Stator manufacturing apparatus and manufacturing method

Abstract

The present invention provides a stator manufacturing apparatus and manufacturing method that can be applied to stators with narrow radial spacing between pairs of lead ends to be connected, or narrow spacing between rows of lead ends. [Solution] The device comprises a pair of comb-shaped clamps 12, each having comb teeth 16 inserted between a pair of lead ends 11 to be joined, arranged to overlap in the axial direction, and each supported to be movable in the radial direction; a side clamp 20, inserted between rows of lead ends arranged radially and at predetermined intervals in the circumferential direction, having a wedge shape that narrows toward the inner diameter direction, and contacting both sides of each lead end by moving toward the inner diameter; a comb-shaped clamp drive device for independently moving the pair of comb-shaped clamps radially; a side clamp drive device for moving the side clamps radially; and an axial movement device for moving the comb-shaped clamps and the side clamps in the axial direction.

Description

Technical Field

[0001] The present invention relates to a manufacturing apparatus and a manufacturing method for a stator that is inserted into a stator core of a rotating electrical machine and forms a coil by joining lead ends of segment coils arranged in the radial direction of the stator core.

Background Art

[0002] Conventionally, a flat wire is bent into a hairpin shape, both side portions thereof are inserted into two predetermined slots of a stator core, lead ends inserted from the slots are formed into a predetermined shape, and a pair of lead ends to be connected are arranged so as to be adjacent in the radial direction. In this state, a pair of lead ends to be connected are held by a jig and welded to form a continuous coil.

[0003] For example, in Patent Document 1 below, a jig including a pair of restraint members having a rod portion extending in the radial direction and tooth portions protruding at a predetermined interval on one side surface of the rod portion is used. The tooth portions of the respective restraint members are inserted between a pair of lead ends to be connected, one restraint member is moved in either direction in the radial direction, and the other restraint member is moved to the opposite side in the radial direction to sandwich the lead ends to be connected between the tooth portions and weld them.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the coil joining method described in Patent Document 1, a pair of restraining members are positioned at the same height and are arranged to sandwich both sides of the lead terminals. Therefore, it is necessary to insert the teeth protruding from the pair of restraining members between the pairs of lead ends to be connected, and to arrange restraining members that hold the lead terminals of adjacent rows between rows of lead terminals arranged radially. This necessitates a wide radial distance between the pairs of lead ends to be connected and a wide distance between rows, which makes it difficult to apply to the manufacture of compact stators with narrower spacing.

[0006] Therefore, an object of the present invention is to provide a stator manufacturing apparatus and manufacturing method that enables welding of a pair of lead ends to be welded, even in stators where the radial distance between the pair of lead ends to be connected or the distance between the rows of lead ends is narrow, by positioning and holding the pair of lead ends to be connected from both radial sides. [Means for solving the problem]

[0007] To achieve the above objective, one aspect of the present invention relates to a stator manufacturing apparatus for a rotating electric machine, which is inserted into the stator core and forms a coil by joining the lead ends of segment coils arranged radially in the stator core, A pair of comb-shaped clamps are arranged superimposed in the axial direction and supported so as to be movable in the radial direction, each having comb teeth that are inserted between a pair of lead ends to be joined, and The aforementioned comb-shaped clamp is offset in the axial direction, inserted between rows of lead ends arranged radially and at predetermined intervals in the circumferential direction, and has a wedge-shaped plate that narrows in the inward direction, and moves in the inward direction to contact both sides of each lead end as a side clamp, A comb-type clamp drive device that moves each of the pair of comb-type clamps independently in the radial direction, A side clamp drive device for moving the side clamp in the radial direction, The present invention provides a stator manufacturing apparatus characterized by comprising an axial movement device for moving the comb-shaped clamp and the side clamp in the axial direction.

[0008] According to the stator manufacturing apparatus described above, by using an axial moving device to bring the comb-shaped clamp and the side clamp close to the end face of the stator core, the comb teeth of the comb-shaped clamp can be inserted between the radially arranged lead ends, and the side clamp can be inserted between the radially arranged rows of lead ends.

[0009] In this state, a pair of comb-shaped clamps, which are arranged overlapping in the axial direction, can be moved in opposite directions radially by a comb-shaped clamp drive device, thereby bringing the pair of lead ends to be joined closer together radially and pressing them together to achieve radial positioning.

[0010] Furthermore, by moving the side clamps in the radial direction using a side clamp drive device, the circumferential positioning can be achieved by clamping both sides of the radially aligned lead ends with the side clamps.

[0011] By positioning the lead ends in this way and welding them together while pressing them radially against each other, a pair of lead ends to be joined can be reliably connected to form a coil.

[0012] After welding is complete, the comb-shaped clamp is moved in the opposite direction by the comb-shaped clamp drive device to separate it from the welded lead end, and the side clamp is moved in the radial direction by the side clamp drive device to separate it from both sides of the welded lead end. In this state, the comb-shaped clamp and the side clamp are separated from the end face of the stator core by the axial movement device, allowing each clamp to be easily removed.

[0013] Furthermore, since the comb-shaped clamps are arranged in an overlapping manner in the axial direction, the comb teeth do not interfere with each other, and even if the spacing between the radially aligned lead ends is narrow, a comb tooth can be inserted as long as there is enough space for one comb tooth.

[0014] Furthermore, the side clamps are positioned axially offset from the comb-shaped clamps, and the wedge-shaped plates inserted between the rows of lead terminals contact the lead terminals on both sides. This allows the side clamps to be installed even when the spacing between rows of lead terminals is narrow.

[0015] As a result, it becomes easier to apply this technology even to stators where the radial spacing between the pair of lead ends to be connected, or the spacing between rows of lead terminals, is narrow.

[0016] Furthermore, the comb-shaped clamps, which are arranged in an overlapping manner in the axial direction, move in opposite directions in the radial direction, allowing them to press and compress the lead ends from the surface direction, thus enabling more secure compression between the lead ends.

[0017] In the stator manufacturing apparatus of the present invention, the comb-shaped clamp that is closer to the end face of the stator core in the axial direction is moved in the radial direction, and the comb-shaped clamp that is further away from the end face of the stator core in the axial direction is moved in the radial direction, thereby pressing together a pair of lead ends to be joined from among the radially arranged lead ends, and it is preferable that the side clamp is positioned offset from the comb-shaped clamp in the axial direction away from the end face of the stator core.

[0018] According to the above embodiment, by moving the comb-shaped clamp closer to the end face of the stator core in the axial direction and moving the comb-shaped clamp further away from the end face of the stator core in the axial direction, the pair of lead ends to be joined are pressed together. When the side clamp is moved in the axial direction to clamp both sides of the lead ends with the side clamp, the inward movement of the side clamp can prevent the lead end positioned on the inner side of the pair of lead ends to be joined, which are arranged in the axial direction, from being rubbed against the side clamp and moving inward, thus preventing the lead ends from separating.

[0019] Furthermore, in the stator manufacturing apparatus of the present invention, it is preferable that the inner diameter end and outer diameter end of the side clamp are provided with grounding clamps that press against a grounded component, respectively.

[0020] According to the above embodiment, by pressing the inner and outer diameter ends of the side clamps that grip both sides of the lead end against the grounded component by the ground clamp, grounding can be achieved in both radial directions. As a result, the arc spread becomes uniform, the shape of the weld ball is improved, and interference with the weld ball can be more effectively suppressed when removing each clamp.

[0021] Furthermore, in the stator manufacturing apparatus of the present invention, it is preferable that the comb-shaped clamp and the side clamp are provided for multiple rows of lead ends arranged radially and at predetermined intervals in the circumferential direction, and that the comb-shaped clamp drive device and the side clamp drive device are structured to move the comb-shaped clamp and the side clamp corresponding to each row of lead ends in conjunction and simultaneously.

[0022] According to the above embodiment, positioning and clamping can be performed simultaneously on multiple rows of lead ends arranged radially, thereby improving work efficiency.

[0023] Another aspect of the present invention is a method for manufacturing a stator that is inserted into a stator core of a rotating electrical machine and forms a coil by joining lead ends of segment coils arranged in the radial direction of the stator core, each having a comb tooth inserted between a pair of lead ends to be joined among the lead ends arranged in the radial direction, a pair of comb-shaped clamps that are axially overlapped and arranged, and are each supported so as to be movable in the radial direction, a wedge-shaped plate that is arranged offset in the axial direction from the comb-shaped clamp, arranged side by side in the radial direction, inserted between rows of the lead ends arranged at a predetermined interval in the circumferential direction, and has a width that becomes narrower toward the inner diameter direction, and a side clamp that abuts on both sides of each lead end by moving in the inner diameter direction are used, a first step of bringing the comb-shaped clamp and the side clamp close to the end face of the stator core from the axial direction of the stator core, inserting the comb teeth between the pair of lead ends to be joined, and inserting the side clamp between the rows of the lead ends arranged side by side in the radial direction, a second step of pressing the pair of lead ends to be joined close to each other in the radial direction by moving the pair of axially overlapped comb-shaped clamps in opposite directions in the radial direction, a third step of sandwiching both sides of the lead ends arranged side by side in the radial direction with the side clamp by moving the side clamp in the inner diameter direction, a fourth step of welding the pair of lead ends pressed by the pair of comb-shaped clamps by welding, a fifth step of releasing the clamp by moving the pair of comb-shaped clamps in the radial direction in the opposite direction to the second step and moving the side clamp in the outer diameter direction, and a sixth step of moving the comb-shaped clamp and the side clamp axially away from the end face of the stator core and extracting them from the lead ends, and provides a method for manufacturing a stator characterized by including the above steps.

[0024] According to the stator manufacturing method of the present invention, welding is performed while the stator is pressed radially by a pair of comb-shaped clamps and both sides are held in place by side clamps, so that the pair of lead ends to be joined are reliably joined together to form a coil.

[0025] Furthermore, in the sixth step, when the comb-shaped clamp and side clamp are moved axially away from the end face of the stator core and removed from the lead end, each clamp can be easily removed.

[0026] Furthermore, since the comb-shaped clamps are arranged in an overlapping manner in the axial direction, the comb teeth do not interfere with each other, and even if the spacing between the radially aligned lead ends is narrow, a comb tooth can be inserted as long as there is enough space for one comb tooth.

[0027] Furthermore, the side clamps are positioned axially offset from the comb-shaped clamps, and the wedge-shaped plates inserted between the rows of lead terminals contact the lead terminals on both sides. This allows the side clamps to be installed even when the spacing between rows of lead terminals is narrow.

[0028] As a result, it becomes easier to apply this technology even to stators where the radial spacing between the pair of lead ends to be connected, or the spacing between rows of lead terminals, is narrow.

[0029] Furthermore, the comb-shaped clamps, which are arranged in an overlapping manner in the axial direction, move in opposite directions in the radial direction, allowing them to press and compress the lead ends from the surface direction, thus enabling more secure compression between the lead ends. [Effects of the Invention]

[0030] According to the present invention, a coil can be formed by reliably joining a pair of lead ends to be connected, and the invention can be easily applied even to stators where the radial distance between the pair of lead ends to be connected or the distance between rows of lead terminals is narrow. [Brief explanation of the drawing]

[0031] [Figure 1] This is a perspective view showing one embodiment of the stator manufacturing apparatus of the present invention, with the support frame in a raised state. [Figure 2] This is a perspective view showing the manufacturing apparatus with the support frame in a lowered position. [Figure 3] Figure 2 is a partially enlarged perspective view showing the lead ends of the segment coil, the comb-shaped clamp, and the side clamp. [Figure 4] This is an exploded perspective view showing the comb-shaped clamp and side clamp of the manufacturing apparatus. [Figure 5] This is a perspective view showing the comb-type clamp drive mechanism of the manufacturing equipment. [Figure 6] This is a partially enlarged perspective view showing the manufacturing apparatus with a comb-shaped clamp holding a pair of lead ends to be connected to a segment coil. [Figure 7] This is a partially enlarged perspective view showing the manufacturing apparatus with side clamps holding both ends of the lead of the segment coil. [Figure 8] This is a perspective view showing the manufacturing apparatus with the side clamp's radial ends pressed by a retaining plate to which the ground wire is connected. [Figure 9] This is a partially enlarged perspective view showing the state in which a pair of lead ends to be connected to a segment coil have been welded by welding in the manufacturing apparatus. [Figure 10] This is a partially enlarged perspective view showing the state after welding is complete, with the comb-shaped clamp and side clamps released from the manufacturing apparatus. [Figure 11] This is a partially enlarged perspective view showing the state after welding is complete in the manufacturing apparatus, with the comb-shaped clamp and side clamp raised to remove the segment coil from the lead end. [Modes for carrying out the invention]

[0032] The present invention will be described below with reference to the drawings, but the present invention is not limited to this embodiment.

[0033] As shown in Figure 1, the stator manufacturing apparatus 10 forms a coil by inserting both sides of a segment coil into predetermined slots (not shown) of the stator core 18 and welding the radially aligned lead ends 11 of the segment coil, which protrude from one end face. In the drawing, only the outer shape of the stator core 18 is shown with dashed lines, and the slots and the overall shape of the segment coil are omitted as they are well known. The lead ends 11 are arranged radially and in rows at predetermined intervals in the circumferential direction.

[0034] The stator manufacturing apparatus 10 has a support frame 17 that moves up and down by a lifting device (not shown). A comb-shaped clamp 12 and a side clamp 20, as shown in Figure 4, are mounted on this support frame 17.

[0035] First, let's describe the comb-shaped clamp 12. The comb-shaped clamp 12 consists of a first comb-shaped clamp 12a and a second comb-shaped clamp 12b, which are positioned overlapping and offset from each other in the axial direction of the stator core 18. In the axial direction of the stator core 18, the first comb-shaped clamp 12a is positioned on the side away from the end face of the stator core 18.

[0036] The first comb-shaped clamp 12a and the second comb-shaped clamp 12b each have a base portion 13, a pin mounting hole 14 provided at the base end of the base portion 13, a radial extension portion 15 extending radially inward from the base portion 13, and a plurality of comb teeth 16 protruding from one side of the radial extension portion 15. In this embodiment, three notches 19 are formed between the comb teeth 16 for inserting a pair of lead ends 11.

[0037] With respect to the base portion 13, the radial extension portion 15 extends in the inner diameter direction of the stator core 18 from a position offset in the axial direction of the stator core 18 away from the end face of the stator core 18, via a stepped portion formed at the tip of the base portion 13. Furthermore, the base portion 13 is formed to be thicker than the radial extension portion 15.

[0038] Next, the side clamp 20 will be described. The side clamp 20 has a base portion 21, a wedge-shaped plate 22 that extends from the tip of the base portion 21 in the inward diameter direction of the stator core 18 and has a shape that becomes narrower towards the inward diameter, and a pin mounting hole 23 provided in the portion of the base portion 21 adjacent to the wedge-shaped plate 22. The base portion 21 is formed to be thicker than the wedge-shaped plate 22, and the base portion 21 protrudes from the wedge-shaped plate 22 in a direction that approaches the end face of the stator core 18.

[0039] When the side clamp 20, the first comb-shaped clamp 12a, and the second comb-shaped clamp 12b are superimposed in the axial direction of the stator core 18, the base 21 of the side clamp 20, the base 13 of the first comb-shaped clamp 12a, and the base 13 of the second comb-shaped clamp 12b overlap, and the wedge-shaped plate 22 of the side clamp 20, the radial extension 15 of the first comb-shaped clamp 12a, and the radial extension 15 of the second comb-shaped clamp 12b overlap.

[0040] As shown in Figure 2, when the support frame 17 is lowered in a direction approaching the end face of the stator core 18, as shown in Figure 3, a pair of lead ends 11, consisting of a first lead end 11a and a second lead end 11b, are inserted into the notches 19 formed between the comb teeth 16, and the wedge-shaped plate 22 is positioned between the rows of lead ends 11.

[0041] Figure 5 shows a comb-type clamp drive device 30 that moves the first comb-type clamp 12a and the second comb-type clamp 12b independently. The comb-type clamp drive device 30 has a first slide plate 31 that moves the first comb-type clamp 12a and a second slide plate 32 that moves the second comb-type clamp 12b.

[0042] The first comb-shaped clamp 12a is provided with a pin 33 that is mounted in a pin mounting hole 14. The first slide plate 31 has a planar shape that widens in an inner diameter and narrows in an outer diameter. Multiple pin engagement holes 36 are formed at predetermined intervals in the circumferential direction in the fan-shaped portion of the first slide plate 31. Multiple pins 33 of the first comb-shaped clamps 12a, which are arranged in the circumferential direction, are inserted into each pin engagement hole 36. In addition, a drive pin engagement hole 34 is provided at the outer diameter end of the first slide plate 31, into which a drive pin 35 of a drive mechanism (not shown) is inserted.

[0043] When the drive pin 35 moves to the outer diameter side of the stator core 18 by a drive mechanism (not shown), the first comb-shaped clamps 12a are pulled and moved to the outer diameter side via the first slide plate 31 and pin 33. When the drive pin 35 moves to the inner diameter side of the stator core 18, the first comb-shaped clamps 12a are pushed and moved to the inner diameter side via the first slide plate 31 and pin 33.

[0044] The second slide plate 32 also has a structure similar to that described above, with multiple second comb-shaped clamps 12b connected via pins 33, and is provided with a drive mechanism similar to that described above. When the second slide plate 32 moves toward the inner diameter by the drive mechanism (not shown), each second comb-shaped clamp 12b is pushed toward the inner diameter and moves, and when the second slide plate 32 moves toward the outer diameter, each second comb-shaped clamp 12b is pulled toward the outer diameter and moves.

[0045] As shown in Figure 6, when a pair of lead ends 11, consisting of a first lead end 11a and a second lead end 11b, are inserted into the notches 19 of the first comb-type clamp 12a and the second comb-type clamp 12b, and the first comb-type clamp 12a moves in the outer diameter direction A and the second comb-type clamp 12b moves in the inner diameter direction B, the second lead end 11b is pushed outward by the comb teeth 16 of the first comb-type clamp 12a and the first lead end 11a is pushed inward by the comb teeth 16 of the second comb-type clamp 12b, so that the tips of the first lead end 11a and the second lead end 11b are pressed together and held in place.

[0046] Furthermore, as shown in Figure 10, when the first comb-shaped clamp 12a moves in the inward direction B and the second comb-shaped clamp 12b moves in the outward direction A, the comb teeth 16 of the first comb-shaped clamp 12a move away from the second lead end 11b, and the comb teeth 16 of the second comb-shaped clamp 12b move away from the first lead end 11a, thereby releasing the clamp.

[0047] Figure 7 shows a side clamp drive device 40 for moving the side clamp 20 radially around the stator core 18. Pins 43 are mounted in the pin mounting holes 23 (see Figure 4) of the side clamp 20. An arc-shaped cam plate 41 is provided so as to overlap the arrangement of pins 43 of the side clamp 20, which are arranged at predetermined intervals in the circumferential direction. The arc-shaped cam plate 41 is provided with slit-shaped cam grooves 42 that extend diagonally with respect to the radial direction, corresponding to each pin 43, and the pins 43 are inserted into the corresponding cam grooves 42. As shown in Figures 1 and 2, a side clamp drive bracket 72 is connected to the arc-shaped cam plate 41, and the side clamp drive bracket 72 is connected to a rod 71 of a side clamp drive air cylinder. The arc-shaped cam plate 41 is made capable of reciprocating in the circumferential direction around the axis of the stator core 18 by the pushing and pulling motion of the rod 71.

[0048] In this embodiment, when the arc-shaped cam plate 41 moves in the direction of arrow C in Figure 7, the pins 43 mounted on each side clamp 20 are pushed inward by the cam groove 42, and the side clamps 20 are pushed outward in the direction of arrow D. As a result, the wedge-shaped plates 22 are pressed against the lead ends 11 on both sides, and the lead ends 11 are sandwiched between the wedge-shaped plates 22 positioned on both sides, thereby positioning them in the circumferential direction, and the lead ends 11 and the wedge-shaped plates 22 become electrically conductive.

[0049] Furthermore, when the arc-shaped cam plate 41 moves in the opposite direction to arrow C in Figure 7, the pins 43 attached to each side clamp 20 are pushed outward by the cam groove 42, causing the side clamps 20 to move outward in the opposite direction to arrow D. As a result, both sides of the wedge-shaped plate 22 separate from the lead end 11, resulting in a clamp-release state where the wedge-shaped plate 22 and the lead end 11 do not come into contact.

[0050] As shown in Figures 1 and 2, a first retaining plate 51 is positioned on the support frame 17 so as to cover the tips of a plurality of wedge-shaped plates 22 arranged in the circumferential direction, with the tips of the wedge-shaped plates 22 inserted below the first retaining plate 51. The first retaining plate 51 is normally maintained in a state that is slightly elevated away from the wedge-shaped plates 22. A first ground wire 52 is connected to the first retaining plate 51 by a fixing bolt 53. Two lifting guide shafts (not shown) are provided that pass through the first retaining plate 51, and levers 54 are rotatably mounted on each lifting guide shaft via pivot shafts 55. An air cylinder connecting portion 57 (not shown) is provided at the end of the lever 54, to which the operating rod of an air cylinder (not shown) is connected. The outer circumference of the part of the lever 54 into which the pivot shaft 55 is inserted forms an eccentric cam portion 56. As shown in Figure 8, when the lever 54 is rotated by an air cylinder (not shown) to tilt, the first retaining plate 51 is pushed downward by the eccentric cam portion 56 against an elastic member (not shown), pressing the tip of the wedge-shaped plate 22 toward the support frame 17, thereby ensuring electrical contact between the wedge-shaped plate 22 and the first ground wire 52.

[0051] Furthermore, as shown in Figures 2 and 8, a second retaining plate 61 made of an arc-shaped plate is positioned on the support frame 17 so as to cover the bases 21 of a plurality of side clamps 20 arranged in the circumferential direction, and the bases 21 of the side clamps 20 are inserted below the second retaining plate 61. The second retaining plate 61 is normally maintained in a state slightly elevated away from the bases 21 by an elastic member (not shown). A second ground wire 62 is connected to the second retaining plate 61 by a fixing bolt 63. In addition, two lifting guide shafts (not shown) are provided that pass through the second retaining plate 61, and a lever 64 is rotatably mounted on each lifting guide shaft via a pivot shaft 65. An air cylinder connecting portion 67 is provided at the end of the lever 64 to which the operating rod of an air cylinder (not shown) is connected. The outer circumference of the portion into which the pivot shaft 65 of the lever 64 is inserted forms an eccentric cam portion 66. As shown in Figure 8, when the lever 64 is rotated by an air cylinder (not shown) to tilt, the second retaining plate 61 is pushed downward by the eccentric cam portion 66 against an elastic member (not shown), pressing the base portion 21 of the side clamp 20 toward the support frame 17, ensuring that the base portion 21 and the second ground wire 62 are reliably connected.

[0052] Furthermore, a welding device (not shown) is positioned above the lead end 11, and a high voltage is applied between the wedge-shaped plate 22, base 21, first pressing plate 51, second pressing plate 61, first ground wire 52, and second ground wire 62, which are grounded to the lead end 11, allowing the tips of the first lead end 11a and second lead end 11b, which are pressed and held by the comb teeth 16 of the first comb-shaped clamp 12a and second comb-shaped clamp 12b, to be welded.

[0053] Next, an embodiment of the method for manufacturing a stator according to the present invention using the stator manufacturing apparatus 10 will be described.

[0054] (1st step) As shown in Figure 1, the support frame 17 is raised, and then lowered by an axial moving device (not shown) as shown in Figure 2. Then, as shown in Figure 3, a pair of lead ends 11, consisting of a first lead end 11a and a second lead end 11b, are inserted into a notch 19 formed between the comb teeth 16 of the first comb-type clamp 12a and the second comb-type clamp 12b, and the wedge-shaped plates 22 of the side clamps 20 are positioned on both sides of the lead ends 11. In this state, one comb tooth 16 of the first comb-type clamp 12a and the second comb-type clamp 12b is inserted between the pair of radially arranged lead ends 11, and the comb teeth 16 of the first comb-type clamp 12a and the second comb-type clamp 12b overlap in a nearly aligned manner, and the lead ends 11 do not come into contact with the radially extended portion 15 and the comb teeth 16. Furthermore, the side clamp 20 is retracted towards the outer diameter side and is not in contact with the lead end 11 and the wedge-shaped plate 22.

[0055] (2nd process) As shown in Figure 5, by moving the first slide plate 31 of the comb-type clamp drive device 30 toward the outer diameter side of the stator core 18 and moving the second slide plate 32 toward the inner diameter side, the first comb-type clamp 12a is moved toward the outer diameter side indicated by arrow A, and the second comb-type clamp 12b is moved toward the inner diameter side indicated by arrow B, as shown in Figure 6. As a result, the comb teeth 16 of the first comb-type clamp 12a press the second lead end 11b toward the outer diameter side, and the comb teeth 16 of the second comb-type clamp 12b press the first lead end 11a toward the inner diameter side, so that the tips of the first lead end 11a and the second lead end 11b to be connected are pressed and held. Furthermore, since the comb-type clamp drive device 30 moves multiple first comb-type clamps 12a and second comb-type clamps 12b simultaneously via the first slide plate 31 and the second slide plate 32, the drive mechanism can be simplified and workability can be improved.

[0056] (3rd step) As shown in Figure 7, the arc-shaped cam plate 41 of the side clamp drive device 40 is rotated in the direction of arrow C, the pin 43 is pressed in the inward direction of the stator core 18 by the cam groove 42, the side clamp 20 is moved inward, and the wedge-shaped plate 22 is pushed between the rows of lead ends 11. As a result, both sides of the lead end 11 are clamped by the wedge-shaped plate 22, and the circumferential position of the lead end 11 is accurately maintained. In this embodiment, as shown in Figure 6, the comb teeth 16 of the first comb-shaped clamp 12a, which is positioned away from the end face of the stator core 18, are pressing against the second lead end 11b, which is located on the inward side. Therefore, even if the wedge-shaped plate 22 moves inward and rubs against the second lead end 11b, it is possible to prevent the second lead end 11b from moving inward and separating from the first comb-shaped clamp 12a. Furthermore, by rotating the arc-shaped cam plate 41 of the side clamp drive device 40, multiple side clamps 20 can be moved simultaneously, thus simplifying the drive mechanism and improving work efficiency.

[0057] (4th step) As shown in Figure 8, the lever 54 is rotated downward by an air cylinder (not shown), and the eccentric cam portion 56 pushes down the first retaining plate 51, pressing it against the wedge-shaped plate 22 of the side clamp 20, thereby creating electrical contact between the wedge-shaped plate 22 and the first ground wire 52 via the first retaining plate 51. Since the wedge-shaped plate 22 clamps both sides of the first lead end 11a and the second lead end 11b, the first lead end 11a and the second lead end 11b also become electrically connected to the first ground wire 52.

[0058] Similarly, an air cylinder (not shown) rotates the lever 64 downward, causing the eccentric cam portion 66 to push down the second retaining plate 61, pressing it against the base portion 21 of the side clamp 20, thereby establishing electrical contact between the base portion 21 and the second ground wire 62 via the second retaining plate 61. Since the wedge-shaped plate 22 of the side clamp 20 clamps both sides of the first lead end 11a and the second lead end 11b, the first lead end 11a and the second lead end 11b also become electrically connected to the second ground wire 62.

[0059] In this state, a high voltage is applied to the pair of lead ends 11 to be connected, consisting of a first lead end 11a and a second lead end 11b, using a welding apparatus (not shown), to weld the tips of the first lead end 11a and the second lead end 11b. As a result, as shown in Figure 9, a molten ball 73 is formed at the tips of the first lead end 11a and the second lead end 11b, and the tips of the first lead end 11a and the second lead end 11b to be connected are joined. At this time, the wedge-shaped plate 22 of the side clamp 20 is electrically connected to the first ground wire 52 via the first retaining plate 51, and the base 21 of the side clamp 20 is electrically connected to the second ground wire 62 via the second retaining plate 61. Therefore, grounding can be achieved in both radial directions via the side clamp 20, thereby suppressing deflection due to electromagnetic force and resulting in a good shape for the molten ball 73.

[0060] (5th step) As shown in Figure 10, the comb-type clamp drive device 30 moves the first comb-type clamp 12a in the inward direction indicated by arrow B, and moves the second comb-type clamp 12b in the outward direction indicated by arrow A, returning the comb teeth 16 of the first comb-type clamp 12a and the second comb-type clamp 12b to their initial state where they are almost aligned and overlapping. As a result, the first lead end 11a and the second lead end 11b no longer come into contact with the comb teeth 16 and the radial extension portion 15, and the radial clamping is released.

[0061] The arc-shaped cam plate 41 of the side clamp drive device 40 is rotated in the opposite direction to arrow C shown in Figure 7, pressing the pin 43 in the outer diameter direction of the stator core 18 via the cam groove 42, and moving the side clamp 20 in the outer diameter direction. As a result, the wedge-shaped plate 22 of the side clamp 20 separates from both sides of the lead end 11, and the circumferential clamp is released.

[0062] (6th step) As shown in Figure 1, the support frame 17 is raised by an axial moving device (not shown), and as shown in Figure 11, the first lead end 11a and the second lead end 11b, which are joined by the molten ball 73, are pulled out from the notch 19 between the comb teeth 16, returning the stator manufacturing apparatus 10 to the initial position shown in Figure 1.

[0063] At this time, as mentioned above, the shape of the molten ball 73 that joins the first lead end 11a and the second lead end 11b is formed well, so the molten ball 73 can be removed without getting caught on the comb teeth 16 or the wedge-shaped plate 22.

[0064] Furthermore, according to this stator manufacturing apparatus 10, as shown in Figures 3, 6, 10, and 11, the first comb-shaped clamp 12a, the second comb-shaped clamp 12b, and the side clamp 20 are arranged so that they overlap in the axial direction. Therefore, between the pair of lead ends 11 to be connected, only one comb tooth 16 of the first comb-shaped clamp 12a and the second comb-shaped clamp 12b needs to be placed in an overlapping state, and between the rows of radially aligned lead ends 11, only one wedge-shaped plate 22 of the side clamp 20 needs to be placed. Thus, it is possible to apply this apparatus even if the radial distance between the pair of lead ends 11 to be connected or the circumferential distance between the rows of radially aligned lead ends 11 is narrow, and a compact stator can be manufactured.

[0065] Furthermore, if laser welding is used as the welding method, the first ground wire 52 and the second ground wire 62 become unnecessary. [Explanation of Symbols]

[0066] 10 Stator manufacturing equipment 11 Lead ends 11a First lead end 11b Second lead end 12 Comb-shaped clamps 13 Base 14 pin mounting holes 15 Radial extension 16 comb teeth 17 Support frame 18 Stator Core 19 Notch 12a First comb-type clamp 12b Second comb-type clamp 20 Side Clamps 21 Base 22 Wedge-shaped plate 23 Pin mounting holes 30 Comb-type clamp drive device 31. First slide plate 32. Second slide plate 33 pins 34 Drive pin engagement holes 35 drive pins 36 Pin engagement holes 40 Side clamp drive device 41. Arc-shaped cam plate 42 cam groove 43 pins 51 First retaining plate 52. First ground wire 53 Fixing bolts 54 Lever 55 Spindle 56 Eccentric cam section 57 Air cylinder connection section 61. Second retaining plate 62 Second ground wire 63 Fixing bolts 64 Lever 65 Spindle 66 Eccentric cam section 67 Air cylinder connection section 71 Side clamp drive air cylinder rod 72 Side clamp drive bracket 73 molten spheres

Claims

1. In a stator manufacturing apparatus for a rotating electric machine, in which the lead ends of segment coils, which are inserted into the stator core and arranged radially within the stator core, are joined together to form a coil, A pair of comb-shaped clamps are arranged superimposed in the axial direction and supported so as to be movable in the radial direction, each having comb teeth that are inserted between a pair of lead ends to be joined, and The aforementioned comb-shaped clamp is offset in the axial direction, inserted between rows of lead ends arranged radially and at predetermined intervals in the circumferential direction, and has a wedge-shaped plate that narrows in the inward direction, and moves in the inward direction to contact both sides of each lead end as a side clamp, A comb-type clamp drive device that moves each of the pair of comb-type clamps independently in the radial direction, A side clamp drive device for moving the side clamp in the radial direction, A stator manufacturing apparatus characterized by comprising an axial movement device for moving the comb-shaped clamp and the side clamp in the axial direction.

2. The comb-type clamp drive device is configured to move the comb-type clamp closer to the end face of the stator core in the axial direction in the radial direction, and the comb-type clamp further away from the end face of the stator core in the axial direction in the radial direction, thereby pressing together a pair of lead ends to be joined from among the radially arranged lead ends, and the side clamp is positioned offset from the comb-type clamp in the axial direction away from the end face of the stator core, as described in claim 1, for the stator manufacturing apparatus.

3. A stator manufacturing apparatus according to claim 1 or 2, wherein the inner diameter end and outer diameter end of the side clamp are provided with grounding clamps that press against a grounded component, respectively.

4. A stator manufacturing apparatus according to claim 1 or 2, wherein the comb-shaped clamp and the side clamp are provided for multiple rows of lead ends arranged radially and at predetermined intervals in the circumferential direction, and the comb-shaped clamp drive device and the side clamp drive device are structured to move the comb-shaped clamp and the side clamp corresponding to each row of lead ends in conjunction and simultaneously.

5. In a method for manufacturing a stator, in which a coil is formed by joining the lead ends of segment coils that are inserted into the stator core of a rotating electric machine and arranged radially within the stator core, A pair of comb-shaped clamps are arranged superimposed in the axial direction and supported so as to be movable in the radial direction, each having comb teeth that are inserted between a pair of lead ends to be joined, and The comb-shaped clamp is offset in the axial direction, and the side clamps are inserted between the rows of lead ends which are arranged radially and spaced apart in the circumferential direction. The side clamps have a wedge-shaped plate that narrows in the inward direction and moves in the inward direction to contact both sides of each lead end. The first step involves bringing the comb-shaped clamp and the side clamp close to the end face of the stator core from the axial direction of the stator core, inserting the comb teeth between the pair of lead ends to be joined, and inserting the side clamp between the rows of lead ends arranged in the radial direction. The second step involves moving the pair of comb-shaped clamps, which are arranged overlapping in the axial direction, in opposite directions in the radial direction, thereby bringing the pair of lead ends to be joined closer together in the radial direction and pressing them together. A third step involves moving the side clamp in the inward diameter direction to clamp both sides of the lead ends aligned in the radial direction with the side clamp, A fourth step involves welding together the pair of lead ends that have been pressed together by the pair of comb-shaped clamps, A fifth step involves moving the pair of comb-shaped clamps radially in the direction opposite to the second step, and moving the side clamps radially outward to release the clamps. A method for manufacturing a stator, comprising a sixth step of moving the comb-shaped clamp and the side clamp axially away from the end face of the stator core and removing them from the lead end.

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