Alignment coil manufacturing equipment

Abstract

This invention provides a coil manufacturing apparatus capable of aligning segment coils where the pitch of one leg differs from the pitch of the other leg. [Solution] An alignment coil manufacturing apparatus (1) according to one embodiment of the present disclosure comprises a slitting jig (3), an inner diameter side guide (4), and an outer diameter side guide (5). The inner diameter side guide (4) has a first notch into which one leg (2a) of a segment coil (2) is inserted, and the outer diameter side guide (5) has a second notch into which the other leg (2b) of a segment coil (2) is inserted. The first and second notches have a length that overlaps with a plurality of slits (3a) in the circumferential direction of the slitting jig (3) so that a plurality of types of segment coils (2) with different pitches between one leg (2a) and the other leg (2b) can be rotated and one leg (2a) and the other leg (2b) can be inserted into the gap (6).

Description

Technical Field

[0001] The present disclosure relates to an alignment coil manufacturing apparatus, for example, an apparatus for manufacturing an alignment coil by aligning segment coils.

Background Art

[0002] For example, as shown in FIG. 3, the alignment coil manufacturing apparatus 101 of Patent Document 1 includes a slit jig 102 having a slit 102a, an inner diameter side guide 104 having a notch 104a into which one leg 103a of a segment coil 103 inserted into the slit 102a is inserted, and an outer diameter side guide 105 having a notch 105a into which the other leg 103b of the segment coil 103 inserted into the slit 102a is inserted.

[0003] When aligning the segment coil 103 in such an alignment coil manufacturing apparatus 101, first, as shown in FIG. 3, one leg 103a of the segment coil 103 is inserted into the slit 102a of the slit jig 102 and also inserted into the notch 104a of the inner diameter side guide 104.

[0004] At the same time, the other leg 103b of the segment coil 103 is inserted into a different slit 102a of the slit jig 102 and also inserted into the notch 105a of the outer diameter side guide 105.

[0005] Then, the slit jig 102 is rotated to revolve the segment coil 103, and one leg 103a of the segment coil 103 is guided from the notch 104a of the inner diameter side guide 104 to the outer diameter side of the slit jig 102.

[0006] At the same time, by guiding the other leg 103b of the segment coil 103 from the notch 105a of the outer diameter side guide 105 to the inner diameter side of the slit jig 102, the segment coil 103 is rotated.

[0007] This inserts one leg 103a and the other leg 103b of the segment coil 103 into the gap 106 between the inner diameter guide 104 and the outer diameter guide 105. By repeating this process, the segment coil 103 is aligned. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] Japanese Patent Publication No. 2024-124842 [Overview of the Initiative] [Problems that the invention aims to solve]

[0009] The applicant has identified the following problem: In the aligned coil manufacturing apparatus 101 of Patent Document 1, the notches 104a of the inner diameter side guide 104 and 105a of the outer diameter side guide 105 are shaped to allow only one predetermined type of segment coil 103 to rotate.

[0010] Therefore, the coil alignment apparatus 101 of Patent Document 1 required the replacement of the inner diameter guide 104 and the outer diameter guide 105 each time a segment coil 103 with different pitches between one leg 103a and the other leg 103b was to be aligned.

[0011] This disclosure provides an alignment coil manufacturing apparatus capable of aligning segment coils with different pitches between the legs of one leg and the other, without replacing the inner diameter guide and the outer diameter guide. [Means for solving the problem]

[0012] An alignment coil manufacturing apparatus according to one aspect of the present disclosure is an apparatus for manufacturing alignment coils by aligning segment coils, A slitting jig having multiple slits arranged radially at predetermined angular intervals to correspond to the slots of the stator core, An inner diameter side guide is positioned below the slitting jig and coaxially with the slitting jig, An outer diameter guide surrounds the inner diameter guide below the slit jig and is positioned coaxially with the slit jig, Equipped with, The inner diameter side guide has a first notch on its peripheral edge facing the outer diameter side guide into which one leg of the segment coil inserted into the slit is inserted, and which can guide the one leg from the inner diameter side to the outer diameter side of the slit jig. The outer diameter side guide has a second notch on its peripheral edge facing the inner diameter side guide into which the other leg of the segment coil inserted into a different slit is inserted, and which can guide the other leg from the outer diameter side to the inner diameter side of the slit jig. When the slitting jig is rotated to revolve the segment coil, one leg of the segment coil is guided by the first notch towards the outer diameter side of the slitting jig, or the other leg of the segment coil is guided by the second notch towards the inner diameter side of the slitting jig, causing the segment coil to rotate on its own axis and the one leg and the other leg of the segment coil to be inserted into the gap between the inner diameter guide and the outer diameter guide. The first and second notches have a length that overlaps with the multiple slits in the circumferential direction of the slitting jig, so that multiple types of segment coils with different pitches between one leg and the other leg are rotated, respectively, and the one leg and the other leg are inserted into the gap.

[0013] In the above-described aligned coil manufacturing apparatus, the first notch portion has an inclined portion on the side of the slit jig in the direction of rotation that slopes toward the outer diameter side of the slit jig, Preferably, the inclined portion of the first notch allows one leg of the segment coil to contact the inclined portion of the first notch and guide it into the gap.

[0014] In the above-described alignment coil manufacturing apparatus, the second notch portion has an inclined portion that inclines toward the side in the rotational direction of the slit jig on the side portion in the rotational direction of the slit jig as it goes toward the inner diameter side of the slit jig. It is preferable that the inclined portion of the second notch portion can guide the other leg of the segment coil to the gap portion by bringing the other leg of the segment coil into contact with the inclined portion of the second notch portion.

Advantages of the Invention

[0015] According to the present disclosure, it is possible to realize an alignment coil manufacturing apparatus capable of aligning segment coils having different pitches between one leg and the other leg without replacing the inner diameter side guide and the outer diameter side guide.

Brief Description of the Drawings

[0016] [Figure 1] It is a perspective view showing a state where a segment coil is aligned using the alignment coil manufacturing apparatus of the embodiment. [Figure 2] It is a plan view showing a state where a segment coil is aligned using the alignment coil manufacturing apparatus of the embodiment. [Figure 3] It is a plan view showing a state where a segment coil is aligned using a general alignment coil manufacturing apparatus.

Modes for Carrying Out the Invention

[0017] Hereinafter, specific embodiments to which the present disclosure is applied will be described in detail with reference to the drawings. However, the present disclosure is not limited to the following embodiments. Also, for clarity of explanation, the following description and drawings are simplified as appropriate.

[0018] First, the configuration of the alignment coil manufacturing apparatus of the present embodiment will be described. Since the alignment coil manufacturing apparatus of the present embodiment has a configuration substantially equal to that of the alignment coil manufacturing apparatus of Patent Document 1, the description will focus on the different configurations.

[0019] FIG. 1 is a perspective view showing a state in which a segment coil is aligned using the alignment coil manufacturing apparatus of the present embodiment. FIG. 2 is a plan view showing a state in which a segment coil is aligned using the alignment coil manufacturing apparatus of the present embodiment.

[0020] As shown in FIGS. 1 and 2, the alignment coil manufacturing apparatus 1 is suitable for manufacturing an alignment coil by aligning segment coils 2 in an annular shape. The alignment coil manufacturing apparatus 1 includes a slit jig 3, an inner diameter side guide 4, and an outer diameter side guide 5.

[0021] The slit jig 3 is, for example, a plate body having an annular shape when viewed from the vertical direction as shown in FIGS. 1 and 2, and includes slits 3a corresponding to the slots of the stator core. Therefore, a plurality of slits 3a are radially arranged at a predetermined angular interval in the circumferential direction of the slit jig 3. The slit jig 3 is rotatable about an axis extending in the vertical direction at the center of the slit jig 3.

[0022] The inner diameter side guide 4 is, for example, a plate body having a circular shape when viewed from the vertical direction as shown in FIGS. 1 and 2, and includes a notch 4a at the peripheral edge of the inner diameter side guide 4. The inner diameter side guide 4 is disposed below the slit jig 3, and the center of the slit jig 3 and the center of the inner diameter side guide 4 are disposed substantially coaxially.

[0023] As shown in FIGS. 1 and 2, the notch 4a has a length overlapping a plurality (for example, three) of slits 3a of the slit jig 3 in the circumferential direction of the inner diameter side guide 4, and is preferably, for example, substantially trapezoidal when viewed from the vertical direction.

[0024] That is, as shown in FIGS. 1 and 2, the notch 4a preferably includes an inclined portion 4c that inclines outward in the radial direction of the inner diameter side guide 4 as it goes toward the counterclockwise side when viewed from above in the notch 4a on the side portion 4b on the counterclockwise side. At this time, the region where the inclined portion 4c is formed in the notch 4a has a length overlapping one slit 3a.

[0025] As shown in Figures 1 and 2, the outer diameter guide 5 is a ring-shaped plate when viewed from above, and has a notch 5a on its inner peripheral edge. The outer diameter guide 5 is positioned below the slitting jig 3 so as to surround the inner diameter guide 4, and the center of the slitting jig 3 and the center of the outer diameter guide 5 are positioned substantially coaxially.

[0026] At this time, as shown in Figures 1 and 2, a gap 6 is formed between the peripheral edge of the inner diameter guide 4 and the inner peripheral edge of the outer diameter guide 5, into which one leg 2a and the other leg 2b of the segment coil 2 can be inserted.

[0027] As shown in Figures 1 and 2, the notch 5a is positioned so that the other leg 2b of the segment coil 2 can be inserted when one leg 2a of the segment coil 2 is inserted into the notch 4a of the inner diameter side guide 4. In other words, the notch 4a of the inner diameter side guide 4 and the notch 5a of the outer diameter side guide 5 are positioned with a predetermined distance between them in the circumferential direction of the slit jig 3.

[0028] As shown in Figures 1 and 2, the notch 5a is approximately L-shaped when viewed from above. In other words, the notch 5a comprises a first portion 5b that extends in the circumferential direction of the outer diameter side guide 5, and a second portion 5c that extends radially inward from the counterclockwise end of the first portion 5b and reaches the inner peripheral edge of the outer diameter side guide 5.

[0029] As shown in Figures 1 and 2, the notch 5a has a length that overlaps with multiple (for example, two) slits 3a of the slit jig 3 in the circumferential direction of the outer diameter guide 5. In other words, as will be described in detail later, the lengths of the notches 4a of the inner diameter guide 4 and 5a of the outer diameter guide 5 are set so that multiple types of segment coils 2 with different pitches (spacing) between one leg 2a and the other leg 2b can be rotated.

[0030] The notch 5a may have an inclined portion 5e on the counterclockwise side 5d of the notch 5a that slopes radially inward of the outer diameter side guide 5 as it moves towards the counterclockwise side. In this case, the region in the notch 5a where the inclined portion 5e is formed has a length that overlaps with one slit 3a.

[0031] Next, the process of manufacturing aligned coils using the aligned coil manufacturing apparatus of this embodiment will be explained. In Figures 1 and 2, the segment coil 2 is shown by a solid line representing a segment coil 21 where the pitch between one leg 2a and the other leg 2b is 5 slits, and by a dashed-dotted line representing a segment coil 22 where the pitch between one leg 2a and the other leg 2b is 6 slits.

[0032] First, the process of aligning the segment coils 21 to manufacture aligned coils will be explained. For example, as shown in Figures 1 and 2, the inner diameter guide 4 and the outer diameter guide 5 are positioned with the notch 5a of the outer diameter guide 5 rotated counterclockwise by four slits relative to the notch 4a of the inner diameter guide 4.

[0033] In this case, for example, as shown in Figures 1 and 2, the notch 4a of the inner diameter guide 4 is aligned with the three slits 3a of the slit jig 3, and the notch 5a of the outer diameter guide 5 is aligned with the two slits 3a of the slit jig 3. In addition, the gap 6 is positioned at a predetermined radial position of the slits 3a of the slit jig 3.

[0034] In this state, one leg 2a of the segment coil 21 is inserted from above into the slit 3a that is on the most clockwise side when viewed from above, among the slits 3a that overlap with the notch 4a of the inner diameter side guide 4 of the slit jig 3, and is also inserted into the notch 4a of the inner diameter side guide 4.

[0035] At the same time, the other leg 2b of the segment coil 21 is inserted from above into the slit 3a on the clockwise side when viewed from above, which overlaps with the notch 5a of the outer diameter side guide 5 in the slit jig 3, and is also inserted into the notch 5a of the outer diameter side guide 5. Then, the slit jig 3 is rotated by two slit widths in the counterclockwise direction.

[0036] As a result, the segment coil 21 revolves along with the rotation of the slit jig 3, and one leg 2a of the segment coil 21 contacts the inclined portion 4c of the notch 4a of the inner diameter side guide 4, while the other leg 2b of the segment coil 21 contacts the inclined portion 5e of the notch 5a of the outer diameter side guide 5.

[0037] Then, one leg 2a of the segment coil 21 is guided radially outward by the inclined portion 4c of the notch 4a of the inner diameter side guide 4, and the other leg 2b of the segment coil 21 is guided radially inward by the inclined portion 5e of the notch 5a of the outer diameter side guide 5, and as viewed from above, the segment coil 2 rotates counterclockwise, and one leg 2a and the other leg 2b of the segment coil 2 are inserted into the gap 6.

[0038] Similarly, by inserting one leg 2a of the segment coil 21 from above into the slit 3a of the slit jig 3 and the notch 4a of the inner diameter side guide 4, and inserting the other leg 2b of the segment coil 2 from above into the slit 3a of the slit jig 3 and the notch 5a of the outer diameter side guide 5, and repeating the process of rotating the slit jig 3 in the counterclockwise direction around the circumferential direction of the slit jig 3, an aligned coil can be manufactured.

[0039] Next, the process of aligning the segment coils 22 to manufacture aligned coils will be explained. With the inner diameter guide 4 and outer diameter guide 5 positioned relative to the slits 3a of the slit jig 3 as described above, one leg 2a of the segment coil 22 is inserted from above into the slit 3a on the most clockwise side when viewed from above, which overlaps with the notch 4a of the inner diameter guide 4 in the slit jig 3, and is also inserted into the notch 4a of the inner diameter guide 4.

[0040] At the same time, the other leg 2b of the segment coil 22 is inserted from above into the slit 3a on the counterclockwise side when viewed from above, which overlaps with the notch 5a of the outer diameter side guide 5 in the slit jig 3, and is also inserted into the notch 5a of the outer diameter side guide 5. Then, the slit jig 3 is rotated by one slit in that counterclockwise direction.

[0041] As a result, the segment coil 22 revolves along with the rotation of the slit jig 3, and the other leg 2b of the segment coil 22 contacts the inclined portion 5e of the notch 5a of the outer diameter side guide 5. Then, the other leg 2b of the segment coil 22 is guided radially inward of the outer diameter side guide 5 by the inclined portion 5e of the notch 5a of the outer diameter side guide 5, and as viewed from above, the segment coil 2 rotates counterclockwise, and the other leg 2b of the segment coil 22 is inserted into the gap 6.

[0042] Next, the slitting jig 3 is rotated one slit further in the counterclockwise direction. As a result, the segment coil 22 revolves along with the rotation of the slitting jig 3, and one leg 2a of the segment coil 22 is also inserted into the gap 6.

[0043] Similarly, by inserting one leg 2a of the segment coil 22 from above into the slit 3a of the slit jig 3 and the notch 4a of the inner diameter side guide 4, and inserting the other leg 2b of the segment coil 22 from above into the slit 3a of the slit jig 3 and the notch 5a of the outer diameter side guide 5, and repeating the process of rotating the slit jig 3 in the counterclockwise direction around the circumferential direction of the slit jig 3, an aligned coil can be manufactured.

[0044] Thus, the notches 4a of the inner diameter guide 4 and 5a of the outer diameter guide 5 have a length that overlaps with the multiple slits 3a in the circumferential direction of the slit jig 3, so that multiple types of segment coils 2 with different pitches between one leg 2a and the other leg 2b can be rotated and one leg 2a and the other leg 2b can be inserted into the gap 6. Therefore, for example, aligned coils can be manufactured using different types of segment coils 2 without replacing the inner diameter guide 4 and the outer diameter guide 5.

[0045] Incidentally, for example, a stator can be manufactured by repeatedly performing the following steps: pulling out the manufactured alignment coil upwards and inserting the legs 2a and 2b of each segment coil into the slots of the stator core from above; and replacing the inner diameter guide 4 and the outer diameter guide 5 to manufacture alignment coils of different diameters.

[0046] Thus, the coil alignment manufacturing apparatus 1 of this embodiment can align segment coils 2 with different pitches between one leg 2a and the other leg 2b without replacing the inner diameter guide 4 and the outer diameter guide 5. Therefore, aligned coils can be manufactured inexpensively and quickly.

[0047] The shapes of the notches 4a of the inner diameter guide 4 and 5a of the outer diameter guide 5 in this embodiment are illustrative examples. In short, they just need to have a length that overlaps with the multiple slits 3a in the circumferential direction of the slit jig 3 so that multiple types of segment coils 2 with different pitches between one leg 2a and the other leg 2b can be rotated and one leg 2a and the other leg 2b can be inserted into the gap 6.

[0048] This disclosure is not limited to the embodiments described above, and may be modified as appropriate without departing from the spirit of the invention. [Explanation of Symbols]

[0049] 1. Alignment coil manufacturing apparatus 2, 21, 22 segment coil, 2a one leg, 2b the other leg 3 Slitting jig, 3a Slit 4 inner diameter side guide, 4a notch, 4b side, 4c inclined section 5 Outer diameter side guide, 5a Notch, 5b First part, 5c Second part, 5d Side part, 5e Inclined part 6. Gap 101 Alignment Coil Manufacturing Machine 102 Slitting jig, 102a Slit 103 Segment coil, 103a one leg, 103b the other leg 104 Inner diameter side guide, 104a Notch 105 Outer diameter side guide, 105a Notch 106 Gap

Claims

1. A device for manufacturing aligned coils by aligning segment coils, A slitting jig having multiple slits arranged radially at predetermined angular intervals to correspond to the slots of the stator core, An inner diameter side guide is positioned below the slitting jig and coaxially with the slitting jig, An outer diameter guide surrounds the inner diameter guide below the slit jig and is positioned coaxially with the slit jig, Equipped with, The inner diameter side guide has a first notch on its peripheral edge facing the outer diameter side guide into which one leg of the segment coil inserted into the slit is inserted, and which can guide the one leg from the inner diameter side to the outer diameter side of the slit jig. The outer diameter side guide has a second notch on its peripheral edge facing the inner diameter side guide into which the other leg of the segment coil inserted into a different slit is inserted, and which can guide the other leg from the outer diameter side to the inner diameter side of the slit jig. When the slitting jig is rotated to revolve the segment coil, one leg of the segment coil is guided by the first notch towards the outer diameter side of the slitting jig, or the other leg of the segment coil is guided by the second notch towards the inner diameter side of the slitting jig, causing the segment coil to rotate on its own axis, and both legs of the segment coil are inserted into the gap between the inner diameter guide and the outer diameter guide. Aligned coil manufacturing apparatus, wherein the first and second notches have a length that overlaps with the multiple slits in the circumferential direction of the slit jig, so that multiple types of segment coils with different pitches between one leg and the other leg are rotated and the one leg and the other leg are inserted into the gap.

2. The first notch has an inclined portion on the side of the slit jig in the direction of rotation that slopes toward the outer diameter side of the slit jig, The aligned coil manufacturing apparatus according to claim 1, wherein the inclined portion of the first notch can guide one leg of the segment coil into the gap by bringing it into contact with the inclined portion of the first notch.

3. The second notch has an inclined portion on the side of the slit jig in the direction of rotation that slopes toward the inner diameter side of the slit jig, The aligned coil manufacturing apparatus according to claim 1 or 2, wherein the inclined portion of the second notch can guide the other leg of the segment coil into the gap by bringing it into contact with the inclined portion of the second notch.

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