Winding machine for stator coil and winding method for stator coil

Abstract

To provide a winding machine for a stator coil that is highly productive and can achieve a high space factor, and a winding method for the stator coil.SOLUTION: A winding machine 100 for a stator coil includes: a mounting device 20 having a work chunk mechanism 21 and a work swinging mechanism 22; and a nozzle drive device 40 having a first drive mechanism 41 that positions a nozzle 40N, which dispenses a wire W that forms a coil 53 of a stator 50, in a radial direction X relative to a stator core 51, a second drive mechanism 42 that operates in conjunction with the first drive mechanism 41 to position the nozzle 40N in an axial direction Y relative to the stator core 51, and a third drive mechanism 43 that operates in conjunction with the second drive mechanism 42 to change the orientation of the nozzle 40N within a range of 180 degrees.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a stator coil winding machine and a stator coil winding method. [Background technology]

[0002] Conventionally, the stator core of a rotating electric machine has an annular yoke and multiple teeth extending radially inward from the inner circumferential surface of the yoke. The spaces between adjacent teeth in the stator core are called slots. Coils are formed by inserting wire into the slots. An in-slot portion inserted into one slot and an in-slot portion inserted into another slot are connected in a U-shape, protruding axially outward from both end faces of the stator core, to form coil end portions.

[0003] A proposed wire winding machine for forming this coil is equipped with a nozzle that can unwind the wire from the tip. In such a winding machine, the nozzle is held horizontally, and a drive mechanism is used to wind the wire unwound from the nozzle around the teeth. In a wire winding method using such a winding machine, the wire is wound around one tooth to form a coil (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-004477 Summary of the Invention [Problem to be solved by the invention]

[0005] One method of winding coils on the stator core of a rotating electrical machine is distributed winding, in which wire is wound to form a coil in two slots that are two slot pitches or more apart. To form a distributed winding coil, the coil is formed in any two slots, so the wire must be wound at any angle around the circumferential direction of the stator core.

[0006] In a distributed winding coil, a portion of the coil protrudes axially outward from both end faces of the stator core. This protruding portion is called a coil end portion and is formed by a portion protruding from two of the openings of the multiple slots in the end face of the stator core and a portion connecting these. In a distributed winding coil, each coil must be wound so as to avoid the coil end portions of other wound coils.

[0007] To form a new coil so as to avoid the end of the previously wound coil, either manual coil insertion, which is less productive, or the inserter method, which is more productive but results in a lower space factor, is used.

[0008] The present disclosure discloses a technique for solving the above-described problems, and aims to provide a stator coil winding machine and a stator coil winding method that are highly productive and can achieve a high space factor, and that can wind coil wire without limiting the type of stator core that can be wound or the coil formation method. [Means for solving the problem]

[0009] The stator coil winding machine of the present disclosure includes: a stand device including a work chuck mechanism that fixes the stator core and a work rocking mechanism having a first drive source that rotates the work chuck mechanism forward and backward in a circumferential direction; The nozzle drive device includes a first drive mechanism that positions the radial position of a nozzle that pays out wire that forms the stator coil relative to the stator core, a second drive mechanism that works in conjunction with the first drive mechanism and positions the axial position of the nozzle relative to the stator core, and a third drive mechanism that works in conjunction with the second drive mechanism and is capable of rotating the orientation of the nozzle within a range of 180 degrees from one axial side to the other axial side toward the radially outward direction. Further, the winding method of the stator coil of the present disclosure includes the steps of: A stator coil winding method using the stator coil winding machine, When winding the coil into the slot, the nozzle is moved in the axial direction so as to face radially outward; when forming a coil end portion on one end side in the axial direction, the nozzle is directed toward the other end side in the axial direction, and the main plate and the plurality of links of the third drive mechanism are located outside the stator, When forming the coil end portion on the other axial end side, the nozzle is directed toward one axial end side, and the main plate and the multiple links of the third drive mechanism are inserted inside the stator core. [Effects of the Invention]

[0010] According to the stator coil winding machine and stator coil winding method of the present disclosure, it is possible to provide a stator coil winding machine and stator coil winding method that are highly productive and can achieve a high space factor, and that can wind coil wire without limiting the type of stator core that can be wound or the method of forming the coil. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a perspective view showing a schematic configuration of a winding machine for a stator coil according to a first embodiment. [Figure 2] 1 is a front view of a winding machine according to a first embodiment. [Figure 3] 1 is a right side view of the winding machine according to the first embodiment. FIG. [Figure 4] 2 is a schematic right side view of the stand device for the winding machine according to the first embodiment. FIG. [Figure 5] FIG. 2 is a perspective view of a work chuck mechanism according to the first embodiment. [Figure 6] FIG. 2 is a top view of the work chuck mechanism according to the first embodiment. [Figure 7] FIG. 2 is a perspective view of a link mechanism according to the first embodiment. [Figure 8] 2 is a side view showing the configuration of a main plate and each link of the link mechanism according to the first embodiment. FIG. [Figure 9] 2 is a perspective view showing the configuration of a main plate and each link of the link mechanism according to the first embodiment. FIG. [Figure 10] FIG. 2 is a perspective view of a stator according to the first embodiment. [Figure 11] FIG. 2 is a perspective view of a stator core according to the first embodiment. [Figure 12] FIG. 1 is a perspective view of an insulator according to a first embodiment. [Figure 13] 1 is a side view showing a state in which a wire is routed around an insulator attached to one axial end face of the stator core according to the first embodiment to form a coil end portion. FIG. [Figure 14] 1 is a side view showing a state in which a wire is routed around an insulator attached to one axial end face of the stator core according to the first embodiment to form a coil end portion. FIG. [Figure 15] 10 is a side view showing a state in which a wire is routed around an insulator attached to the other axial end surface of the stator core according to the first embodiment to form a coil end portion. FIG. [Figure 16] 10 is a side view showing a state in which a wire is routed around an insulator attached to the other axial end surface of the stator core according to the first embodiment to form a coil end portion. FIG. [Figure 17] 3 is a top view showing a state in which a wire is routed within a slot of the stator core according to the first embodiment to form an in-slot storage portion. FIG. [Figure 18]3 is a side view showing a state in which a wire is routed within a slot of the stator core according to the first embodiment to form an in-slot storage portion. FIG. [Figure 19] 4 is an enlarged view of a main part showing a state in which a wire is routed within a slot of the stator core according to the first embodiment to form an in-slot storage portion. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0012] Embodiment 1 In the following description, the circumferential direction, axial direction, and radial direction of the stator in which the coil is wound by the stator coil winding machine are referred to as the circumferential direction Z, the axial direction Y, and the radial direction X, respectively. The outside of the radial direction X is referred to as the outside X1, and the inside of the radial direction X is referred to as the inside X2. In the stator core and the winding machine, the respective directions may also be described based on these directions.

[0013] For convenience of explanation, the axial direction Y is illustrated and described as one side Y1 (upper side in FIG. 1) or the other side Y2 (lower side in FIG. 1) in some places. In particular, when there is no need to distinguish, only the axial direction Y is shown.

[0014] FIG. 1 is a perspective view showing a schematic configuration of a winding machine 100 for a stator coil (hereinafter simply referred to as winding machine 100) according to a first embodiment. FIG. 2 is a front view of the winding machine 100. FIG. 3 is a right side view of the winding machine 100. FIG. 4 is a right side view of the stand device 20 of the winding machine 100. As shown in FIG. FIG. 5 is a perspective view of the work chuck mechanism 21. As shown in FIG. FIG. 6 is a top view of the work chuck mechanism 21. As shown in FIG. The winding machine 100 is a device used to wind a wire W around a stator core 51 of a rotating electrical machine to form a coil.

[0015] 1, the winding machine 100 includes a pedestal device 20 and a nozzle driving device 40 fixed to the pedestal device 20. As shown in FIGS. 4, 5, and 6, the pedestal device 20 includes a work chuck mechanism 21 that fixes a stator core 51 of a stator 50, and a work swinging mechanism 22 having a servo motor 22M (first driving source) that swings the work chuck mechanism 21 by rotating forward and backward in the circumferential direction Z.

[0016] The nozzle driving device 40 has a horizontal driving mechanism 41 (first driving mechanism) that positions the nozzle 40N, which pays out the wire that forms the stator coil, in the radial direction X relative to the stator core 51, a vertical driving mechanism 42 (second driving mechanism) that positions the nozzle 40N in the axial direction Y relative to the stator core 51, and a link mechanism 43 (third driving mechanism) that can change the orientation of the nozzle 40N from downward to upward, or vice versa, within a range of 180 degrees to the outer side X1 in the radial direction X.

[0017] The horizontal drive mechanism 41 is powered by a servo motor 41M and moves horizontally by a ball screw 41B directly connected to the servo motor 41M via a coupling. The vertical drive mechanism 42 is linked to the horizontal drive mechanism 41. Therefore, when the horizontal drive mechanism 41 moves horizontally, the vertical drive mechanism 42 also moves horizontally.

[0018] A link mechanism 43 having a nozzle 40N is attached to the vertical drive mechanism 42, and the link mechanism 43 is interlocked with the vertical drive mechanism 42. Therefore, when the vertical drive mechanism 42 moves in the axial direction Y (the vertical direction in FIG. 1 etc.), the link mechanism 43 also moves in the axial direction Y. Therefore, when either or both of the horizontal drive mechanism 41 and the vertical drive mechanism 42 move, the link mechanism 43 also moves in a direction that matches the movement directions of the respective mechanisms.

[0019] 1 to 3, the vertical drive mechanism 42 is powered by a servo motor 42M. The vertical drive mechanism 42 is moved in the axial direction Y by a ball screw 42B connected via a pulley and a belt that are directly connected to the servo motor 42M.

[0020] FIG. 7 is a perspective view of the link mechanism 43. As shown in FIG. FIG. 8 is a side view showing the main plate 43A of the link mechanism 43 and the configuration of each link. FIG. 9 is a perspective view showing the main plate 43A of the link mechanism 43 and the configuration of each link. The link mechanism 43 includes a servo motor 43M (third drive source), a nozzle 40N that pays out the wire rod, two elongated, plate-like main plates 43A that can be inserted axially inside the stator core 51, a nozzle holding portion 43H that is rotatably attached to a rotating shaft 43P that is inserted through the lower ends 43A1 of each of the two main plates 43A and holds the nozzle 40N, and a link 43L that is connected to the nozzle holding portion 43H and drives the nozzle holding portion 43H in the axial direction Y by the servo motor 43M, causing the nozzle holding portion 43H to rotate 180 degrees around the rotating shaft 43P.

[0021] The link 43L of the link mechanism 43 has a first link 43L1, a second link 43L2, a third link 43L3, a fourth link 43L4, a fifth link 43L5, and a sixth link 43L6, and the respective connection portions are rotatably connected.

[0022] In order to wind the coil 53 on the stator core 51 that is long in the axial direction Y, the link mechanism 43 that is attached to the vertical drive mechanism 42 and that rotates the nozzle 40N needs to be a tool that is long in the axial direction Y (vertical direction). Furthermore, the link mechanism 43 needs to be able to be inserted into the stator core 51 without interfering with the stator core 51. Furthermore, the structure needs to be such that the nozzle holding portion 43H and the nozzle 40N do not interfere with the stator core 51 and the insulator attached to the stator core 51 even when the nozzle holding portion 43H is rotated to change the orientation of the nozzle 40N.

[0023] Therefore, the second link 43L2 and the fourth link 43L4, which are connected in the vertical direction, have a single structure with a large width and thickness to increase rigidity. The first link 43L1 and the third link 43L3 have short lengths, so they are made up of two plate-like pieces that sandwich the second link 43L2 and the third link 43L3 from both sides. The fifth link 43L5 and the sixth link 43L6 also have a two-plate structure.

[0024] One end L1E1 of the first link 43L1 is connected to the rotation shaft of the servo motor 43M. One end L2E1 of the second link 43L2 is connected above the other end L1E2 of the first link 43L1. One end L3E1 of the third link 43L3 is rotatably connected to the main plate 43A and the other end L3E2 is connected to the other end L2E2 of the second link 43L2 so as to be parallel to the first link 43L1.

[0025] In addition, the fourth link 43L4 has its upper end L4E1 connected to the middle between the connection point of the third link 43L3 with the main plate 43A and the connection point of the third link 43L3 with the second link 43L2, and its lower end L4E2 connected to one end L5E1, L6E1 of the fifth link 43L5 and the sixth link 43L6, respectively.

[0026] The other end L5E2 of the fifth link 43L5 is connected to one side Y1 in the axial direction Y (upward in the plane of FIG. 7) of the rotation shaft 43P of the nozzle holding portion 43H of the main plate 43A. The other end L6E2 of the sixth link 43L6 is connected to the nozzle holding portion 43H. The connection portion of the other end L6E2 of the sixth link 43L6 is midway between the rotation shaft 43P of the nozzle holding portion 43H and the base of the nozzle 40N. The fifth link 43L5 is curved so as to protrude diagonally upward and outward in the radial direction X when the nozzle 40N is facing downward, and the sixth link 43L6 is curved so as to protrude diagonally downward and inward in the radial direction X when the nozzle 40N is facing downward.

[0027] The connection portions at both ends of each of the first link 43L1, the second link 43L2, the third link 43L3, the fourth link 43L4, the fifth link 43L5, and the sixth link 43L6 are all connected rotatably relative to the connected objects.

[0028] The power source for the rotational motion of the nozzle 40N is a servo motor 43M. The servo motor 43M is connected to a shaft fixed to the first link 43L1 via a coupling and a reducer. The power of the servo motor 43M is transmitted from the shaft to the nozzle holder 43H via the first link 43L1, the second link 43L2, the third link 43L3, the fourth link 43L4, the fifth link 43L5, and the sixth link 43L6. This rotates the nozzle holder 43H and the nozzle 40N attached to the nozzle holder 43H around the rotation axis 43P, thereby controlling the angle of the nozzle 40N. As a result, the nozzle 40N can rotate within a range of 180 degrees from one side Y1 in the axial direction Y to the outer side X1 in the radial direction X and further to the other side Y2 in the axial direction Y.

[0029] 4 is connected to a shaft 22S by a coupling via a reducer 22D. The work chucking mechanism 21 is fixed to the shaft 22S by a screw 22N on the top surface of the shaft 22S. This allows the rotational motion powered by the servo motor 22M to be transmitted to the work chucking mechanism 21.

[0030] By controlling the rotational motion of the servo motor 22M, it is possible to arbitrarily determine the swing angle of the stator core 51, which varies depending on the shape, size, and winding type of the stator core 51. Therefore, it is possible to form coils by winding wire in predetermined slots of the stator core 51 without being limited by the type of stator core 51 or the winding configuration.

[0031] As shown in FIGS. 5 and 6, the workpiece chuck mechanism 21 includes an inner frame 21A having a cylindrical inner peripheral surface for fixing the stator core 51, and an outer frame 21B into which the inner frame 21A is inserted and fixed. The outer peripheral surface 21AOUT of the inner frame 21A has at least three curved surface portions 21AR that conform to the inner peripheral surface 21BIN of the outer frame 21B, and at least three flat surface portions 21AH formed between the two curved surface portions 21AR. The stator core 51 is fixed to the inner frame 21A inside the outer frame 21B by stator fixing portions 21AK provided on the flat surface portions 21AH. The inner frame 21A is also fixed to the outer frame 21B by inner frame fixing portions 21BK provided on the portions of the outer frame 21B corresponding to the curved surface portions 21AR. The stator fixing portions 21AK and the inner frame fixing portions 21BK are formed by screws NE and nuts NA.

[0032] FIG. 10 is a perspective view of the stator 50. As shown in FIG. FIG. 11 is a perspective view of the stator core 51. As shown in FIG. FIG. 12 is a perspective view of the insulator 52A. The stator 50 has a stator core 51, an insulator 52A and an insulator 52B respectively arranged on both end surfaces of the stator core 51 in the axial direction Y, and a coil 53 wound around the stator core 51 via the insulators 52A and 52B.

[0033] The stator core 51 has an annular yoke portion 51Y and a plurality of teeth 51T protruding inward in the radial direction X2 from the inner circumferential surface of the yoke portion 51Y. The spaces between adjacent teeth 51T of the stator core 51 are called slots 51S. A wire W is wound and inserted into the slots 51S to form a coil 53. The in-slot portion of the coil 53 inserted into one slot 51S and the in-slot portion of the coil 53 inserted into another slot 51S protrude from both end faces of the stator core 51 in the axial direction Y and are connected in a U-shape. This portion is called a coil end portion 53E. The number and shape of the teeth 51T of the stator core 51 vary depending on the specifications of the stator core 51.

[0034] Therefore, the pitch of the coil end portion 53E that connects the in-slot portions housed in the two slots 51S differs depending on the shape of the stator core 51. The present winding machine 100 can arbitrarily determine the swing range of the work chuck mechanism 21 that chucks the stator core 51, and therefore can wind the wire W around the stator core 51 to form a coil without being limited by the shape of the stator core 51.

[0035] 10 , an insulator 52A is disposed on one side Y1 of the stator core 51 in the axial direction Y, and an insulator 52B is disposed on the other side Y2. Note that the insulators 52A and 52B may be collectively referred to as insulators 52. The insulators 52 have a function of electrically insulating the coils 53 from the stator core 51 and a function of guiding the coil end portions 53E of the coils 53.

[0036] 12, the insulator 52 has an annular connecting plate 52D and a plurality of pillar portions 52P. The connecting plate 52D has portions corresponding to the teeth 51T and the slots 51S formed in the same shapes as the respective shapes on the end face of the stator core 51 in the axial direction Y.

[0037] The plurality of pillar portions 52P are formed above each tooth portion 51T so as to rise in a direction away from the stator core 51 in the axial direction Y. The insulator 52 is formed with pillar portions 52P equal to or less than the number of teeth portions 51T. The coil end portions 53E of the coils 53 are engaged with the pillar portions 52P and routed in the circumferential direction Z.

[0038] Each pillar portion 52P is formed to be connected to an annular connecting plate 52D. The insulator 52 has pillar portions 52P, which are made up of a plurality of first pillar portions 52P1 and a plurality of second pillar portions 52P2. The pillar portions 52P are formed in portions corresponding to the end faces of the teeth 51T in the axial direction Y. Between the first pillar portions 52P1 adjacent in the circumferential direction Z, guide plates 52G are formed in the circumferential direction Z to separate two adjacent coil end portions 53E in the axial direction Y.

[0039] The guide plate 52G is formed so as to protrude from the middle of the first pillar portion 52P1 in the axial direction Y to the outer side X1 in the radial direction X and connect the multiple first pillar portions 52P1. The inner side X2 in the radial direction X of the guide plate 52G is cut out in the same shape as the end face of the slot 51S in the axial direction Y. Furthermore, reinforcing wall portions 52Q are formed on the stator core side in the axial direction Y and on the outer side X1 in the radial direction X of the multiple adjacent first pillar portions 52P1, and are formed continuously in the circumferential direction Z so as to cover the outer peripheral surfaces of the multiple first pillar portions 52P1. The reinforcing wall portions 52Q reinforce the insulator 52 and also guide the coil end portions 53E when they are routed in the circumferential direction Z.

[0040] Furthermore, the first pillar portion 52P1 is provided with a protrusion G2 that protrudes from the upper end in the axial direction Y to the outer side X1 in the radial direction X.

[0041] The second pillar portion 52P2 differs from the first pillar portion 52P1 described above in that no guide plate 52G is formed between adjacent second pillar portions 52P2, and instead has a protrusion G3 that protrudes outward X1 in the radial direction X at the same position in the axial direction Y as the guide plate 52G. The protrusion G2 is formed in the same manner as the first pillar portion 52P1. The insulators 52A and 52B have a mirror-like shape.

[0042] 10, in the insulator 52, a first groove 52M1 is formed in the circumferential direction Z between the connecting plate 52D and the guide plate 52G and protrusion G3. A second groove 52M2 is formed in the circumferential direction Z between the guide plate 52G and the protrusion G3 and protrusion G2. The first groove 52M1 and the second groove 52M2 are stacked in the axial direction Y.

[0043] Then, by winding the wire W fed from the nozzle 40N attached to the link mechanism 43 along the inside of each of the first groove 52M1 and the second groove 52M2, the multiple coil end portions 53E are stored insulated from each other.

[0044] Next, a specific process for winding the coil 53 will be described. 13 and 14 are side views showing a state in which a wire W is routed around an insulator 52A attached to an end face (upper face) on one side Y1 in the axial direction of the stator core 51 to form a coil end portion 53E. 15 and 16 are side views showing a state in which the wire W is routed around the insulator 52B attached to the end face (lower face) of the stator core 51 on the other side Y2 in the axial direction Y to form the coil end portion 53E. FIG. 17 is a top view showing a state in which the wire W is routed in the slot 51S of the stator core 51 to form the in-slot storage portion 53IN. FIG. 18 is a side view showing a state in which the wire W is routed through the slot 51S of the stator core 51 to form the in-slot storage portion 53IN. FIG. 19 is an enlarged view of a main part showing a state in which the wire W is routed in the slot 51S of the stator core 51 to form the in-slot accommodation portion 53IN.

[0045] To form the coil 53 of the stator 50, the horizontal drive mechanism 41, the vertical drive mechanism 42, and the link mechanism 43 are driven to change the position and orientation of the nozzle 40N, and the wire W is fed from the nozzle 40N while swinging the work chuck mechanism 21 as necessary.

[0046] First, the end of the wire W is locked in a wire end locking portion (not shown) provided on the work chuck mechanism 21. Next, the tip of the nozzle 40N is raised to a position above the end of one side Y1 in the axial direction Y of the insulator 52A, and the link mechanism 43 is moved to a position above the inside of the stator core while unwinding the wire W. At this time, the wire W is introduced into the inside of the stator core 51 through between the first pillar portion 52P1 and the second pillar portion 52P2 shown in FIG. 12. During the movement, the link mechanism 43 is driven to rotate the nozzle holding portion 43H by 90 degrees, so that the tip of the nozzle 40N faces the outside X1 in the radial direction X.

[0047] Next, as shown in Figures 17, 18, and 19, the vertical drive mechanism 42 is driven downward, and the main plate 43A and up to the fourth link 43L4 of the link mechanism 43 are inserted inside the stator core 51, while the in-slot storage portion 53IN of the coil 53 is routed through the slot 51S.

[0048] When the nozzle 40N moves below the end of the insulator 52B on the other side Y2 in the axial direction Y, the link mechanism 43 is further lowered. When the tip of the nozzle 40N passes the insulator 52B, the horizontal drive mechanism 41 is driven to move the link mechanism 43 to the outer side X1 in the radial direction X. The link mechanism 43 is then driven to rotate the nozzle holder 43H by 90 degrees, so that the tip of the nozzle 40N faces the one side Y1 in the axial direction Y. The position of the tip of the nozzle 40N is finely adjusted by raising or lowering the vertical drive mechanism 42. As a result, the tip of the nozzle 40N is positioned on the outer side X1 in the radial direction X of the first groove 52M1 of the insulator 52B, as shown in FIG. 15 .

[0049] Next, while maintaining the position and orientation of the nozzle 40N, the work chuck mechanism 21 is rotated forward by a predetermined slot pitch, whereby the wire W is pulled out from the nozzle and routed around the coil end portion 53E. After the coil end portion 53E has been routed, the vertical drive mechanism 42 is driven downward, and once the tip of the nozzle 40N is positioned so that it does not interfere with the insulator 52B, the horizontal drive mechanism 41 is driven to route the wire W between the first pillar portion 52P1 and the second pillar portion 52P2 of the insulator 52B and into the inside of the stator core 51. During this movement, the link mechanism 43 may be driven to rotate the orientation of the nozzle 40N by 90 degrees again so that it faces the outer side X1 of the radial direction X.

[0050] Next, the vertical drive mechanism 42 is driven upward to draw the in-slot storage portion 53IN of the coil 53 into the other slot 51S.

[0051] When the nozzle 40N moves above the end of one side Y1 in the axial direction Y of the insulator 52A, the link mechanism 43 is further raised, and when the tip of the nozzle 40N passes the end of one side Y1 in the axial direction Y of the insulator 52A, the horizontal drive mechanism 41 is driven to move the link mechanism 43 to the outside X1 in the radial direction X. Next, the link mechanism 43 is driven to rotate the orientation of the nozzle 40N by 90 degrees so that the other side in the axial direction Y faces the Y2 side. Then, when the vertical drive mechanism 42 is driven to lower the link mechanism 43, the tip of the nozzle 40N is positioned on the outside X1 in the radial direction X of the first groove 52M1 of the insulator 52A, as shown in FIG. 13 .

[0052] Next, while maintaining the position and orientation of the nozzle 40N, the work chuck mechanism 21 is rotated in the reverse direction by a predetermined slot pitch, whereby the wire W is drawn out from the nozzle 40N and the coil end portion 53E is pulled around. This completes one turn of one distributed winding coil 53.

[0053] Next, the work chuck mechanism 21 is rotated 120 degrees to form the second coil 53, and then the work chuck mechanism 21 is rotated another 120 degrees to form the third coil 53 in the first groove 52M1, thereby forming the first layer coil end portions 53E on both sides in the axial direction Y. The second layer coil end portions 53E in the axial direction Y are formed in the same manner, but the winding format varies depending on the specifications.

[0054] For example, the coil 53 wound in the first groove 52M1 in Fig. 13 and the coil 53 wound in the second groove 52M2 in Fig. 14 are separated into individual coils, and the coil ends are connected in a connecting process after the winding process. After the coil 53 wound in the first groove 52M1 or the second groove 52M12 is fixed to the outside of the stator core 51, the coil ends are cut and the next coil 53 is wound.

[0055] When the coil end portion 53E is being pulled around, the operation of the vertical drive mechanism 42 is controlled by the servo motor 42M, thereby changing the position of the tip of the nozzle 40N in the axial direction Y for each revolution, thereby improving the alignment of the coil end portion 53E.

[0056] By improving the alignment of the coil end portions 53E, it is possible to form the coil end portions 53E so as to reduce the dead space in the first grooves 52M1 of the insulators 52A. If the coil end portions 53E are small, when a voltage is applied to the coils 53 formed in the stator core 51, a larger current flows through the coils 53, and the larger the magnetic field generated.

[0057] Therefore, improving the alignment of coil end portions 53E makes it possible to reduce the circumferential length of coils 53 formed on stator core 51, and to increase the magnetic field flowing through stator core 51.

[0058] 19, when the wire W is drawn through the slot 51S of the stator core 51, the tip of the nozzle 40N is not inside the slot 51S but is located inside the stator core 51 relative to the slot opening 51S1. The servo motor 22M of the work rocking mechanism 22 is controlled to position the winding start position so that the wire W does not come into contact with the tips of the adjacent teeth 51T through the gap between the tips of the teeth 51T. Thereafter, the nozzle 40N is moved in the axial direction Y while unwinding the wire W so that the wire W falls radially outward from the stator core 51.

[0059] By dropping the wire W into the slot 51S in this manner, it becomes possible to arrange the slot storage portion 53IN of the coil 53 up to the narrow gap of the slot opening 51S1 inside the slot 51S, and it is possible to increase the coil space factor, which indicates the proportion of the wire W filled in the slot 51S.

[0060] Furthermore, it is possible to drop the wire rods W one by one into the slots 51S of the stator core 51 so as not to cause twisting. If twisting occurs in the wire rods W, dead space is created in the slots 51S, which reduces the space factor. Therefore, by dropping the wire rods W one by one from the tip of the nozzle 40N so as not to cause twisting, it is possible to increase the space factor.

[0061] The width of the slot opening 51S1 of the slot 51S in the circumferential direction Z is narrower than the interior of the slot 51S, but when the wire W unwound from the tip of the nozzle 40N attached to the vertical drive mechanism 42 and the link mechanism 43 is passed through the gap, the rotational position of the work chuck mechanism 21 to which the stator core 51 is chucked is precisely controlled by the servo motor 22M, so that the wire W can be dropped into the slot 51S without coming into contact with the tooth portion 51T.

[0062] As described above, when the coil end portion 53E is routed around the insulator 52B on the other side Y2 in the axial direction Y, the nozzle holding portion 43H is rotated in the outer X1 direction in the X direction, whereby the nozzle 40N can be positioned facing upward and on the outer side X1 in the radial direction X than the main plate 43A inserted inside the stator core 51. This allows the distributed winding coil 53 to be wound directly around the stator core 51 via the insulator 52. Furthermore, even when the work chuck mechanism 21 is rotated to route the coil end portion 53E on the other side Y2 in the axial direction Y, the nozzle 40N does not interfere with the insulator 52B. Furthermore, as shown in Figure 15, because the fifth link 43L5 and the sixth link 43L6 are bent, the fifth link 43L5 and the sixth link 43L6 do not interfere with the main plate 43A, and therefore the nozzle holding portion 43H can be rotated 180 degrees, and the orientation of the nozzle 40N held therein can be changed within a range of 180 degrees in the vertical direction.

[0063] In addition, by driving the horizontal drive mechanism 41 and the vertical drive mechanism 42 with servo motors, it is possible to change the tip position of the nozzle 40N and improve the alignment of the coil end portion 53E of the coil 53 and the in-slot storage portion 53IN shown in Figure 19.

[0064] According to the stator coil winding machine according to the first embodiment, a stand device including a work chuck mechanism that fixes the stator core and a work rocking mechanism having a first drive source that rotates the work chuck mechanism forward and backward in a circumferential direction; a nozzle drive device including a first drive mechanism that positions a nozzle, which pays out wire that forms a stator coil, in a radial direction relative to the stator core; a second drive mechanism that works in conjunction with the first drive mechanism and positions the nozzle in an axial direction relative to the stator core; and a third drive mechanism that works in conjunction with the second drive mechanism and is capable of rotating the orientation of the nozzle within a range of 180 degrees from one side in the axial direction to the other side in the axial direction toward the radially outward direction, It is possible to provide a stator coil winding machine that can wind coil wire without limiting the type of stator core that can be wound or the coil formation method, that is highly productive, and that can achieve a high space factor.

[0065] The third drive mechanism is a third drive source; an elongated main plate inserted axially inside the stator core; a nozzle holder rotatably attached to a rotation shaft inserted through a lower end of the main plate and holding the nozzle; a plurality of links connected to the nozzle holding portion and configured to rotate the nozzle holding portion around the rotation axis by the third drive source, It can be inserted into the narrow space inside the stator core, and distributed winding coils can be wound even on small stator cores.

[0066] The third drive mechanism includes a first link, a second link, a third link, a fourth link, a fifth link, and a sixth link as the links, one end of the first link is connected to the third drive source, one end of the second link is connected to the other end of the first link, the third link has one end rotatably connected to the main plate and the other end connected to the other end of the second link so as to be parallel to the first link; one end of the fourth link is connected between a connection portion of the third link with the main plate and a connection portion of the third link with the second link, and the other end is connected to one end of each of the fifth link and the sixth link; the other end of the fifth link is connected to the nozzle holding portion of the main plate above the rotation axis, the other end of the sixth link is connected to the nozzle holding portion, the fifth link is curved so as to protrude obliquely upward and outward in the radial direction when the nozzle is facing downward, The sixth link is curved so as to protrude diagonally downward and inward in the radial direction when the nozzle is facing downward, The link mechanism can be inserted and moved inside the stator core without interfering with the stator core itself.

[0067] The work chuck mechanism is an inner frame having a cylindrical inner circumferential surface to which the stator core is fixed; an outer frame that is inserted into and fixed to the inner frame; The inner frame has at least three curved surface portions whose outer peripheral surfaces follow the inner peripheral surface of the outer frame; and at least three flat surfaces formed between the two curved surfaces, the stator core is fixed to the inner frame by a stator fixing portion provided on the flat portion, The inner frame is fixed to the outer frame by an inner frame fixing portion provided on the outer frame corresponding to the curved surface portion. The same winding machine can be used to form distributed winding coils on stator cores of various shapes. In addition, the stator core and inner frame can be easily replaced, reducing the time required for changeover.

[0068] Furthermore, according to the stator coil winding method according to the first embodiment, The stator coil winding method using the stator coil winding machine includes: When winding the coil into the slot, the nozzle is moved in the axial direction so as to face radially outward; when forming a coil end portion on one end side in the axial direction, the nozzle is directed toward the other end side in the axial direction, and the main plate and the plurality of links of the third drive mechanism are located outside the stator, When forming the coil end portion on the other end side in the axial direction, the nozzle is directed toward one end side in the axial direction, and the main plate and the plurality of links of the third drive mechanism are inserted inside the stator core, All distributed winding coils can be formed continuously using a winding machine.

[0069] Furthermore, when winding the coil into the slot, the circumferential position of the tip of the nozzle is positioned by controlling the first drive source of the workpiece swinging mechanism so that the wire forming the coil does not come into contact with the tip of the teeth that form the slot. The space factor of the storage area in the slot can be improved.

[0070] In addition, the gantry rotates forward and backward so as to wind the coils in a distributed manner at a predetermined coil pitch. Distributed winding coils can be formed continuously.

[0071] Although the present disclosure describes exemplary embodiments, the various features, aspects, and functions described in the embodiments are not limited to application to a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are contemplated within the scope of the technology disclosed in this specification, including, for example, modifying, adding, or omitting at least one component.

[0072] Various aspects of the present disclosure are summarized below as appendices.

[0073] (Appendix 1) a stand device including a work chuck mechanism that fixes the stator core and a work rocking mechanism having a first drive source that rotates the work chuck mechanism forward and backward in a circumferential direction; a nozzle drive device having: a first drive mechanism that positions a nozzle, which pays out wire that forms a stator coil, in a radial direction relative to the stator core; a second drive mechanism that works in conjunction with the first drive mechanism and positions the nozzle in an axial direction relative to the stator core; and a third drive mechanism that works in conjunction with the second drive mechanism and is capable of rotating the orientation of the nozzle within a range of 180 degrees from one axial side to the other axial side toward the radially outward direction. (Appendix 2) The third drive mechanism is a third drive source; an elongated main plate inserted axially inside the stator core; a nozzle holder rotatably attached to a rotation shaft inserted through a lower end of the main plate and holding the nozzle; a plurality of links connected to the nozzle holding portion and configured to rotate the nozzle holding portion around the rotation axis by the third drive source. (Appendix 3) the third drive mechanism includes a first link, a second link, a third link, a fourth link, a fifth link, and a sixth link as the links, one end of the first link is connected to the third drive source, one end of the second link is connected to the other end of the first link, the third link has one end rotatably connected to the main plate and the other end connected to the other end of the second link so as to be parallel to the first link; one end of the fourth link is connected between a connection portion of the third link with the main plate and a connection portion of the third link with the second link, and the other end is connected to one end of each of the fifth link and the sixth link; the other end of the fifth link is connected to the nozzle holding portion of the main plate above the rotation axis, the other end of the sixth link is connected to the nozzle holding portion, the fifth link is curved so as to protrude obliquely upward and outward in the radial direction when the nozzle is facing downward, 3. The stator coil winding machine according to claim 2, wherein the sixth link is curved so as to protrude diagonally downward and inward in the radial direction when the nozzle is facing downward. (Appendix 4) The work chuck mechanism includes: an inner frame having a cylindrical inner circumferential surface to which the stator core is fixed; an outer frame that is inserted into and fixed to the inner frame; The inner frame has at least three curved surface portions whose outer peripheral surfaces follow the inner peripheral surface of the outer frame; and at least three flat surfaces formed between the two curved surfaces, the stator core is fixed to the inner frame by a stator fixing portion provided on the flat portion, 4. A stator coil winding machine according to claim 1, wherein the inner frame is fixed to the outer frame by an inner frame fixing portion provided on the outer frame corresponding to the curved portion. (Appendix 5) A stator coil winding method using the stator coil winding machine according to Supplementary Note 2 or Supplementary Note 3, When winding the coil into the slot, the nozzle is moved in the axial direction so as to face radially outward; when forming a coil end portion on one end side in the axial direction, the nozzle is directed toward the other end side in the axial direction, and the main plate and the plurality of links of the third drive mechanism are located outside the stator, When forming the coil end portion on the other axial end side, the nozzle is directed toward one axial end side, and the main plate and the plurality of links of the third drive mechanism are inserted inside the stator core. (Appendix 6) A stator coil winding method as described in Appendix 5, wherein when winding the coil into the slot, the circumferential position of the tip of the nozzle is positioned by controlling a first drive source of the work rocking mechanism so that the wire forming the coil does not come into contact with the tip of the tooth portion that forms the slot. (Appendix 7) 7. The stator coil winding method according to claim 5, wherein the mounting device rotates the stator coil forward and backward so as to achieve distributed winding at a predetermined coil pitch. [Explanation of symbols]

[0074] 100 stator coil winding machine, 20 stand device, 21 work chuck mechanism, 21A inner frame, 21B outer frame, 21AH flat surface, 21AR curved surface, 21AK stator fixing part, 21AOUT outer surface, 21BIN inner surface, 21BK Inner frame fixing part, 22 Workpiece swing mechanism, 22D Reducer, 22M servo motor, 22S shaft, 40 nozzle drive unit, 40N nozzle, 41 horizontal drive mechanism, 41M servo motor, 42 vertical drive mechanism, 42M servo motor, 43 link mechanism, 43A main plate, 43A1 lower end, 43H nozzle holder, 43L link, 43L1 first link, 43L2 2nd link, 43L3 3rd link, 43L4 4th link, 43L5 5th link, 43L6 6th link, 43M servo motor, 43P rotating shaft, 50 stator, 51 stator core, 51S slot, 51S1 slot opening, 51T teeth part, 51Y yoke part, 52 insulator, 52A insulator, 52B insulator, 52D connecting plate, 52G guide plate, 52M1 first groove, 52M2 second groove, 52P column section, 52P1 first column section, 52P2 second column section, 52Q reinforced wall section, 53 coil, 53E coil end, 53IN slot storage section, G2,G3 protrusions, L1E1,L2E1,L3E1,L4E1,L5E1,L6E1 One end, L1E2,L2E2,L3E2,L4E2,L5E2,L6E2 other end, NA nut, NE screw, W wire rod, X radial direction, X1 outer side, X2 inner side, Y axial direction, Y1 one side, Y2 other side, Z circumferential direction.

Claims

1. a stand device including a work chuck mechanism that fixes the stator core and a work rocking mechanism having a first drive source that rotates the work chuck mechanism forward and backward in a circumferential direction; a nozzle drive device having: a first drive mechanism that positions a radial position of a nozzle that pays out wire that forms a stator coil with respect to the stator core; a second drive mechanism that works in conjunction with the first drive mechanism and positions an axial position of the nozzle with respect to the stator core; and a third drive mechanism that works in conjunction with the second drive mechanism and is capable of rotating an orientation of the nozzle within a range of 180 degrees from one axial side to the other axial side toward the radially outward direction.

2. The third drive mechanism is a third drive source; an elongated main plate inserted axially inside the stator core; a nozzle holder rotatably attached to a rotation shaft inserted through a lower end of the main plate and holding the nozzle; 2. The stator coil winding machine according to claim 1, further comprising a plurality of links connected to the nozzle holder, the links rotating the nozzle holder around the rotation axis by the third drive source.

3. the third drive mechanism includes a first link, a second link, a third link, a fourth link, a fifth link, and a sixth link as the links, one end of the first link is connected to the third drive source, one end of the second link is connected to the other end of the first link, the third link has one end rotatably connected to the main plate and the other end connected to the other end of the second link so as to be parallel to the first link; one end of the fourth link is connected between a connection portion of the third link with the main plate and a connection portion of the third link with the second link, and the other end is connected to one end of each of the fifth link and the sixth link; the other end of the fifth link is connected to the nozzle holding portion of the main plate above the rotation axis, the other end of the sixth link is connected to the nozzle holding portion, the fifth link is curved so as to protrude obliquely upward and outward in the radial direction when the nozzle is facing downward, 3. The winding machine for a stator coil according to claim 2, wherein the sixth link is curved so as to protrude diagonally downward and inward in the radial direction when the nozzle is facing downward.

4. The work chuck mechanism includes: an inner frame having a cylindrical inner circumferential surface to which the stator core is fixed; an outer frame that is inserted into and fixed to the inner frame; The inner frame has at least three curved surface portions whose outer peripheral surfaces follow the inner peripheral surface of the outer frame; and at least three flat surfaces formed between the two curved surfaces, the stator core is fixed to the inner frame by a stator fixing portion provided on the flat portion, 2. The stator coil winding machine according to claim 1, wherein the inner frame is fixed to the outer frame by an inner frame fixing portion provided on the outer frame corresponding to the curved surface portion.

5. A stator coil winding method using the stator coil winding machine according to claim 2 or 3, comprising: When winding the coil into the slot, the nozzle is moved in the axial direction so as to face radially outward; when forming a coil end portion on one end side in the axial direction, the nozzle is directed toward the other end side in the axial direction, and the main plate and the plurality of links of the third drive mechanism are located outside the stator, A stator coil winding method in which, when forming the coil end portion on the other axial end side, the nozzle is directed toward one axial end side, and the main plate and the multiple links of the third drive mechanism are inserted inside the stator core.

6. 6. A stator coil winding method according to claim 5, wherein when winding the coil into the slot, the circumferential position of the tip of the nozzle is positioned by controlling the first drive source of the work rocking mechanism so that the wire forming the coil does not come into contact with the tip of the tooth portion that constitutes the slot.

7. 6. The stator coil winding method according to claim 5, wherein the mounting device rotates forward and backward so as to form a distributed winding at a predetermined coil pitch.

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