Segment coil alignment method
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- TOYOTA JIDOSHA KK
- Filing Date
- 2025-01-17
- Publication Date
- 2026-07-30
AI Technical Summary
【0009】 本開示のセグメントコイルの整列方法によれば、製造コストを大幅に増加させることなく、引出線コイルを含む複数のセグメントコイルを整列して組み付けることができるセグメントコイルの整列方法を提供することができる。
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Figure 2026123589000001_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to a method for aligning segment coils.
Background Art
[0002] Patent Document 1 discloses an aligning device capable of forming aligned coils of various diameters by aligning a plurality of segment coils in a circular shape. In the manufacture of a segment coil type stator core using this aligning device, after aligning a plurality of segment coils on the circumference, the segment coils arranged in an annular shape are stacked in the axial direction to form an aligned coil, and the formed aligned coil is assembled to the stator core.
[0003] In the aligning device described in Patent Document 1, an aligned coil is formed from a segment coil bent in a U shape, and the U-shaped segment coil can be easily supported by any two of a plurality of partition members arranged radially with a gap.
Prior Art Documents
Patent Documents
[0004]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0005] However, when assembling a segment coil (hereinafter referred to as a "lead-out coil") that inserts only one end into the stator core and is used as a lead-out wire to the stator core, in the aligning device described in Patent Document 1, since it is supported only at one end, there is a problem that the lead-out coil cannot be stably supported.
[0006] This disclosure was made to solve these problems and aims to provide a segment coil alignment method that enables the alignment and assembly of multiple segment coils, including lead wire coils, without significantly increasing manufacturing costs. [Means for solving the problem]
[0007] A method for aligning segment coils according to a first aspect of this disclosure is: A first step is to prepare an alignment device comprising a plurality of slits arranged radially at predetermined angular intervals, an outer diameter side guide that guides one leg of a first lead wire coil inserted into a corresponding slit from the outer diameter side, and an inner diameter side guide that guides one leg of a second lead wire coil inserted into a corresponding slit from the inner diameter side. The second step involves assembling one leg of the first lead wire coil to the outer diameter guide of the alignment device, The third step involves assembling one leg of the second lead wire coil to the inner diameter guide of the alignment device, After the second and third steps, the fourth step involves inserting both legs of each of the multiple U-shaped segment coils into the corresponding two slits and assembling them. Includes, In the fourth step, both legs of each of the multiple U-shaped segment coils are inserted into the two corresponding slits at an angle to the circumferential direction of the alignment device, so as to avoid the first and second lead wire coils that were assembled in the second and third steps, respectively.
[0008] A method for aligning segment coils according to a second aspect of this disclosure is: A first step is to prepare an alignment device comprising a plurality of slits arranged radially at predetermined angular intervals, and a plurality of guide bars inserted into each of the plurality of slits, A second step involves forming a first annular aligned coil consisting of multiple lead wire coils and multiple U-shaped segment coils, A third step involves inserting all the downward-facing legs of the first aligned coil into multiple slits while bringing one leg of each of the multiple lead wire coils into contact with the corresponding guide bar of the multiple guide bars, A fourth step involves forming a second annular aligned coil consisting of multiple U-shaped segment coils, A fifth step involves inserting the second alignment coil axially inside the first alignment coil such that at least a portion of the second alignment coil overlaps with multiple lead wire coils of the first alignment coil, After inserting the second alignment coil until the orientation of the multiple lead wire coils is maintained, the sixth step involves moving multiple guide bars out of multiple slits so as not to interfere with the second alignment coil, It includes. [Effects of the Invention]
[0009] The segment coil alignment method of this disclosure provides a method for aligning and assembling multiple segment coils, including lead wire coils, without significantly increasing manufacturing costs. [Brief explanation of the drawing]
[0010] [Figure 1] This is a schematic diagram showing a state in which multiple segment coils, including lead wire coils, are aligned by an alignment device. [Figure 2] This is a schematic diagram of the process of assembling one leg of the first and second lead wire coils into the slit of the alignment device. [Figure 3] This is a schematic diagram of the process of assembling multiple U-shaped segment coils into the slits of an alignment device. [Figure 4] This is a schematic diagram of the process of inserting a second annular alignment coil, consisting of multiple U-shaped segment coils, into an alignment device. [Figure 5] This is a magnified view of a part of the alignment device shown in Figure 4. [Figure 6] This diagram shows the first and second alignment coils before they are inserted into the alignment device.
Best Mode for Carrying Out the Invention
[0011] Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the invention according to the claims is not limited to the following embodiments. Also, not all of the configurations described in the embodiments are essential as means for solving the problems. For the sake of clarity of explanation, the following description and drawings have been appropriately omitted and simplified. In each drawing, the same elements are denoted by the same reference numerals, and duplicate explanations are omitted as necessary.
[0012] (Embodiment 1) <Configuration of Alignment Device> Before explaining the method of aligning the segment coils, an alignment device for aligning the alignment coils according to this embodiment will be described. FIG. 1 is a schematic diagram showing a state in which a plurality of segment coils including lead-out coils are aligned by an alignment device. As partially shown in FIG. 1, the alignment device 100 according to this embodiment has substantially the same diameter as the stator core to be manufactured.
[0013] As shown in FIG. 1, the alignment device 100 has a plurality of slits 110 arranged radially at predetermined angular intervals. Each of the plurality of slits 110 has an opening shape that penetrates the alignment device 100 body in the vertical direction and has a groove shape extending in the radial direction.
[0014] By providing the plurality of slits 110, the alignment device 100 has blade-like blades 120 extending in the radial direction between each adjacent pair of slits 110. That is, the alignment device 100 has a plurality of blades 120 arranged radially at regular angular intervals.
[0015] FIG. 2 is a schematic diagram of the process of assembling one leg of the first lead-out coil 1 and the second lead-out coil 2 into the slit 110 of the alignment device 100. FIG. 3 is a schematic diagram of the process of assembling a plurality of U-shaped segment coils 3 into the slit 110 of the alignment device 100.
[0016] As shown in FIGS. 2(b) and 3(b), the alignment device 100 includes an outer diameter side guide 130 and an inner diameter side guide 140. As will be described in detail in the method for aligning the segment coils, the outer diameter side guide 130 is configured to guide one leg of the first lead-out coil 1 inserted into the corresponding slit 110 from the outer diameter side. The inner diameter side guide 140 is configured to guide one leg of the second lead-out coil 2 inserted into the corresponding slit 110 from the inner diameter side.
[0017] As shown in FIGS. 2(b) and 3(b), the outer diameter side guide 130 has a hole into which one leg of the first lead-out coil 1 is inserted, and the inner diameter side guide 140 has a hole into which one leg of the second lead-out coil 2 is inserted.
[0018] Here, each of the first lead-out coil 1 and the second lead-out coil 2 has a shape (crank shape) as shown in FIG. 1, in which one leg extends upward from the stator core to be manufactured, and the other leg is inserted into the slit 110 of the alignment device 100. When assembling such lead-out coils 1 and 2 to the alignment device 100, it can only be supported by the other leg inserted into the slit 110 of the alignment device 100, and it has been difficult to assemble the subsequent U-shaped segment coil 3.
[0019] On the other hand, the alignment device 100 according to the present embodiment includes the outer diameter side guide 130 and the inner diameter side guide 140, so that one leg of the first lead-out coil 1 and the second lead-out coil 2 can be reliably supported by the holes of the outer diameter side guide 130 and the inner diameter side guide 140, respectively. As a result, the post-assembly postures of the first lead-out coil 1 and the second lead-out coil 2 are maintained, and thus there is a unique effect that the subsequent assembly of the U-shaped segment coil 3 becomes easy.
[0020] Note that the position of the inner diameter side guide 140 in the radial direction of the alignment device 100 may be variable according to the radial size of the stator core to be manufactured.
[0021] <Method for Aligning Segment Coils> Next, the method for aligning segment coils according to this embodiment will be described. The method for aligning segment coils includes the following four steps.
[0022] In the first step, the alignment device 100 described above is prepared. Specifically, in the first step, the alignment device 100 is prepared, which comprises a plurality of slits 110 arranged radially at predetermined angular intervals, an outer diameter side guide 130 that guides one leg of the first lead wire coil 1 inserted into the corresponding slit 110 from the outer diameter side, and an inner diameter side guide 140 that guides one leg of the second lead wire coil 2 inserted into the corresponding slit 110 from the inner diameter side.
[0023] Next, in the second step, one leg of the first lead wire coil 1 is attached to the outer diameter side guide 130 of the alignment device 100. Then, in the third step, one leg of the second lead wire coil 2 is attached to the inner diameter side guide 140 of the alignment device 100. Note that the order of the second and third steps may be reversed, or the second and third steps may be performed simultaneously.
[0024] Figure 2(a) shows the case where the order of the second and third steps is reversed. Figure 2(a) shows the state in which one leg of the first lead wire coil 1 is inserted into the corresponding slit 110 of the alignment device 100 relative to the outer diameter side guide 130 (not shown) in the direction indicated by arrow X. Finally, when the first lead wire coil 1 and the second lead wire coil 2 are assembled to the outer diameter side guide 130 and the inner diameter side guide 140, as shown in Figure 2(b), the first lead wire coil 1 and the second lead wire coil 2 maintain their orientation. In other words, the outer diameter side guide 130 and the inner diameter side guide 140 can stabilize the orientation of the first lead wire coil 1 and the second lead wire coil 2 after they have been assembled.
[0025] Next, in this state, the fourth step involves inserting both legs of each of the multiple U-shaped segment coils 3 into the corresponding two slits 110. In this case, the fourth step involves inserting both legs of each of the multiple U-shaped segment coils 3 into the corresponding two slits 110 at an angle with respect to the circumferential direction of the alignment device 100, so as to avoid the first lead wire coil 1 and the second lead wire coil 2 that were assembled in the second and third steps, respectively.
[0026] Specifically, as shown in Figure 3(a), when inserting a single U-shaped segment coil 3 into the alignment device 100 in the direction indicated by arrow X, one leg of the U-shaped segment coil 3 is inserted into a slit 110 located at a predetermined insertion position, and the other leg of the U-shaped segment coil 3 is inserted into another slit 110 located a predetermined number of spaces away from the first slit 110. At this time, in order to avoid the first lead wire coil 1 and the second lead wire coil 2, the single U-shaped segment coil 3 is inserted into the two slits 110 while the alignment device 100 is rotated (rotated) by a predetermined angle clockwise with respect to the circumferential direction.
[0027] As described above, the segment coil alignment method according to this embodiment includes a first step of preparing the alignment device 100, a second step of assembling one leg of the first lead wire coil 1 to the outer diameter side guide 130 of the alignment device 100, a third step of assembling one leg of the second lead wire coil 2 to the inner diameter side guide 140 of the alignment device 100, and a fourth step, after the second and third steps, of assembling each of the multiple U-shaped segment coils 3 by inserting both legs into the corresponding two slits 110. In the fourth step, each of the multiple U-shaped segment coils 3 is inserted into the corresponding two slits 110 at an angle with respect to the circumferential direction of the alignment device 100 so as to avoid the first lead wire coil 1 and the second lead wire coil 2 assembled in the second and third steps, respectively. By configuring the segment coil alignment method in this way, segment coils 1 to 3, including the first lead coil 1 and the second lead coil 2, can be aligned and assembled without significantly increasing manufacturing costs.
[0028] Although not shown in the diagram, the following steps may be added instead of or after the fourth step. In the fifth step, a ring-shaped aligned coil is formed from multiple U-shaped segment coils 3, separate from the multiple U-shaped segment coils 3 assembled in the fourth step. Then, in the sixth step, each leg of the ring-shaped aligned coil is inserted into multiple slits 110 of the alignment device 100. By adding such steps, the time required to align the segment coils 1 to 3 can be shortened compared to the case where many U-shaped segment coils 3 are assembled into the slits 110 in the fourth step. Therefore, the manufacturing time of the stator core using the aligned segment coils 1 to 3 can also be shortened.
[0029] (Embodiment 2) <Configuration of the alignment device> Before describing the method for aligning the segment coils, we will first describe the alignment device for aligning the aligned coils according to this embodiment. The alignment device according to this embodiment differs from the alignment device 100 according to Embodiment 1 in that, instead of the outer diameter side guide 130 and the inner diameter side guide 140 in Embodiment 1, it comprises a plurality of guide bars configured to be inserted into a plurality of slits.
[0030] Figure 4 is a schematic diagram of the process of inserting an annular second alignment coil 20, which consists of multiple U-shaped segment coils 3, into the alignment device 200. Figure 5 is an enlarged view of a part of the alignment device 200 shown in Figure 4. Figure 6 shows the first alignment coil 10 and the second alignment coil 20 before being inserted into the alignment device 200. As partially shown in Figure 5, the alignment device 200 according to this embodiment has approximately the same diameter as the stator core being manufactured.
[0031] In the segment coil alignment method according to this embodiment, a first annular alignment coil 10 as shown in Figure 6(a) and a second annular alignment coil 20 as shown in Figure 6(b) are formed in advance, and these alignment coils 10 and 20 are inserted sequentially into the alignment device 200.
[0032] As shown in Figure 6(a), the first alignment coil 10 is composed of a plurality of first lead wire coils 1, one of which is inserted into the outer diameter side, a plurality of second lead wire coils 2, one of which is inserted into the inner diameter side, and a plurality of U-shaped segment coils 3. As shown in Figure 6(b), the second alignment coil 20 is composed only of a plurality of U-shaped segment coils 3.
[0033] As shown in Figure 5, the alignment device 200 has a plurality of slits 210 arranged radially at predetermined angular intervals. Each of the plurality of slits 210 has an opening shape that penetrates the body of the alignment device 200 in the vertical direction and has a groove shape that extends in the radial direction.
[0034] Furthermore, as shown in Figure 5, the alignment device 200 includes a plurality of guide bars 220 configured to be insertable into each of the plurality of slits 210. When assembling the first alignment coil 10 into the alignment device 200, the plurality of guide bars 220 are used to insert all the downward-facing legs of the segment coils 1 to 3 constituting the first alignment coil 10 into the plurality of slits 210 of the alignment device 200, while bringing one leg each of the first lead wire coil 1 and the second lead wire coil 2 into contact with the corresponding guide bar 220 of the plurality of guide bars 220.
[0035] <Method for aligning segment coils> Next, a method for aligning segment coils according to this embodiment will be described. The method for aligning segment coils includes the following six steps.
[0036] In the first step, the alignment device 200 described above is prepared. Specifically, in the first step, an alignment device 200 is prepared that comprises a plurality of slits 210 arranged radially at predetermined angular intervals, and a plurality of guide bars 220 inserted into each of the plurality of slits 210.
[0037] Next, in the second step, as shown in Figure 6(a), a ring-shaped first alignment coil 10 is formed, consisting of multiple lead wire coils 1 and 2 and multiple U-shaped segment coils 3. In the third step, although not shown, all the downward-facing legs of the first alignment coil 10 are inserted into multiple slits 210, while one leg of each of the multiple lead wire coils 1 and 2 is brought into contact with the corresponding guide bar 220 of the multiple guide bars 220. In this way, by bringing one leg of each of the multiple lead wire coils 1 and 2 into contact with the corresponding guide bar 220, the orientation of the multiple lead wire coils 1 and 2 can be stably maintained.
[0038] Next, in the fourth step, as shown in Figure 6(b), a ring-shaped second alignment coil 20 consisting only of a plurality of U-shaped segment coils 3 is formed. In the fifth step, as shown in Figure 4, the second alignment coil 20 is inserted axially into the first alignment coil 10 such that at least a portion of the second alignment coil 20 overlaps with the plurality of lead wire coils 1 and 2 of the first alignment coil 10.
[0039] Next, in the sixth step, although not shown in the diagram, the second alignment coil 20 is inserted until the orientation of the multiple lead wire coils 1 and 2 is maintained, and then the multiple guide bars 220 are moved out of the multiple slits 210 of the alignment device 200 so as not to interfere with the second alignment coil 20.
[0040] Finally, the second alignment coil 20 is fully assembled to the first alignment coil 10 within the alignment device 200.
[0041] As described above, the segment coil alignment method according to this embodiment includes a first step of preparing an alignment device 200, a second step of forming a first alignment coil 10, a third step of inserting all the downward-facing legs of the first alignment coil 10 into a plurality of slits 210 while bringing one leg of each of the plurality of lead wire coils 1 and 2 into contact with the corresponding guide bar 220 of the plurality of guide bars 220, a fourth step of forming a second alignment coil 20, a fifth step of axially inserting the second alignment coil 20 inside the first alignment coil 10 so that at least a part of the second alignment coil 20 overlaps with the plurality of lead wire coils 1 and 2 of the first alignment coil 10, and a sixth step of moving the plurality of guide bars 220 out of the plurality of slits 210 so as not to interfere with the second alignment coil 20 after inserting the second alignment coil 20 until the orientation of the plurality of lead wire coils 1 and 2 is maintained. By configuring the segment coil alignment method in this way, segment coils 1 to 3, including the first lead coil 1 and the second lead coil 2, can be aligned and assembled without significantly increasing manufacturing costs.
[0042] Although the present invention has been described with reference to embodiments, the present invention is not limited to the above embodiments and can be modified as appropriate without departing from the spirit of the invention. [Explanation of Symbols]
[0043] 1. First lead wire coil 2. Second lead wire coil 3 U-shaped segment coils 10. First Alignment Coil 20. Second Alignment Coil 100, 200 alignment device 110, 210 slits 120 blades 130 Outer diameter side guide 140 Inner diameter side guide 220 Guide Bar
Claims
1. A first step is to prepare an alignment device comprising a plurality of slits arranged radially at predetermined angular intervals, an outer diameter guide that guides one leg of a first lead wire coil inserted into a corresponding slit from the outer diameter side, and an inner diameter guide that guides one leg of a second lead wire coil inserted into a corresponding slit from the inner diameter side. A second step involves assembling one leg of the first lead wire coil to the outer diameter side guide of the alignment device, A third step involves assembling one leg of the second lead wire coil to the inner diameter side guide of the alignment device, A fourth step is to assemble the U-shaped segment coils by inserting both legs of each into the corresponding two slits, after the second and third steps described above. Includes, In the fourth step, both legs of each of the plurality of U-shaped segment coils are inserted into the two corresponding slits at an angle with respect to the circumferential direction of the alignment device, so as to avoid the first and second lead wire coils assembled in the second and third steps, respectively. Method for aligning segment coils.
2. The inner diameter side guide has a variable position relative to the radial direction of the alignment device. The method for aligning segment coils according to claim 1.
3. A fifth step, performed in lieu of or after the fourth step, is to form an annular aligned coil consisting of a plurality of U-shaped segment coils. A sixth step involves inserting each leg of the annular alignment coil into the plurality of slits of the alignment device, Further including, A method for aligning segment coils according to claim 1 or 2.
4. A first step is to prepare an alignment device comprising a plurality of slits arranged radially at predetermined angular intervals, and a plurality of guide bars inserted into each of the plurality of slits, A second step involves forming a first annular aligned coil consisting of multiple lead wire coils and multiple U-shaped segment coils, A third step involves inserting all the downward-facing legs of the first alignment coil into the plurality of slits while bringing one leg of each of the plurality of lead wire coils into contact with the corresponding guide bar of the plurality of guide bars, A fourth step involves forming a second annular aligned coil consisting of multiple U-shaped segment coils, A fifth step is to insert the second alignment coil axially into the first alignment coil such that at least a portion of the second alignment coil overlaps with the plurality of lead wire coils of the first alignment coil, After inserting the second alignment coil until the orientation of the plurality of lead wire coils is maintained, a sixth step is to move the plurality of guide bars out of the plurality of slits so as not to interfere with the second alignment coil, including, Method for aligning segment coils.