumferential direction, an insulator (3) connected by an annular member (7) to integrate the plurality of split cores, and a coil (4) wound around each of the split cores, comprising: a step (S2) of gripping the split core unit from the radially outer side; a step (S4) of expanding the gripped divided core units radially outward; a step (S6) of assembling the expanded divided core units to form a ring; A method for manufacturing a stator core (1) comprising:

Images