Lead wire manufacturing system, lead wire manufacturing method, stator manufacturing method, and rotating electric machine manufacturing method

Abstract

When connecting wires between coils by forming them into a predetermined shape, such as jumper wires connected to stators, multiple devices are required to form the wires into the desired shape, and the wires must be passed between these devices multiple times by workers or robots. [Solution] A manufacturing system comprising a first device for gripping a lead wire at two points separated by a predetermined distance, a second device for shaping the lead wire gripped by the first device into a predetermined shape, and a control unit for controlling the first device to move the lead wire without releasing its grip after the lead wire gripped by the first device has been shaped by the second device, until it is positioned at a predetermined location, can improve productivity by reducing the man-hours required for handling the lead wires, and can also improve the accuracy of the shape after shaping because there is no misalignment of the wires that occurs during handling.

Description

Technical Field

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[0001] The present disclosure relates to a lead wire manufacturing system, a lead wire manufacturing method, a stator manufacturing method, and a rotating electrical machine manufacturing method.

Background Art

[0002] A conventional stator of a rotating electrical machine is composed of a stator core having teeth with a plurality of magnetic poles along the inner peripheral portion, and windings wound around each tooth of the stator core via an insulating member. A restraining portion for restraining the winding terminal portion is provided on the end face of the stator core. The restraining portion is provided with a restraining groove for restraining the start terminal portion or the end terminal portion of the winding. Further, in the restraining groove, lead wires connecting the start terminal portions of the windings to each other, connecting the power source and the windings, and connecting the end terminal portions of the windings to each other to form a neutral point are also restrained. The terminal portions of the restrained windings and the lead wires are connected by metal pieces fitted into the restraining portion. The lead wires are formed into an arc shape and connect between desired windings through each tooth, facilitating the connection between the windings of the stator.

[0003] An example of a member used for a lead wire is a coated electric wire. Wire materials such as coated electric wires are flexible, and since it is difficult to regulate the position when handling them, the wiring work is often performed manually. However, proposals have been made to automate the wiring using an automated robot (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The technology described in Patent Document 1 involves stripping the insulation coating from the end of an electric wire using a coating stripping machine, gripping the electric wire with a wire handling device, and wiring it to a predetermined location. Thus, automatic wiring of electric wires is disclosed through three steps: (1) holding both ends of the electric wire from which the insulation coating has been stripped, (2) receiving both ends of the electric wire and transporting them to the wiring location, and (3) inserting both ends of the electric wire into the wiring location and connecting them. However, when electric wires are formed into a predetermined shape and connected between coils, such as jumper wires connected when manufacturing stators, multiple devices are required to form the electric wire into the desired shape, and multiple transfers of the electric wire by workers or robots are required. This results in a large number of device components, increased working time due to transfers, and decreased productivity due to deviations in the positional control of the electric wire during transfers.

[0006] This disclosure is made to solve the above-mentioned problems and aims to provide a lead wire manufacturing system, a lead wire manufacturing method, a stator manufacturing method, and a rotating electric machine manufacturing method that can facilitate lead wire forming and wiring work and improve productivity. [Means for solving the problem]

[0007] The lead wire manufacturing system according to this disclosure comprises a first device for gripping a lead wire at two points separated by a predetermined distance, a second device for shaping the lead wire gripped by the first device into a predetermined shape, and a control unit that controls the first device to move the lead wire without releasing its grip until it is positioned at a predetermined location after the lead wire gripped by the first device has been shaped by the second device. [Effects of the Invention]

[0008] According to the lead wire manufacturing system described herein, productivity can be improved because the lead wire is formed and the gripping of the lead wire is maintained until it is placed in a predetermined position, eliminating the need to transfer it to another device. Furthermore, the accuracy of the shape after molding can be improved because there is no misalignment of the gripping part that occurs during transfer. [Brief explanation of the drawing]

[0009] [Figure 1] This is a cross-sectional view of a rotating electric machine according to an embodiment. [Figure 2] This is a perspective view of the laminated core of a rotating electric machine according to an embodiment. [Figure 3] This is a perspective view of an insulator constituting the stator of a rotating electric machine according to an embodiment. [Figure 4] This is a perspective view of a winding assembly that constitutes the stator of a rotating electric machine according to an embodiment. [Figure 5] This is a top view showing lead wires wired to the stator of a rotating electric machine according to an embodiment. [Figure 6] This diagram illustrates the shape of the lead wires of a rotating electric machine according to an embodiment. [Figure 7] This diagram illustrates the process of wiring lead wires to the stator of a rotating electric machine according to Embodiment 1. [Figure 8] This diagram illustrates the process of wiring lead wires to the stator of a rotating electric machine according to Embodiment 1. [Figure 9] This is a schematic diagram illustrating the configuration of a device for wiring lead wires to the stator of a rotating electric machine according to Embodiment 1. [Figure 10] This figure shows an example of a hardware configuration illustrating the control unit of a device for wiring lead wires to the stator of a rotating electric machine according to Embodiment 1. [Figure 11] This diagram illustrates the process of cutting lead wires for a rotating electric machine according to Embodiment 1. [Figure 12] This diagram illustrates the process of generating the arc of the lead wire of a rotating electric machine according to Embodiment 1. [Figure 13] This diagram illustrates the wiring of the lead wires of a rotating electric machine according to Embodiment 1. [Figure 14] It is a diagram for explaining a jig for wiring a lead wire to the rotating electric machine according to Embodiment 1. [Figure 15] It is a perspective view of a jig for wiring a lead wire to the rotating electric machine according to Embodiment 2. [Figure 16] It is a diagram for explaining the wiring of the lead wire of the rotating electric machine according to Embodiment 2. [Figure 17] It is a diagram in which a lead wire is arranged on a jig for wiring a lead wire to the rotating electric machine according to Embodiment 2. [Figure 18] It is a diagram for explaining the steps for wiring a lead wire to the rotating electric machine according to Embodiment 2.

Mode for Carrying Out the Invention

[0010] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. However, the embodiments described below are limited to the technologies suitable for implementing the present disclosure, but the technical scope of the present disclosure is not limited to the following embodiments and drawings. For the same content and corresponding parts, the same reference numerals are assigned, and detailed descriptions thereof are omitted. The same applies to the following embodiments, and duplicate descriptions for the configurations with the same reference numerals are omitted. Further, in the following description, the rotation axis direction (the left-right direction in FIG. 1) is defined as the axial direction, the direction perpendicular to the rotation axis (the up-down direction in FIG. 1) is defined as the radial direction, and the direction along the rotation direction centered on the rotation axis is defined as the circumferential direction (see FIG. 2) for explanation.

[0011] Embodiment 1. FIG. 1 is a cross-sectional view showing a rotating electric machine 10 according to Embodiment 1. A winding assembly 17 in which a coil 16 is wound around a laminated core 14 via insulators 15a and 15b is arranged annularly and press-fitted or shrink-fitted into a frame 11 to form a stator 12, a field magnet 13 having permanent magnets arranged on the inner peripheral side of the stator 12, a bracket 18a on the connection side and a bracket 18b on the anti-connection side for holding the stator 12 and the field magnet 13, and a power connector 19. Further, the field magnet 13 is rotatably held by brackets 18a and 18b by bearings not shown.

[0012] The coils 16 wound around the insulators 15a and 15b are electrically connected to the lead wires 20. The lead wires 20 are composed of power supply lead wires 20a for inputting the U, V, and W phases of three-phase alternating current and a cross wire 20b that serves as a neutral wire and connects between the winding assembly 17. Connector terminals are provided at the ends of the input portions 20c, which are the ends of the power supply lead wires 20a of the U, V, and W phases, and are connected to the power connector 19.

[0013] FIG. 2 is a perspective view of the laminated core 14. The laminated core 14 is formed by a plurality of electromagnetic steel sheets 14d laminated in the axial direction. On the outer peripheral side of the laminated core 14, a yoke portion 14a extending in the circumferential direction is formed. On the inner peripheral side of the yoke portion 14a, a tooth portion 14b protruding in the inner peripheral side radial direction from the central position in the circumferential direction of the yoke portion 14a is formed. At the end on the inner peripheral side of the laminated core 14, a protruding portion 14c having a shape that spreads on both sides in the circumferential direction is formed.

[0014] FIG. 3 is a perspective view of the insulators 15a and 15b attached to both axial ends of the laminated core 14. FIG. 3(a) shows the insulator 15a attached to the connection side in the axial direction of the laminated core 14, and FIG. 3(b) shows the insulator 15b attached to the opposite connection side in the axial direction of the laminated core 14.

[0015] FIG. 4 is a perspective view of the winding assembly 17 in which the insulators 15a and 15b are attached to the laminated core 14 and the coil 16 is wound. The coil 16 is wound around the tooth portion 14b shown in FIG. 2 via the insulators 15a and 15b. Also, an insulating member such as an insulating film is disposed between the circumferential side surface of the laminated core 14 and the wound coil 16.

[0016] Further, the winding assembly 17 is composed of a set of two continuous windings in which the coil 16 is wound around another laminated core 14 to which the insulators 15a and 15b are attached via the insulator 15b on the opposite connection side.

[0017] As shown in Figures 3 and 4, the outer flange portion 15a1 of the insulator 15a on the connection side and the outer flange portion 15b1 of the insulator 15b on the non-connection side have different shapes. The insulator 15 is composed of outer flange portions 15a1, 15b1, inner flange portions 15a2, 15b2, and body portions 15a3, 15b3. The outer flange portions 15a1, 15b1 cover the yoke portion 14a from both axial sides, the inner flange portions 15a2, 15b2 cover the protruding portion 14c from both axial sides, and the body portions 15a3, 15b3 cover the teeth portion 14b from both axial sides.

[0018] A first restraining groove 15c and a second restraining groove 15d are formed in the outer flange portion 15a1 of the insulator 15a on the connection side. As shown in Figure 4, the coil end portion 16a of the coil 16 that makes up the winding assembly 17 is inserted into the first restraining groove 15c, and the lead wire end portions 21a and 21b of the lead wires 20, which will be described later in Figure 5, are inserted into the second restraining groove 15d so as to protrude from the radially inner circumference side to the outer circumference side of the outer flange portion 15a1. The multiple winding assemblies 17 are then arranged in a ring shape and fitted into the frame 11 by press-fitting or shrink-fitting to form the stator 12.

[0019] Figure 5 is a top view of the stator 12 of the rotating electric machine 10 in Figure 1, viewed from the axial top. As explained in Figure 1, the wired lead wires 20 consist of power lead wires 20a that input the U, V, and W phases of the three-phase AC, and jumper wires 20b that serve as the neutral wire and connect the winding assemblies. The power lead wires 20a for the U, V, and W phases are provided with connector terminals at their ends to connect to the power connector 19 in Figure 1, and thus constitute the input section 20c.

[0020] Figure 6 shows the shape of the lead wire 20 wired to the stator 12, and Figures 7 and 8 illustrate the process of wiring the lead wire 20 to the stator 12. A lead wire 20A, formed in the same manner as the lead wire 20 shown in Figure 6, has one lead wire end portion 21aA inserted into a second restraint groove 15d provided in the insulator 15a of the winding assembly 17a, as shown in Figure 7. A lead wire molded portion 21cA is formed on the upper part of the coil 16 from the winding assembly 17a to 17e, and the other lead wire end portion 21bA of the lead wire 20A is inserted into a second restraint groove 15d of the insulator 15a disposed on the winding assembly 17e.

[0021] Figure 8 illustrates the process of wiring another lead wire 20B after the process shown in Figure 7. Another lead wire 20B is placed between the winding assemblies 17a and 17d in Figure 8. The lead wire end portion 21aB of this lead wire 20B is inserted into the second restraint groove 15d of the insulator 15a of the winding assembly 17a, forming a lead wire molding portion 21cB on the upper part of the coil 16 from winding assemblies 17a to 17d, and the other lead wire end portion 21bB of the lead wire 20B is inserted into the second restraint groove 15d of the insulator 15a of the winding assembly 17d. In this state, the conductive metal piece 30 is inserted into the second restraining groove 15d of the insulator 15 of the winding assemblies 17a, 17d, and 17e, to which the lead wires 20A and 20B are wired, and contact is made with the coil 16 and the lead wire terminals 21aA, 21aB, 21bA, and 21bB, thereby electrically connecting each terminal.

[0022] As is clear from Figure 8, when joining with the metal piece 30, the lead wire terminals 21aA and 21aB are joined together to the metal piece 30, while the lead wire terminals 21bA and 21bB are joined individually to the metal piece 30. Furthermore, depending on the number of winding assemblies 17 that pass through, lead wires 20 with different lengths of the lead wire forming portion 21c and different interior angles of the arc are manufactured, as shown in Figure 6 for lead wires 20A and 20B. In addition, by cutting off the excess terminals of the lead wires 20 in a later process, the wiring state shown in Figure 8 is achieved.

[0023] Then, by connecting the other lead wires 20 in the same manner as shown in Figure 5, the electrical connection between the coil 16 of the stator 12 and the lead wires 20 is completed. After this, the field element 13 and brackets 18a and 18b shown in Figure 1 are combined with the stator 12, and the input section 20c is inserted into the power connector 19 to manufacture the rotating electric machine 10.

[0024] Next, a method for manufacturing the lead wire 20 and a method for manufacturing the stator 12 by inserting the manufactured lead wire 20 into the insulator 15 of the winding assembly 17 will be described.

[0025] This section describes a method for cutting the lead wire 20 shown in Figure 6 to a predetermined length and forming an arc that will become the lead wire forming section 21c. For example, as schematically shown in Figure 9, the forming is performed using a reel 31 from which the strands of the lead wire 20 are supplied, a detangling jig 24 for correcting the coiling of the supplied lead wire, nippers 26 for cutting the lead wire 20 to a predetermined length (omitted in Figure 9, see Figure 11), two articulated robots 28a and 28b, a jig 29, etc. Articulated robot 28a has joints 28a1, 28a4, and 28a6 that rotate in the left-right direction of the plane of the paper and joints 28a2, 28a3, and 28a5 that rotate in the up-down direction of the plane of the paper, and a hand 27a is attached to joint 28a6. Similarly, articulated robot 28b also has six joints, and a hand 27b is attached to joint 28b6. However, the number of joints and the direction of joint movement are examples only and are not limited to these.

[0026] The jig 29 is positioned in the part of the stator 12 where the rotor is housed, and is a cylindrical or cylindrical jig that is taller than the stator. The member forming the stator 12 on which the jig 29 is positioned (hereinafter abbreviated as stator 12) is rotatably positioned opposite the lead wire 20 that has been gripped and cut by the hands 27a and 27b. As the hands 27a and 27b move in the direction of the cylindrical or cylindrical side surface of the jig 29 protruding from the stator 12, the side surface of the jig 29 and the cut lead wire 20 come into contact. Furthermore, as the hands 27a and 27b move radially along the cylindrical jig 29, the lead wire 20 is pressed against the jig 29 and forms an arc. The hands 27a and 27b, which are gripping the lead wire 20 having formed an arc, are lowered from the jig 29 toward the stator 12, so that one end of the lead wire 21a is inserted into a second restraining groove 15d provided in the insulator 15a of the winding assembly 17, and the other end of the lead wire 20 21b is inserted into a second restraining groove 15d of the insulator 15a of another winding assembly 17. After this, the grip of the lead wire 20 by the hands 27a and 27b is released.

[0027] The gripping and movement operations of the hands 27a and 27b of these articulated robots 28a and 28b are synchronized by the transmission and reception of data with the control unit 100. This data transmission and reception with the control unit 100 may also be coordinated not only with the articulated robots 28a and 28b, but also with the detangling jig 24, nippers 26, chuck unit 25, and reel 31, which will be described later, to control each of them so that the cutting and shaping operations of the lead wire 20 proceed smoothly.

[0028] Figure 10 shows an example of the microcontroller hardware within the control unit 100. It consists of a processor 200 and a storage device 300. Although not shown, the storage device 300 includes a volatile storage device such as random access memory and a non-volatile auxiliary storage device such as flash memory. Alternatively, a hard disk may be provided as an auxiliary storage device instead of flash memory. The processor 200 executes a program input from the storage device 300 to send and receive data to, for example, articulated robots 28a and 28b, and synchronizes the operation between the articulated robots 28a and 28b. In this case, the program is input from the auxiliary storage device to the processor 200 via the volatile storage device. The processor 200 may also output data such as calculation results to the volatile storage device of the storage device 300, or it may save the data to the auxiliary storage device via the volatile storage device. The control unit 100 is provided with a transmitting / receiving unit 400, which transmits control signals to synchronize each device for, for example, cutting and shaping lead wires 20, and receives information that each device has responded to the control signals and completed its operation. The transmitting / receiving unit 400 may transmit and receive data wirelessly or via wired connections.

[0029] Figures 11(a) to 11(c) are schematic diagrams illustrating the details of the operations performed in area A of Figure 9. The arrangement of each component, the direction of movement of each component, and the direction of gripping and cutting the lead wire 20 in the figures are examples only and are not limited to these.

[0030] The cutting process for lead wire 20 and the arc generation process are explained below with reference to Figures 11 and 12. <Process for cutting lead wire 20> First, the process of cutting the lead wire 20 will be explained. As shown in Figure 11(a), the lead wire 20, either in single-wire or bundled state, is passed through a straightening jig 24 that corrects the bend of the individual wires (step S1), and then the hand 27a of the articulated robot 28a grasps the lead wire 20 (step S2). With the hand 27a grasping the lead wire 20, it is moved a predetermined length to the left of the paper to pull the lead wire 20 out of the reel 31 (step S3). At this time, the chuck part 25 that grasps the lead wire and the nippers 26 that cut the lead wire 20 are moved out of the way in the vertical direction of the paper so as not to interfere with the movement of the hand 27a (step S4). As shown in Figure 11(b), the tip of the pulled-out lead wire 20 is grasped by the hand 27b of the articulated robot 28b (step S5). After the hand 27a moves past the position of the retracted chuck 25 and nipper 26 before they were retracted, the chuck 25 and nipper 26 are returned to their previous positions, and the chuck 25 grips the lead wire 20 (step S6). Furthermore, as shown in Figure 11(c), the nipper 26 cuts the lead wire 20 (step S7). This makes it possible to cut a predetermined length of lead wire 20 while it is being gripped by the hands 27a and 27b of the articulated robots 28a and 28b.

[0031] <Process for generating the arc of lead wire 20> Next, the method for forming the arc that will become the lead wire forming section 21c will be explained. While the lead wire 20 is held in place by the hands 27a and 27b, the lead wire 20, which has been cut to a predetermined length, is moved in the direction of arrow B shown in Figures 11(c), 12(a), and (b). By pressing the lead wire 20 against the jig 29, an arc is formed to conform to the shape of the jig 29, as shown in Figure 12(b). In this case, the dimensions of the jig 29 are determined from the diameter of the lead wire 20 so that the arc fits between the outer flanges 15a1 and 15b1 and the inner flanges 15a2 and 15b2 of the insulator 15 shown in Figure 3. Subsequently, as shown in Figure 12(b), the lead wire 20 is moved in the direction of arrow B while the lead wire terminals 21a and 21b, which are held by hands 27a and 27b, are moved in the direction of arrow C, thereby forming predetermined angles between the lead wire forming section 21c and the lead wire terminal 21a, and between the lead wire forming section 21c and the lead wire terminal 21b, as shown in Figure 12(c). In this embodiment, the shape formed by pressing the lead wire 20 against the jig 29 is an arc, but other shapes are also acceptable, with the main objective being to form the lead wire according to the shape of the jig 29 against which it is pressed.

[0032] Furthermore, by changing the position and angle when pressed, multiple patterns of angles formed by the lead wire terminals 21a and 21b in the outer diameter direction can be formed, eliminating the need for a separate mold for each shape and reducing mold manufacturing costs.

[0033] Next, as shown in Figure 13, the hands 27a and 27b are moved axially downward (in the direction of arrow D) to move the formed lead wire 20 from the jig 29 to the stator 12. One end of the lead wire 21a is inserted into the second restraint groove 15d provided in the insulator 15a of the winding assembly, and the other end of the lead wire 20 21b is inserted into the second restraint groove 15d of the insulator 15a of another winding assembly. After this, the grip on the lead wire 20 is released and the wiring is completed. Since the wired lead wires 20 are insulated by the coating, a short circuit will not occur even if the lead wires 20 come into contact with each other.

[0034] Furthermore, after forming the lead wire 20 into an arc, only both ends of the lead wire are fixed by the first restraint groove 15c or the second restraint groove 15d provided on the outer diameter side flange of the insulator 15a. Therefore, the position of the arc portion of the lead wire forming part 21c is not restricted. However, since the upper surface of the inner flange portion 15a2 of the insulator 15a is higher than the lead wire 20, it is possible to prevent the lead wire 20 from falling out towards the inner diameter side and interfering with the field insertion part.

[0035] <Explanation of Hands 27a and 27b> Here, the gripping portions of hands 27a and 27b will be described. Figure 14(a) is a side view of hands 27a and 27b, and Figure 14(b) is a bottom view of hands 27a and 27b viewed from the axial lower side. As shown in Figure 14, when pulling the lead wire 20 from the reel 31, the projection 27c is hooked onto the lead wire 20 and pulled out. This is particularly effective when the frictional force between the insulation of the lead wire 20 and the gripping portion is small. The portion of the insulation that comes into contact with the projection 27c and the lead wire 20 is cut in a later process after wiring, so even if the insulation is damaged, it will not affect the performance of the rotating electric machine 10. The gripping portion also has a notch 27d, which prevents interference with the insulator 15a or the jig 29. Furthermore, by bringing the pulled-out lead wire 20 into contact with the lead wire retaining plate 27e provided on the sides of the hands 27a and 27b, and applying a load to the end of the lead wire by the projection 27c in contact with the lead wire 20 and the lead wire retaining plate 27e, it becomes possible to insert the lead wire 20 into the second restraining groove 15d or the like in a state where the lead wire 20 is less likely to deform. In addition, by pressing the projection 27c against the insulation of the lead wire 20, the gripping force is increased, and the lead wire 20 can be handled without slipping. Note that the gripping part is cut, so even if the insulation is damaged, it does not affect the product. Moreover, even if the lead wire 20 is a stranded wire which has lower rigidity than a single wire, it can be maintained in the desired shape due to the effect of gripping at two points on the hands 27a and 27b.

[0036] With the configuration shown in Figure 9 and the method described in Figures 11 and 12, a lead wire 20 of a desired length can be formed, and no additional forming equipment is required, as only the jig 29 is placed on the stator 12. Therefore, the formation workability is improved because there is no need to transfer the lead wire 20 between devices. Furthermore, even when forming multiple types of shapes for the lead wire 20, by simply setting the pressing angle between the hands 27a and 27b, a single device can produce lead wires 20 formed into the desired shapes, reducing the number of jigs and the effort required for setup changes. This improves the formation workability of the lead wire 20 and reduces equipment costs, allowing the rotating electric machine 10 and its stator 12 to be provided at a low cost.

[0037] Although the description has been based on a continuous winding configuration with two coils 16 wound around each other, it may also be constructed with individual winding assemblies 17, or for example, with three winding assemblies 17 wound in a continuous configuration. Furthermore, the method of inserting the constraining grooves is not limited to the first constraining groove 15c shown in this embodiment, where the coil end portion 16a of the coil 16 and the end portion of the lead wire 20 are inserted into the second constraining groove 15d, with the ends protruding from the radially inner circumference to the outer circumference of the outer flange portions 15a1 and 15b1. For example, the coil end portion 16a of the winding assembly 17a in Figure 6 may be inserted into the first constraining groove 15c, and the coil end portion 16a of the winding assembly 17d may be inserted into the second constraining groove 15d, or the coils may be placed in the constraining groove at a position that is easy to insert them into. Furthermore, although an example was described in which the electrical connection between the terminals of the coil 16 and the terminals of the lead wires 20 is made by inserting them into the restraining grooves and then making contact and electrical conductivity with the metal piece 30, connections by brazing, soldering, or crimp terminals may also be used. Also, although articulated robots 28a and 28b were used as examples, any device equipped with a mechanism that can move in the axial and radial directions will suffice.

[0038] Embodiment 2. In Embodiment 1, as shown in Figure 13, an example was shown in which the lead wire 20 formed by the lead wire molding section 21c is directly wired to the second restraint groove 15d provided in the insulator 15a of the stator 12. However, the destination of the lead wire 20 does not have to be directly the stator 12. For example, as shown in Figure 15, jig 29A can be used instead of jig 29. As shown in Figure 15, jig 29A consists of a cylindrical or columnar jig 29dA at the innermost circumference, a ring-shaped jig 29aA provided on the radially outer circumference in contact with jig 29dA at the inner circumference, where the molded lead wire 20 is temporarily placed, and a ring-shaped jig 29eA provided on the radially outer circumference in contact with the ring-shaped jig 29aA at the inner circumference, where a lead wire terminal holding section 29bA and a guide section 29cA are formed.

[0039] Using the jig 29dA, the lead wire forming portion 21c is formed on the lead wire 20 in the same manner as in Embodiment 1. Then, as described in Figure 13, the hands 27a and 27b are moved axially downward to move the lead wire 20 formed on the ring-shaped jig 29aA from the jig 29dA, as shown in Figure 16. To restrict the position of the lead wire 20, the lead wire terminal portions 21a and 21b are inserted into the lead wire terminal holding portion 29bA. Also, when transferring to the stator 12, the lead wire terminal portions 21a and 21b are inserted into the guide portion 29cA so that the lead wire 20 can be guided into the first restraint groove 15c or the second restraint groove 15d of the insulator 15a. After this, the hands 27a and 27b release their grip on the lead wire 20.

[0040] After placing the lead wires 20 in the jig 29A, as shown in Figure 18(a), the jig 29dA is inserted into the part of the stator 12 where the field element 13 is housed. Then, the ring-shaped jig 29aA and the lead wires 20 are simultaneously transferred to the stator 12. The jig 29dA and the ring-shaped jig 29eA are removed, and as shown in Figure 18(b), the ends of the lead wires 20 are inserted into the first restraint groove 15c or the second restraint groove 15d, and then wired to the stator 12. The method for drawing out and cutting the lead wires 20 to the desired length, the method for connecting with the metal piece 30, and the method for manufacturing the rotating electric machine are the same as those described in Embodiment 1.

[0041] This configuration provides the same effects as in Embodiment 1 when forming the lead wires 20, and by preparing multiple subassemblies with the lead wires 20 wired to the jig 29A, they can be stockpiled. Wiring work can be simplified by simply transferring them to the stator 12 that flows through the production line, thereby improving the productivity of the wiring work.

[0042] While this disclosure describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but are applicable individually or in various combinations to the embodiments. Accordingly, countless variations not illustrated are conceivable within the scope of the technology disclosed in the specification. These include, for example, modifying, adding or omitting at least one component, or even extracting at least one component and combining it with components of other embodiments.

[0043] The various aspects of this disclosure are summarized below as an appendix.

[0044] [Note 1] A lead wire manufacturing system comprising: a first device for gripping a lead wire at two points separated by a predetermined distance; a second device for shaping the lead wire gripped by the first device into a predetermined shape; and a control unit for controlling the first device to move the lead wire without releasing its grip after the lead wire gripped by the first device has been shaped by the second device, until it is positioned at a predetermined location. [Note 2] The lead wire manufacturing system according to Appendix 1, characterized in that the first device is the hands of two articulated robots, and each hand is synchronously controlled by the control unit. [Note 3] The lead wire manufacturing system according to Appendix 2, characterized in that the hand has a projection on a part of the opening and closing part, and the projection contacts only the portion of the terminal end of the lead wire that will be cut in a later process. [Note 4] The lead wire manufacturing system according to Appendix 3, characterized in that the hand is provided with a pressing plate that contacts the lead wire, and a load is applied to the end of the lead wire by the projection and the pressing plate. [Note 5] The lead wire manufacturing system according to any one of the appendices 1 to 4, characterized in that the second apparatus is a stator member and a cylindrical or cylindrical jig inserted into the field insertion portion of the stator member. [Note 6] The lead wire manufacturing system according to any one of the appendices 1 to 4, wherein the second apparatus comprises a cylindrical or cylindrical jig, a first ring-shaped jig whose inner circumference is in contact with the cylindrical or cylindrical jig and whose outer circumference extends radially concentrically from the side surface of the cylindrical or cylindrical jig, and a second ring-shaped jig whose inner circumference is in contact with the first ring-shaped jig and extends radially concentrically from the first ring-shaped jig, the second ring-shaped jig having a lead wire terminal holding portion for holding the terminal portion of the lead wire and a guide portion for guiding the terminal portion of the lead wire to a stator. [Note 7] A method for manufacturing a lead wire, wherein, using the lead wire manufacturing system described in Appendix 5, the lead wire is pressed against the side portion of the cylindrical or cylindrical jig by the first device to form an arc along the circular upper part of the stator member, and the lead wire having the formed arc is placed on the upper part of the stator member. [Note 8] A method for manufacturing a lead wire, comprising: pressing the lead wire against the side surface of the cylindrical or cylindrical jig to form an arc using the lead wire manufacturing system described in Appendix 6; placing the lead wire having the formed arc on the upper part of the first ring-shaped jig; and inserting the end portion of the lead wire into the lead wire terminal holding portion and the guide portion. [Note 9] A method for manufacturing a lead wire according to Appendix 7 or 8, characterized in that the shape of the arc is variably formed by changing the position and angle at which the lead wire is pressed against the side portion. [Note 10] A method for manufacturing a stator, comprising connecting both ends of an arc-shaped lead wire, which is placed on the stator member by the lead wire manufacturing method described in Appendix 7, to a coil wound around the stator member. [Note 11] A method for manufacturing a stator, comprising: transferring the molded lead wires to the stator member by inserting a cylindrical or cylindrical jig of the second apparatus on which the molded lead wires are arranged into a portion of the stator member that houses the field magnets, and connecting both ends of the arc-shaped lead wires arranged on the stator member to coils wound around the stator member. [Note 12] A method for manufacturing a lead wire, comprising: grasping the lead wire and pulling it out from a reel; cutting the lead wire to a predetermined length while grasping it; and, while still grasping the cut lead wire, pressing it against a side portion of a cylindrical or cylindrical jig inserted into the field housing of the stator member, which is higher than the axial height of the stator member, thereby forming an arc on the lead wire that follows the circular upper part of the stator member. [Note 13] A method for manufacturing a stator, comprising: grasping a lead wire wound on a reel and pulling it out from the reel; cutting the lead wire to a predetermined length while still grasping it; pressing the cut lead wire against a side portion of a cylindrical or cylindrical jig inserted into the field housing of the stator member, which is higher than the axial height of the stator member, thereby forming an arc on the lead wire that follows the circular upper part of the stator member; inserting both grasped ends of the lead wire with the arc formed into restraint grooves of an insulator disposed on the upper part of the circular stator member; and then releasing the grip to connect both ends of the lead wire to a coil wound around the stator member. [Note 14] A method for manufacturing a rotating electric machine, comprising combining a field element and a bracket with a stator manufactured according to Appendix 13, and connecting the lead wires to a power connector. [Note 15] A method for manufacturing a lead wire, comprising: grasping the lead wire and pulling it out from a reel; cutting the lead wire to a predetermined length while still grasping it; pressing the cut lead wire against the side surface of a cylindrical or cylindrical first jig while still grasping it to form an arc; positioning the arc-shaped portion of the lead wire in a second ring-shaped jig that is in contact with the first jig at its inner circumference and provided on its radially outer circumference; and inserting the end portion of the lead wire into a lead wire terminal holding portion and guide portion formed on a third ring-shaped jig that is in contact with the second ring-shaped jig at its inner circumference and provided on its radially outer circumference, thereby releasing the grip. [Note 16] A method for manufacturing a stator, comprising: grasping a lead wire and pulling it out from a reel; cutting the lead wire to a predetermined length while grasping it; pressing the cut lead wire against the side surface of a cylindrical or cylindrical first jig while still grasping it to form an arc; positioning the arc-shaped portion of the lead wire on a second ring-shaped jig that is in contact with the first jig at its inner circumference and provided on its radially outer circumference; inserting the end portion of the lead wire into a lead wire terminal holding portion and guide portion formed on a third ring-shaped jig that is in contact with the second ring-shaped jig at its inner circumference and provided on its radially outer circumference to release the grip; inserting the first jig into the portion of the stator member that houses the field magnet, thereby inserting the lead wire into a restraining groove of an insulator disposed on the upper part of the stator member; and then connecting both ends of the lead wire to a coil wound around the stator member. [Note 17] A method for manufacturing a rotating electric machine, comprising combining a field element and a bracket with a stator manufactured according to Appendix 16, and connecting the lead wires to a power connector. [Explanation of Symbols]

[0045] 10: Rotating electric machine, 11: Frame, 12: Stator, 13: Field, 14: Laminated core, 14a: Yoke section, 14b: Teeth section, 14c: Protrusion, 14d: Electromagnetic steel sheet, 15, 15a, 15b: Insulator, 15a1, 15b1: Outer flange section, 15a2, 15b2: Inner flange section, 15a3, 15b3: Body section, 15c: First restraining groove, 15d: Second restraining groove, 16: Coil, 16a: Coil end section, 17, 17a, 17b, 17c, 17d, 17e: Winding assembly, 18a, 18b: Bracket, 19: Power connector, 20, 20A, 20B: Lead wire, 20a: Power lead wire, 20b: Jumper wire, 21a, 21b, 21 aA, 21aB, 21bA, 21bB: Lead wire terminal section, 21c, 21cA, 21cB: Lead wire forming section, 24: Detangling jig, 25: Chuck section, 26: Nippers, 27a, 27b: Hand, 27c: Protrusion section, 27d: Notch section, 27e: Lead wire retaining plate, 28a, 28b: Articulated robot, 28a1, 28a2, 28a3, 28a4, 28a5, 28a6: Joints, 29, 29A, 29dA: Jig, 29bA: Lead wire terminal holding section, 29cA: Guide section, 29aA, 29eA: Ring-shaped jig, 30: Metal piece, 31: Reel, 100: Control section, 200: Processor, 300: Memory device, 400: Transceiver section.

Claims

1. A lead wire manufacturing system comprising: a first device for gripping a lead wire at two points separated by a predetermined distance; a second device for shaping the lead wire gripped by the first device into a predetermined shape; and a control unit for controlling the first device to move the lead wire without releasing its grip until it is positioned at a predetermined location after the lead wire gripped by the first device has been shaped by the second device.

2. The lead wire manufacturing system according to claim 1, characterized in that the first device is the hands of two articulated robots, and each hand is synchronously controlled by the control unit.

3. The lead wire manufacturing system according to claim 2, characterized in that the hand has a projection on a part of the opening and closing part, and the projection contacts only the portion of the terminal end of the lead wire that will be cut in a later process.

4. The lead wire manufacturing system according to claim 3, characterized in that the hand is provided with a pressing plate that contacts the lead wire, and a load is applied to the end of the lead wire by the projection and the pressing plate.

5. The lead wire manufacturing system according to any one of claims 1 to 4, characterized in that the second apparatus is a stator member and a cylindrical or cylindrical jig inserted into the field insertion portion of the stator member.

6. The lead wire manufacturing system according to any one of claims 1 to 4, wherein the second apparatus comprises a cylindrical or cylindrical jig, a first ring-shaped jig whose inner circumference is in contact with the cylindrical or cylindrical jig and whose outer circumference extends radially concentrically from the side surface of the cylindrical or cylindrical jig, and a second ring-shaped jig whose inner circumference is in contact with the first ring-shaped jig and extends radially concentrically from the first ring-shaped jig, the second ring-shaped jig having a lead wire terminal holding portion for holding the terminal portion of the lead wire and a guide portion for guiding the terminal portion of the lead wire to a stator.

7. A method for manufacturing a lead wire, comprising pressing the lead wire against the side surface of the cylindrical or cylindrical jig using the first device to form an arc along the circular upper part of the stator member, and placing the lead wire having the formed arc on the upper part of the stator member, according to the lead wire manufacturing system of claim 5.

8. A method for manufacturing a lead wire, comprising: pressing the lead wire against the side surface of the cylindrical or cylindrical jig to form an arc; placing the lead wire having the formed arc on the upper part of the first ring-shaped jig; and inserting the end portion of the lead wire into the lead wire terminal holding portion and the guide portion, according to the lead wire manufacturing system of claim 6.

9. The method for manufacturing a lead wire according to claim 7, characterized in that the shape of the arc is variably formed by changing the position and angle at which the lead wire is pressed against the side portion.

10. A method for manufacturing a stator, comprising connecting both ends of an arc-shaped lead wire, which is placed on the stator member by the lead wire manufacturing method described in claim 7, to a coil wound around the stator member.

11. A method for manufacturing a stator, comprising: transferring the molded lead wire to the stator member by inserting a cylindrical or cylindrical jig of the second apparatus on which the molded lead wire is arranged into a portion of the stator member that houses the field magnet, and connecting both ends of the arc-shaped lead wire arranged on the stator member to a coil wound around the stator member, according to the lead wire manufacturing method described in claim 8.

12. A method for manufacturing a lead wire, comprising: grasping the lead wire and pulling it out from a reel; cutting the lead wire to a predetermined length while grasping it; and, while still grasping the cut lead wire, pressing it against a side portion of a cylindrical or cylindrical jig inserted into the field housing of the stator member, which is higher than the axial height of the stator member, thereby forming an arc on the lead wire that follows the circular upper part of the stator member.

13. A method for manufacturing a stator, comprising: grasping a lead wire wound on a reel and pulling it out from the reel; cutting the lead wire to a predetermined length while still grasping it; pressing the cut lead wire against a side portion of a cylindrical or cylindrical jig inserted into the field housing of the stator member, which is higher than the axial height of the stator member, thereby forming an arc on the lead wire that follows the circular upper part of the stator member; inserting both grasped ends of the lead wire with the arc formed into restraint grooves of an insulator disposed on the upper part of the circular stator member; and then releasing the grip to connect both ends of the lead wire to a coil wound around the stator member.

14. A method for manufacturing a rotating electric machine, comprising combining a field element and a bracket with a stator manufactured according to claim 13, and connecting lead wires to a power connector.

15. A method for manufacturing a lead wire, comprising: grasping the lead wire and pulling it out from a reel; cutting the lead wire to a predetermined length while still grasping it; pressing the cut lead wire against the side surface of a cylindrical or cylindrical first jig while still grasping it to form an arc; positioning the arc-shaped portion of the lead wire in a second ring-shaped jig that is in contact with the first jig at its inner circumference and provided on its radially outer circumference; and inserting the end portion of the lead wire into a lead wire terminal holding portion and guide portion formed on a third ring-shaped jig that is in contact with the second ring-shaped jig at its inner circumference and provided on its radially outer circumference, thereby releasing the grip.

16. A method for manufacturing a stator, comprising: grasping a lead wire and pulling it out from a reel; cutting the lead wire to a predetermined length while grasping it; pressing the cut lead wire against the side surface of a cylindrical or cylindrical first jig while still grasping it to form an arc; positioning the arc-shaped portion of the lead wire on a second ring-shaped jig that is in contact with the first jig at its inner circumference and provided on its radially outer circumference; inserting the end portion of the lead wire into a lead wire terminal holding portion and guide portion formed on a third ring-shaped jig that is in contact with the second ring-shaped jig at its inner circumference and provided on its radially outer circumference to release the grip; inserting the first jig into the portion of the stator member that houses the field magnet, thereby inserting the lead wire into a restraining groove of an insulator disposed on the upper part of the stator member; and connecting both ends of the lead wire to a coil wound around the stator member.

17. A method for manufacturing a rotating electric machine, comprising combining a field element and a bracket with a stator manufactured according to claim 16, and connecting lead wires to a power connector.

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