Manufacturing method of stator, jig, and insulation method

Abstract

To provide a manufacturing method of a stator capable of easily insulating a predetermined portion of a coil.SOLUTION: A manufacturing method of a stator or the like includes a first step of extending a covering range including a first portion of a coil corresponding to a final turn on an outer peripheral side of a first core and a second portion of the coil connected to the first portion and corresponding to a crossover line between the first core and a second core substantially linearly, and a second step of attaching an insulating tape to the covering range extending substantially linearly by the first step. In the first step, by rotating the first core and relatively separating the first core from the second core, the first portion wound around the first core may be pulled out from the first core and the covering range may be extended substantially linearly.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a stator manufacturing method, a jig, and an insulation method. [Background technology]

[0002] Patent document 1 discloses a stator for an automotive rotating electric machine in which the insulator covering the outer periphery of the insulating coating of the coil is composed of a first insulator arranged in the lead wire portion and a second insulator arranged in the coil floating portion and the crossover wire portion. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6557590 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the manufacturing process of the stator described in Patent Document 1 has a problem in that it requires complicated work when placing the insulator on the outer periphery of the insulating coating of the coil.

[0005] The present invention has been made to solve the above problems, and has an object to provide a method for manufacturing a stator that can easily insulate predetermined portions of a coil. [Means for solving the problem]

[0006] In order to solve the above problem, one aspect of the present invention is to a first step of linearly extending a covering range including a first portion of the coil corresponding to the final turn on the outer periphery of a first core and a second portion of the coil connected to the first portion and corresponding to a crossover wire between the first core and a second core; a second step of applying insulating tape to the covering area linearly stretched in the first step; The present invention provides a method for manufacturing a stator, comprising: [Effects of the Invention]

[0007] According to this invention, predetermined portions of the coil can be easily insulated. [Brief explanation of the drawings]

[0008] [Figure 1] 10A to 10C are diagrams showing a series of steps for attaching insulating tape to a coil in the manufacturing method of the stator of the present embodiment. [Figure 1A] 10A to 10C are diagrams showing a series of steps for attaching insulating tape to a coil in the manufacturing method of the stator of the present embodiment. [Figure 1B] 10A to 10C are diagrams showing a series of steps for attaching insulating tape to a coil in the manufacturing method of the stator of the present embodiment. [Figure 2] FIG. 2 is a perspective view showing a first jig used in the step of attaching insulating tape to a coil. [Figure 3] FIG. 10 is a perspective view showing a second jig used in forming the coil. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0010] 1 to 1B are diagrams showing a series of steps for attaching insulating tape to a coil in a manufacturing method of a stator according to this embodiment.

[0011] 1 and 1B. In this state, a coil 3 having an insulating coating formed thereon is wound around the first core 10 and the second core 20. An insulating tape 40 is attached to a covering area 30 including a first portion 31 and a second portion 32 of the coil 3. Here, the first portion 31 corresponds to the final turn on the outer periphery of the first core 10, and the second portion 32 corresponds to the crossover wire between the first core 10 and the second core 20.

[0012] In this embodiment, the first core 10 and the second core 20 each correspond to a slot in a stator that constitutes a brushless motor. The two slots corresponding to the first core 10 and the second core 20 are not adjacent to each other but are spaced apart in the circumferential direction. Therefore, a crossover wire between the first core 10 and the second core 20, i.e., the second portion 32 of the coil 3, is required. In this configuration, the second portion 32 and the first portion 31 connected thereto may interfere with other coils during motor manufacturing or operation, potentially damaging the insulating coating of the coil 3. Therefore, the insulating tape 40 ensures insulation in the covering area 30, including the first portion 31 and the second portion 32.

[0013] FIG. 2 is a perspective view showing a first jig used in the step of attaching insulating tape to a coil, and FIG. 3 is a perspective view showing a second jig used in forming the coil.

[0014] As shown in FIG. 2, the first jig 60 includes a support portion 61 that supports the first core 10 rotatably around an axis (Y axis), a support portion 62 that supports the second core 20, and a slide mechanism 63 that supports the support portion 61 slidably in the X direction.

[0015] As shown in FIG. 3, the second jig 70 includes a support portion 71 that supports the first core 10, a support portion 72 that supports the second core 20, and an insertion portion 73 into which the covering area 30 is inserted.

[0016] Next, a series of steps for attaching the insulating tape 40 to the coil 3 will be described.

[0017] FIG. 2 shows the state corresponding to FIG. 1. First, the first core 10 and the second core 20 are attached to the support portion 61 and the support portion 62, respectively, by inserting them in the -Y direction. At this time, the coil 3 is in a state in which the first portion 31 is wound around the first core 10, i.e., in FIG. 1B, the insulating tape 40 has been removed. From this state, the first core 10 can be separated from the second core 20 by rotating it around its axis (Y axis) counterclockwise in FIG. 2 while sliding it in the X direction using the sliding mechanism 63. This stretches the covering area 30 between the first core 10 and the second core 20 (the state shown in FIG. 2). The operation of sliding the first core 10 may be automated, or the first core 10 may be slid manually.

[0018] Next, the first core 10 and the second core 20 are removed from the first jig 60, and the coil 3 in the covered area 30 is formed into a substantially linear shape. Next, as shown in FIG. 3 , the first core 10 and the second core 20 are inserted into the support portions 71 and 72 of the second jig 70 and attached. At this time, the covered area 30 formed into a substantially linear shape is inserted into the insertion portion 73. In this state, the insulating tape 40 is stretched flat and set in the insertion portion 73. Furthermore, the distance between the pair of sliding portions 73a, which are slidable in the vertical direction in FIG. 3 , is narrowed, and the first core 10 and the second core 20 are pulled out, so that the insulating tape 40 is attached to the covered area 30. Furthermore, the insulating tape 40 can be attached to the covered area 30 by wrapping it around the covered area 30. That is, the insulating tape 40 can be attached to the first portion 31 and the second portion 32 of the coil 3 simultaneously. The process of wrapping the insulating tape 40 around the covered area 30 may be automated, or the insulating tape 40 may be wrapped manually. It is also possible to form the covered area 30 with the first core 10 and the second core 20 set in the first jig 60, and then apply the insulating tape 40 to the covered area 30 as is.

[0019] Next, the first core 10 and the second core 20 are again pulled out from the support parts 71 and 72, and attached by inserting them into the support parts 61 and 62 in the -Y direction.

[0020] Next, with the first core 10 and the second core 20 inserted into the support portions 61 and 62, the first core 10 is rotated clockwise around the axis (Y-axis) in FIG. 2 while the slide mechanism 63 slides the first core 10 in the −X direction so as to approach the second core 20. As a result, as shown in FIG. 1B , the first portion 31 covered with the insulating tape 40 is wound around the first core 10 again. The second portion 32 corresponding to the crossover wire between the first core 10 and the second core 20 is also covered with the insulating tape 40. That is, the first portion 31 corresponding to the final turn on the outer periphery of the first core 10 and the second portion 32 corresponding to the crossover wire between the first core 10 and the second core 20 are continuously covered with the insulating tape 40. The operation of sliding the first core 10 may be automated, or the first core 10 may be slid manually.

[0021] As described above, according to this embodiment, the insulating tape 40 can be applied to the covered area 30, including the first portion 31 and the second portion 32 of the coil 3, in a state in which the covered area 30 is stretched substantially linearly. Therefore, the insulating tape 40 can be easily applied to the entire covered area 30, including the first portion 31 and the second portion 32, with good workability. For example, it is no longer necessary to apply insulating tape separately to the first portion 31 and the second portion 32. Furthermore, as a result of the improved workability, it is possible to suppress variations in the appearance of the covered area 30 to which the insulating tape 40 is applied.

[0022] Furthermore, by using the first jig 60, it is possible to easily transition between a state in which the entire covering area 30 is stretched and exposed and a state in which the first portion 31 is wound around the first core 10 as the final turn. This makes it possible to easily and quickly perform a series of steps for applying the insulating tape 40.

[0023] Furthermore, by using the second jig 70, the insulating tape 40 can be easily applied to the coverage area 30.

[0024] As described above, according to this embodiment, the insulating tape 40 can be applied to the covered area 30, which includes the first portion 31 and the second portion 32 of the coil 3, in a state in which the covered area 30 is stretched substantially linearly. Therefore, the insulating tape 40 can be easily applied to the entire covered area 30, including the first portion 31 and the second portion 32, and the covered area 30 can be insulated with good workability.

[0025] The following additional notes are provided regarding the above-described embodiments of the present invention.

[0026] [Appendix 1] a first step of extending in a substantially linear fashion a covering range including a first portion of the coil corresponding to the final turn on the outer periphery of a first core and a second portion of the coil connected to the first portion and corresponding to a crossover wire between the first core and a second core; a second step of applying an insulating tape to the covering area stretched substantially linearly in the first step; A method for manufacturing a stator, comprising:

[0027] According to the configuration described in Supplementary Note 1, the insulating tape is applied to the coverage area that is stretched in a substantially linear shape, so that the coverage area can be easily covered.

[0028] [Appendix 2] In the first step, the first core is rotated and moved relatively away from the second core, thereby pulling out the first portion wound around the first core from the first core and extending the covering area in a substantially linear manner.

[0029] According to the configuration described in Supplementary Note 2, by rotating the first core and moving the first core relatively away from the second core, the first portion can be reliably pulled out from the first core and the covering range can be extended in a substantially linear manner.

[0030] [Appendix 3] 2. The method for manufacturing a stator according to claim 1, wherein in the first step, the covering area is extended into a substantially linear shape by forming.

[0031] According to the configuration described in Supplementary Note 3, by using forming, the coverage area can be easily extended with good workability.

[0032] [Appendix 4] 2. A method for manufacturing a stator as described in Appendix 1, further comprising a third step of rotating the first core and bringing the first core relatively close to the second core, thereby winding the first portion to which the insulating tape has been attached in the second step around the first core.

[0033] According to the configuration described in Appendix 4, by rotating the first core and bringing the first core relatively close to the second core, the first portion to which the insulating tape is attached can be reliably wound around the first core.

[0034] [Appendix 5] a first step of extending in a substantially linear fashion a covering range including a first portion of the coil corresponding to the final turn on the outer periphery of a first core and a second portion of the coil connected to the first portion and corresponding to a crossover wire between the first core and a second core; a second step of applying an insulating tape to the covering area stretched substantially linearly in the first step; A jig used in a method for manufacturing a stator, comprising: A jig for applying the insulating tape to the area to be covered in the second step.

[0035] According to the configuration described in Supplementary Note 5, since the insulating tape is applied to the covering area that is stretched in a substantially linear shape, the covering area can be easily covered. In addition, the insulating tape can be easily attached to the covering area using a jig.

[0036] [Appendix 6] a first step of extending in a substantially linear fashion a covering range including a first portion of the coil corresponding to the final turn on the outer periphery of a first core and a second portion of the coil connected to the first portion and corresponding to a crossover wire between the first core and a second core; a second step of applying an insulating tape to the covering area stretched substantially linearly in the first step; a third step of winding the first portion to which the insulating tape has been attached in the second step around the first core; A jig used in a method for manufacturing a stator, comprising: In the first step, the first core is rotated and the first core is relatively separated from the second core, thereby pulling out the first portion wound around the first core from the first core, and In the third step, the first core is rotated and brought relatively close to the second core, thereby winding the first portion to which the insulating tape was attached in the second step around the first core.

[0037] According to the configuration described in Supplementary Note 6, since the insulating tape is applied to the substantially linearly stretched covering area, the covering area can be easily covered. Also, the first portion to which the insulating tape is applied can be wound around the first core using a jig.

[0038] [Appendix 7] a first step of extending in a substantially linear fashion a covering range including a first portion of the coil corresponding to the final turn on the outer periphery of a first core and a second portion of the coil connected to the first portion and corresponding to a crossover wire between the first core and a second core; a second step of applying an insulating tape to the covering area stretched substantially linearly in the first step; An insulation method comprising:

[0039] According to the configuration described in Supplementary Note 7, the insulating tape is applied to the area to be covered that is stretched in a substantially linear shape, so that the area to be covered can be easily covered. The insulation method described in Supplementary Note 7 is not limited to stators, but is widely applicable to the case of insulating coils wound around two cores. [Explanation of symbols]

[0040] 3 coils 10 First Core 20 Second Core 30 Coverage range 31 Part 1 32 Part 2 40 Electrical Tape 60 First Jig 70 Second Jig

Claims

1. a first step of extending in a substantially linear fashion a covering range including a first portion of the coil corresponding to the final turn on the outer periphery of a first core and a second portion of the coil connected to the first portion and corresponding to a crossover wire between the first core and a second core; a second step of applying an insulating tape to the covering area stretched substantially linearly in the first step; A method for manufacturing a stator, comprising:

2. 2. The method for manufacturing a stator according to claim 1, wherein in the first step, the first core is rotated and the first core is relatively separated from the second core, thereby pulling out the first portion wound around the first core from the first core and extending the covering range in a substantially linear manner.

3. The method for manufacturing a stator according to claim 1 , wherein in the first step, the covering area is extended into a substantially linear shape by forming.

4. 2. The method for manufacturing a stator according to claim 1, further comprising a third step of rotating the first core and moving the first core relatively close to the second core, thereby winding the first portion to which the insulating tape has been attached in the second step around the first core.

5. a first step of extending in a substantially linear fashion a covering range including a first portion of the coil corresponding to the final turn on the outer periphery of a first core and a second portion of the coil connected to the first portion and corresponding to a crossover wire between the first core and a second core; a second step of applying an insulating tape to the covering area stretched substantially linearly in the first step; A jig used in a method for manufacturing a stator, comprising: A jig for applying the insulating tape to the area to be covered in the second step.

6. a first step of extending in a substantially linear fashion a covering range including a first portion of the coil corresponding to the final turn on the outer periphery of a first core and a second portion of the coil connected to the first portion and corresponding to a crossover wire between the first core and a second core; a second step of applying an insulating tape to the covering area stretched substantially linearly in the first step; a third step of winding the first portion to which the insulating tape has been attached in the second step around the first core; A jig used in a method for manufacturing a stator, comprising: In the first step, the first core is rotated and the first core is relatively separated from the second core, thereby pulling out the first portion wound around the first core from the first core, and In the third step, the first core is rotated and brought relatively close to the second core, thereby winding the first portion to which the insulating tape was attached in the second step around the first core.

7. a first step of extending in a substantially linear fashion a covering range including a first portion of the coil corresponding to the final turn on the outer periphery of a first core and a second portion of the coil connected to the first portion and corresponding to a crossover wire between the first core and a second core; a second step of applying an insulating tape to the covering area stretched substantially linearly in the first step; An insulation method comprising:

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