Stator manufacturing method and stator manufacturing system

Abstract

The objective is to provide a stator manufacturing method and stator manufacturing system that can suppress the temperature drop of the coil. [Solution] The stator manufacturing method involves heating the stator, which includes a core and coils provided on the core, with a heating device, and keeping the stator warm by isolating the stator after it has been discharged from the heating device with a cover member that surrounds the stator.

Description

Technical Field

[0001] The present invention relates to a stator manufacturing method and a stator manufacturing system.

Background Art

[0002] In Patent Document 1, in order to shorten the curing time of the resin composition coated on the coil, the workpiece heated in the heating furnace is conveyed to the powder tank.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in Patent Document 1, when the heated coil is conveyed to the powder tank, the temperature suitable for coating the coil cannot be maintained, and the coating quality of the coil may deteriorate.

[0005] Therefore, an object of the present invention is to provide a stator manufacturing method and a stator manufacturing system capable of suppressing a temperature drop of the coil.

Means for Solving the Problems

[0006] A stator manufacturing method according to an aspect of the present disclosure heats a stator including a core and a coil provided on the core with a heating device, and insulates the stator discharged from the heating device with a cover member covering the periphery of the stator, thereby keeping the stator warm.

Effects of the Invention

[0007] According to the present invention, a temperature drop of the coil can be suppressed.

Brief Description of the Drawings

[0008] [Figure 1] Figure 1 is a perspective view of Core 1 according to an embodiment of this disclosure. [Figure 2] Figure 2 is a perspective view of the coil 2 before it is inserted into the slot 1a of the core 1 shown in Figure 1. [Figure 3] Figure 3 is a perspective view of stator 1A. [Figure 4] Figure 4 shows an example configuration of the stator manufacturing system 100-1 according to the first embodiment of this disclosure. [Figure 5] Figure 5 is a flowchart illustrating the stator manufacturing method using the stator manufacturing system 100-1 according to the first embodiment of this disclosure. [Figure 6] Figure 6 is a diagram illustrating a stator manufacturing method using the stator manufacturing system 100-1 according to the first embodiment of this disclosure. [Figure 7] Figure 7 is a diagram illustrating a stator manufacturing method using a stator manufacturing system 100-1 according to the first embodiment of this disclosure. [Figure 8] Figure 8 is a diagram illustrating a stator manufacturing method using the stator manufacturing system 100-1 according to the first embodiment of this disclosure. [Figure 9] Figure 9 is a diagram illustrating a stator manufacturing method using a stator manufacturing system 100-1 according to the first embodiment of this disclosure. [Figure 10] Figure 10 is a diagram illustrating the effects of the stator manufacturing method according to the first embodiment of this disclosure. [Figure 11] Figure 11 shows an example configuration of the stator manufacturing system 100-1 according to a modified example. [Figure 12] Figure 12 shows an example configuration of the stator manufacturing system 100-2 according to the second embodiment of this disclosure. [Figure 13] Figure 13 is an enlarged view of the cover member 50-2. [Figure 14] Figure 14 is a flowchart illustrating the stator manufacturing method using the stator manufacturing system 100-2 according to the second embodiment of this disclosure. [Figure 15] FIG. 15 is a diagram for explaining a stator manufacturing method by a stator manufacturing system 100-2 according to the second embodiment of the present disclosure. [Figure 16] FIG. 16 is a diagram for explaining a stator manufacturing method by a stator manufacturing system 100-2 according to the second embodiment of the present disclosure. [Figure 17] FIG. 17 is a diagram for explaining a first modification example of a stator manufacturing system 100-2 according to the second embodiment of the present disclosure. [Figure 18] FIG. 18 is a diagram for explaining a first modification example of a stator manufacturing system 100-2 according to the second embodiment of the present disclosure. [Figure 19] FIG. 19 is a diagram for explaining a first modification example of a stator manufacturing system 100-2 according to the second embodiment of the present disclosure. [Figure 20] FIG. 20 is a diagram for explaining a second modification example of a stator manufacturing system 100-2 according to the second embodiment of the present disclosure. [Figure 21] FIG. 21 is a diagram for explaining a second modification example of a stator manufacturing system 100-2 according to the second embodiment of the present disclosure. [Figure 22] FIG. 22 is a diagram showing a configuration example of a stator manufacturing system 100-3 according to the third embodiment of the present disclosure. [Figure 23] FIG. 23 is a flowchart for explaining a stator manufacturing method by a stator manufacturing system 100-3 according to the third embodiment of the present disclosure. [Figure 24] FIG. 24 is a diagram for explaining a stator manufacturing method by a stator manufacturing system 100-3 according to the third embodiment of the present disclosure. [Figure 25] FIG. 25 is a diagram for explaining a stator manufacturing method by a stator manufacturing system 100-3 according to the third embodiment of the present disclosure. [Figure 26] FIG. 26 is a diagram for explaining a stator manufacturing method by a stator manufacturing system 100-3 according to the third embodiment of the present disclosure. [Figure 27]FIG. 27 is a diagram for explaining a stator manufacturing method by a stator manufacturing system 100-3 according to the third embodiment of the present disclosure. [Figure 28] FIG. 28 is a diagram for explaining a stator manufacturing method by a stator manufacturing system 100-3 according to the third embodiment of the present disclosure.

MODE FOR CARRYING OUT THE INVENTION

[0009] Hereinafter, embodiments which are examples of the present invention will be described. In this specification, members having substantially the same functions are given the same reference numerals throughout the drawings, and duplicate explanations may be omitted. In each drawing, the X-axis direction, the Y-axis direction, and the Z-axis direction are perpendicular to each other, the X-axis direction and the Y-axis direction are horizontal directions, and the Z-axis direction is equal to the vertical direction or the axial direction.

[0010] (First Embodiment) The core 1 shown in FIG. 1 is, for example, a stator core for a rotating electrical machine. A plurality of slots 1a are formed in the core 1, each of which extends in the radial direction RD of the core 1 and is arranged apart in the circumferential direction CD of the core 1. Insulating paper (not shown) is inserted into each of the plurality of slots 1a, and a plurality of coils 2 formed in a U shape as shown in FIG. 2, for example, with a flat cross-sectional shape, are inserted into the region inside the insulating paper. Thus, a stator 1A in which a part of the coil 2 is exposed at the axial end AXD of the core 1 as shown in FIG. 3 can be obtained. Note that FIG. 3 shows a schematic configuration of the stator 1A, and the detailed configuration of the plurality of coils 2 is not shown. The tip portions 2a (coil ends) of the coils 2 inserted into the core 1 are joined by welding or the like. In order to insulate the surface of this joined portion, for example, powder coating is performed by immersing the joined portion in a powder tank in which a powder paint flows. The joined portion may be interpreted as, for example, the joined portion between the tip portions 2a or the joined portion between the tip portion 2a and the bus bar. In the embodiment of the present disclosure, after powder coating is performed, varnish is applied to and cured on the stator 1A inserted into the slot 1A.

[0011] Next, with reference to Figure 4, an example configuration of the stator manufacturing system 100-1 will be described. As shown in Figure 4, the stator manufacturing system 100-1 comprises a conveyor device 10, a heating furnace 20, a transport device 30, a powder tank 40 through which powder coating flows, and a cover member 50-1.

[0012] The conveyor device 10 is a device for transporting one or more stators 1A or other objects to be heated. For example, the conveyor device 10 allows for adjustment of the transport speed and transport timing. This enables the conveyor device 10 to intermittently transport the objects to be heated by repeatedly transporting and stopping. The conveyor device 10 is used as a transport means to pass the stators 1A into the heating furnace 20, using a heat-resistant belt with high heat resistance (for example, made of stainless steel or special rubber).

[0013] The heating furnace 20 is a device that heats one or more stators 1A transported by the conveyor device 10 at a high temperature. The heating furnace 20 heats the stators 1A to a constant temperature by, for example, setting a uniform temperature distribution inside the furnace. The heating furnace 20 can control the temperature inside the furnace by, for example, using a temperature sensor. The heating method in the heating furnace 20 can be selected according to the application, for example, an electric heater, a gas burner, or infrared. By combining the conveyor device 10 with the heating furnace 20, continuous heating of the stators 1A becomes possible, improving the productivity of the stators 1A through continuous processing, and allowing for precise control of temperature and processing time. For example, the temperature of each joint part (coil end, busbar, etc.) of multiple stators 1A can be made uniform, and powder coating of the joint parts can be reliably performed in the powder tank described later.

[0014] The heating furnace 20 may be equipped with a shutter 21 for opening and closing the entrance for the stator 1A, and a shutter 22 for opening and closing the exit for the stator 1A. The opening and closing operation of the shutters 21 and 22 is, for example, vertical movement, but is not limited to this, and may be horizontal movement, or inward opening or outward opening.

[0015] The heating furnace 20 may also be provided with a cover member 50-1 that moves up and down in conjunction with the opening and closing operation of the shutter 22 provided at the discharge port, or moves up and down independently of the opening and closing operation of the shutter 22. In the example shown in Figure 4, the heating furnace 20 is provided with a moving device 60 that raises or lowers the cover member 50-1 in conjunction with the shutter 22.

[0016] The moving device 60 may include, for example, a plurality of support members 61 that support the cover member 50-1, and an actuator (not shown) that drives the support members 61.

[0017] For example, when the stator 1A, which has been heated in the heating furnace 20, is removed from the heating furnace 20, the shutter 22 rises and the stator 1A is removed to a predetermined position outside the heating furnace 20. At this point, the moving device 60 may, for example, lower the cover member 50-1 to cover the stator 1A at the same time as the shutter 22 descends. In other words, the moving device 60 may place the cover member 50-1 over the stator 1A immediately after it has been removed from the heating furnace 20.

[0018] The cover member 50-1 is a member for suppressing temperature drop at the joint portion of the stator 1A after it has been removed from the heating furnace 20, specifically at the tip 2a (coil end) of the coil 2 shown in Figure 3. The cover member 50-1 covers the area around the joint portion of the stator 1A so that at least the coil end of the stator 1A is not exposed to the outside of the cover member 50-1, and preferably covers the joint portion and the entire core 1 shown in Figure 3. By covering the entire core 1 in addition to the joint portion, the temperature drop at the joint portion caused by the temperature difference between the joint portion and the core 1 is further suppressed, which can further improve the quality of powder coating of the joint portion in the powder bath. In addition, by covering the area around the joint portion of the stator 1A, reheating of the joint portion for stable powder coating becomes unnecessary, thus reducing energy consumption for reheating and reducing the environmental burden.

[0019] The material of the cover component 50-1 should preferably be able to withstand the highest temperature of the operating environment and be resistant to corrosion in environments exposed to moisture and chemicals. Specifically, examples of materials for the cover component 50-1 include ceramic fibers with excellent thermal insulation properties that can withstand high-temperature environments, glass fibers that are relatively lightweight and can handle a wide temperature range, lightweight and easy-to-process foam materials (polyurethane, elastomer, etc.), and metal sheets (aluminum, stainless steel, etc.) that combine durability and reflective thermal insulation effects.

[0020] The structure of the cover member 50-1 should preferably be such that it is airtight to prevent heat from escaping, can be easily attached to the stator 1A, and can be easily removed from the stator 1A. Furthermore, since a cover member 50-1 that is too heavy may interfere with the operation of the moving device 60, it is desirable that it be lightweight.

[0021] The conveying device 30 is a device that grasps the stator 1A heated in the heating furnace 20 and conveys it to the powder tank. The conveying device 30 has multiple rotary joints and a structure similar to a human arm, and can be exemplified as an articulated (arm-type) robot capable of very flexible movement. However, the conveying device 30 is not limited to this, and may also be a Cartesian (orthogonal) robot arm that operates in three orthogonal axes of X, Y, and Z and enables movement that combines rotation and linear motion, a polar coordinate robot arm that uses a spherical coordinate system (rotation, vertical movement, extension and retraction movement), or a SCARA robot arm that combines movement in a plane and vertical movement.

[0022] For example, after the stator 1A (workpiece that has been preheated for powder coating) has been removed from the heating furnace 20 and the cover member 50-1 has been placed over it, at the timing when powder coating is to be performed in the powder tank 40, the moving device 60 raises the cover member 50-1 to remove it from the stator 1A, and then the chuck 31 of the conveying device 30 holds the stator 1A. After the chuck 31 holds the stator 1A, for example, the arm 32 of the conveying device 30 rotates, and the stator 1A held by the chuck 31 is conveyed to the powder tank 40 where the powder coating 41 is accumulated.

[0023] For example, the arm 32 shown in Figure 4 may be extended to the vicinity of the powder tank 40 to release the stator 1A, and another powder coating robot may hold the stator 1A and submerge a portion of it (the joint) into the powder tank 40. Alternatively, the arm 32 shown in Figure 4 may transport the stator 1A to above the powder tank 40, and then the arm 32 may further submerge a portion of the stator 1A (the joint) into the powder tank 40. An insulating coating is formed on the joint by powder coating. Although powder coating is given as an example of an insulating coating method for the joint here, other coating methods may also be used.

[0024] Thus, the cover member 50-1 is placed over the stator 1A until it is time to perform powder coating, that is, from the moment the stator 1A is removed from the heating furnace 20 until the stator 1A is held in the conveying device 30 for powder coating. This allows the temperature of the stator 1A to decrease gradually over time, thus keeping the temperature of the copper wire, i.e., the temperature of the joints, high during powder coating. In order to suppress discoloration of the coil 2 and stator 1A due to heating, it is desirable to control the heating time and temperature of the heating furnace 20 appropriately.

[0025] Next, the stator manufacturing method using the stator manufacturing system 100-1 will be explained with reference to Figures 5 to 9.

[0026] Figure 5 is a flowchart illustrating the stator manufacturing method using the stator manufacturing system 100-1 according to the first embodiment of this disclosure, and Figures 6 to 9 are diagrams illustrating the stator manufacturing method using the stator manufacturing system 100-1 according to the first embodiment of this disclosure.

[0027] In step S1, the stator 1A is preheated in the heating furnace 20 for powder coating. In step S2, the shutter 22 rises and the stator 1A is transported outside the heating furnace 20 by the conveyor device 10. In step S3, as shown in Figure 6, the moving device 60 lowers the cover member 50-1 and places the cover member 50-1 over the stator 1A.

[0028] Subsequently, when it is time to perform powder coating in the powder tank 40, in step S4, as shown in Figure 7, the moving device 60 raises the cover member 50-1. After the cover member 50-1 has risen to a predetermined position, in step S5, the arm 32 of the conveying device 30, recognizing that the cover member 50-1 has been removed from the stator 1A, moves the chuck 31 closer to the stator 1A as shown in Figure 8, and the chuck 31 holds the stator 1A. In Figure 8, the chuck 31 holds the stator 1A after it has moved a certain amount (after it has moved from the position below the cover member 50-1), but the chuck 31 may also hold the stator 1A even if it has not moved since the cover member 50-1 was removed (while it is in the position below the cover member 50-1). In step S6, as shown in Figure 9, the arm 32 of the conveying device 30 conveys the stator 1A to the powder tank 40 by rotating, for example, while holding the stator 1A.

[0029] In step S7, for example, the joint portion of the stator 1A, which is gripped by the chuck 31 of the conveying device 30, is submerged in the powder tank 40, thereby forming an insulating coating on the joint portion. Then, in step S8, for example, the stator 1A, which is gripped by the chuck 31 of the conveying device 30, is raised out of the powder tank 40 and the stator 1A is conveyed to a predetermined location.

[0030] Figure 10 shows the temperature change of the stator 1A when the cover member 50-1 is not attached (normal solid line) and the temperature change of the stator 1A when the cover member 50-1 is attached until powder coating is performed as described above (thick solid line). In Figure 10, the vertical axis represents the temperature of a specific part of the stator 1A (e.g., the coil end), and the horizontal axis represents time. As a comparative example, when the cover member 50-1 is not attached, the temperature of the stator 1A drops significantly, and if it falls below the temperature required for powder coating, the powder may not adhere properly to the coil end, potentially degrading the coating quality. In contrast, when the cover member 50-1 according to this embodiment is attached, the temperature required for coating can be maintained for a sufficient amount of time compared to the comparative example.

[0031] In the first embodiment, an example was described in which the moving device 60 is provided integrally with the heating furnace 20. However, as shown in Figure 11, for example, the stator manufacturing system 100-1 may use a moving device 60A that is separate from the heating furnace 20. The moving device 60A may, for example, include a plurality of support members 61 that support the cover member 50-1, and an actuator (not shown) that drives the support members 61, similar to the moving device 60 described above.

[0032] For example, when the stator 1A, which has been heated in the heating furnace 20, is removed from the heating furnace 20, the shutter 22 rises and detects that the stator 1A has been removed to a predetermined position outside the heating furnace 20. At that time, the moving device 60A may, for example, lower the cover member 50-1 to cover the stator 1A at the same time as the shutter 22 descends. Also, after the cover member 50-1 has been placed over the stator 1A, when the timing for performing powder coating in the powder tank 40 is detected, the moving device 60A may remove the cover member 50-1 from the stator 1A by raising the cover member 50-1.

[0033] As described above, in the first embodiment, after the stator 1A is discharged from the heating furnace 20 and heated, the cover member 50-1 is placed over it, and then the cover member 50-2 is removed at the time of transport before the stator 1A is transported to the powder tank 40. This allows the heated coil 2 and other components to be isolated from the outside air during the waiting period after discharge from the heating furnace 20 until powder coating is started, and during robot handling. Therefore, even if the stator 1A is made smaller and the copper wire of the coil 2 used is thin, the temperature drop of the coil 2 can be slowed down. Consequently, the stator 1A can be efficiently mass-produced without having to reheat it until it reaches a temperature suitable for powder coating.

[0034] In particular, the joint portion requiring insulating coating is a part that protrudes from the stator 1A, and therefore has higher heat dissipation compared to the part of the coil 2 inserted into the stator 1A, making it prone to temperature drops. In this embodiment, by using the cover member 50-1, the temperature drop of the stator 1A, including the joint portion, can be suppressed, and powder coating of the joint portion can be performed efficiently.

[0035] For example, consider a case where multiple stators 1A are heated at a high temperature in a heating furnace 20, then each stator 1A is removed to the outside and then transported to a powder tank 40. In this case, depending on the time required for powder coating of the previous lot and the timing of discharge from the heating furnace 20, the heated stators 1A may remain outside the heating furnace 20. In this case, in the embodiment of the present disclosure, the temperature drop during the waiting time until powder coating can be suppressed by keeping the stators 1A warm with the cover member 50-1.

[0036] (Second Embodiment) Figure 12 shows an example configuration of a stator manufacturing system 100-2 according to the second embodiment of this disclosure. The difference from the stator manufacturing system 100-1 according to the first embodiment is that in the stator manufacturing system 100-2, a cover member 50-2 is used instead of the moving device 60 and the cover member 50-1.

[0037] As shown in Figure 13, the cover member 50-2 includes a first member 50a and a second member 50b that face the radially outer surface of the core, with the central axis AX of the stator 1A in between.

[0038] The first member 50a has a box shape that opens in the direction of the positive X axis. Specifically, the first member 50a is a box-shaped member with a bottom, having an opening 50a1 in the direction of the positive X axis, a bottom 50a2 in the direction of the negative X axis, and four side portions 50a3 extending in the direction of the positive X axis from the four sides of the bottom portion 50a2.

[0039] Of the four side portions 50a3, the tip of the chuck 31a is inserted into and fixed in the portion opposite the base portion 31c, which movably supports two of the chucks 31a and 31b.

[0040] The second member 50b has a box shape that opens in the direction of the negative X-axis. Specifically, the second member 50b is a bottomed box-shaped member in which an opening 50b1 is formed in the direction of the negative X-axis, a bottom 50b2 is formed in the direction of the positive X-axis, and four side portions 50b3 are formed extending in the direction of the negative X-axis from the four sides of the bottom portion 50b2.

[0041] Here, the first member 50a and the second member 50b are shown as examples of rectangular parallelepiped shapes, but this is merely one example. The first member 50a and the second member 50b only need to be able to form a sealed space inside that can accommodate the stator core 1A when they are integrated. For example, the first member 50a and the second member 50b may each be polygonal, semi-cylindrical, hemispherical, etc., and their sizes and shapes may differ.

[0042] Of the four side portions 50b3, the tip of the chuck 31b is inserted into and fixed to the portion facing the base portion 31c.

[0043] The base portion 31c may include, for example, an actuator that moves the two chucks 31a and 31b in the X-axis direction. The two chucks 31a and 31b and the base portion 31c may be interpreted as a moving device that moves the cover member 50-2 to cover the stator 1A heated in the heating furnace 20.

[0044] As the two chucks 31a and 31b move closer to each other, the stator 1A is gripped by the two chucks 31a and 31b, and as the first member 50a and the second member 50b move closer to each other, a box-like structure is formed around the stator 1A. This allows the stator 1A to be transported to the powder tank 40 while being gripped by the two chucks 31a and 31b, preventing a decrease in the temperature of the stator 1A.

[0045] Next, a stator manufacturing method using the stator manufacturing system 100-2 will be described with reference to Figures 14 to 16. Figure 14 is a flowchart illustrating the stator manufacturing method using the stator manufacturing system 100-2 according to the second embodiment of this disclosure, and Figures 15 and 16 are diagrams illustrating the stator manufacturing method using the stator manufacturing system 100-2 according to the second embodiment of this disclosure.

[0046] In step S11, the stator 1A is preheated in the heating furnace 20 for powder coating. In step S12, the shutter 22 rises and the stator 1A is transported out of the heating furnace 20 by the conveyor device 10. In step S13, the arm 32 of the transport device 30, which has detected that the stator 1A has been transported, moves the chuck 31 closer to the stator 1A. As shown in Figure 15, the two chucks 31a and 31b move closer to each other, thereby covering the stator 1A with the cover member 50-2 as shown in Figure 16.

[0047] Subsequently, when it is time to perform powder coating in the powder tank 40, in step S14, the arm 32 of the conveying device 30 rotates with the cover member 50-2 placed over the stator 1A, and conveys the stator 1A to the powder tank 40.

[0048] In step S15, for example, after transporting the stator 1A near the powder tank 40, the two chucks 31a and 31b move away from each other, releasing the stator 1A and removing the cover member 50-2 from the stator 1A. Then, in step S16, for example, a robot arm (not shown) grasps the stator 1A after the cover member 50-2 has been removed and submerges the joint portion of the stator 1A into the powder tank 40, thereby forming a resin portion at the joint. Then, in step S17, the robot arm raises the stator 1A from the powder tank 40 and transports the stator 1A to a predetermined location.

[0049] (Modified version of the second embodiment) The following describes a modified version of the stator manufacturing system 100-2.

[0050] Figures 17, 18, and 19 illustrate a first modified example of the stator manufacturing system 100-2 according to a second embodiment of the present disclosure. As shown in Figure 17, the cover member 50-21 according to the first modified example of the second embodiment includes an openable top cover 50a31 and a bottom cover 50a32 in place of the side portions 50a3 located in the positive Z-axis direction and the negative Z-axis direction among the four side portions 50a3. The second member 50b includes an top cover 50b31 and a bottom cover 50b32 in place of the side portions 50b3 located in the positive Z-axis direction and the negative Z-axis direction among the four side portions 50b3.

[0051] For example, when placing the cover member 50-21 over the stator 1A, depending on the size of the stator 1A, the lower cover 50a32 and lower cover 50b32 may interfere with the stator 1A. In this case, for example as shown in Figures 18 and 19, the cover member 50-21 can be placed over the stator 1A with the lower cover 50a32 and lower cover 50b32 open, and then the lower cover 50a32 and lower cover 50b32 can be closed to create a space that keeps the stator 1A warm. When the cover member 50-21 and the hand (chuck 31a and chuck 31b) move together and the hand grips the placed stator 1A, for example, the lower part of the cover member 50-21 can be prevented from interfering with the stator 1A by unfolding the lower cover 50a32 and lower cover 50b32 as shown in Figure 19 (folding them outwards from the cover member 50-21). In the example shown in Figure 19, both the upper cover 50b31 and the lower cover 50b32 are shown open. However, when gripping the stator 1A, only the lower cover 50a32 and the lower cover 50b32 may be opened. Also, when working with the stator 1A upside down (for example, powder coating the coil), only the upper cover 50a31 and the upper cover 50b31 may be opened.

[0052] Alternatively, for example, after the stator 1A is transported with the cover member 50-21 attached to it, gripped by the chucks 31a and 31b, as shown in Figures 18 and 19, only the top lids 50a31 and 50b31 may be opened, and the stator 1A may be gripped through the opening by another robot arm, such as one used for powder coating, and removed from the cover member 50-21. This allows the heated state of the stator 1A to be maintained for a longer period of time.

[0053] Figures 20 and 21 illustrate a second modification of the stator manufacturing system 100-2 according to the second embodiment of this disclosure. In the second modification of the second embodiment, a moving device 60B1 is provided on the chuck 31a and a moving device 60B2 is provided on the chuck 31b.

[0054] The moving device 60B1 extends, for example, from the end face of the chuck 31a in the negative X-axis direction and moves the first member 50a in the X-axis direction independently of the movement of the chuck 31a. The moving device 60B1 may include, for example, a support member that supports the first member 50a and an actuator that drives the support member.

[0055] The moving device 60B2 extends, for example, from the end face of the chuck 31b in the positive X-axis direction and moves the second member 50b in the X-axis direction independently of the movement of the chuck 31b. The moving device 60B2 may include, for example, a support member that supports the second member 50b and an actuator that drives the support member.

[0056] For example, when the cover member 50-21 is placed over the stator 1A, the moving devices 60B1 and 60B2 control the movement of the first member 50a and the second member 50b so that they move closer to each other. When the cover member 50-21 is removed from the stator 1A, the moving devices 60B1 and 60B2 control the movement of the first member 50a and the second member 50b so that they move further apart from each other.

[0057] For example, as shown in Figure 21, after gripping the heated stator 1A with the two chucks 31a and 31b, the cover member 50-21 can be placed over the stator 1A. After removing the cover member 50-21 from the stator 1A, the gripped stator 1A can be handed over to another conveying device, such as one for powder coating. This allows the heated state of the stator 1A to be maintained for a longer period until it is handed over to the other conveying device.

[0058] As described above, in the second embodiment, the stator 1A can be transported to the powder tank 40 with the cover members 50-2 and 50-21 placed over the heated stator 1A. This reduces the amount of outside air that comes into contact with the stator 1A when the arm 32 rotates, and suppresses the radiation of heat from the stator 1A to the outside air. Therefore, the cooling curve can be made even gentler, which can further improve the quality of the powder coating.

[0059] Furthermore, cover members 50-1 and 50-2 may be equipped with a heating section to heat the stator 1A in order to suppress the cooling of the stator 1A. The heating section may be, for example, an electric heater.

[0060] Furthermore, the cover members 50-1 and 50-2 may have an insulating structure. For example, insulating material may be added to all or part of the wall surfaces (bottom, side, etc.) that make up each of the cover members 50-1 and 50-2, or the wall surfaces may be made of an insulating material.

[0061] (Third embodiment) Figure 22 shows an example configuration of a stator manufacturing system 100-3 according to the third embodiment of this disclosure. The difference from the stator manufacturing system 100-1 according to the first embodiment is that in the stator manufacturing system 100-3, a cover member 50-3 is used instead of the moving device 60 and the cover member 50-1. In the stator manufacturing system 100-3, the cover member 50-3 is used to form a heat-insulating space (insulated room) provided at the outlet of the heating furnace, thereby suppressing a drop in the temperature of the stator 1A. The space formed by the cover member 50-3 is used as a heat-insulating space to prevent a drop in the temperature of the stator 1A before it is transported to the powder coating process. The inside of the cover member 50-3 may be maintained for a certain period of time with an electric heater, a gas burner, etc.

[0062] In the stator manufacturing system 100-3, a first shutter (shutter 22) is provided at the outlet of the heating furnace 20. Since the cover member 50-3 is provided so as to communicate with the opening opened and closed by the shutter 22, it can be interpreted that the shutter 22 is installed at the entrance of the cover member 50-3. Because the cover member 50-3 is provided in communication with the opening, the possibility of exposure to the outside air can be reduced. Since exposure to the outside air can be reduced as much as possible, the heat retention effect is enhanced. In addition, since the cover member 50-3 can be attached later, it is not necessary to modify the heating furnace 20 itself when forming a space that communicates with the opening. A second shutter (shutter 23) is provided at the outlet of the cover member 50-3 (the outlet of the stator 1A). The shutters 22 and 23 may open and close in conjunction with the position of the stator 1A being transported by the conveyor device 10, or they may open and close independently of the position of the stator 1A.

[0063] Next, the stator manufacturing method using the stator manufacturing system 100-3 will be explained with reference to Figures 23 to 28.

[0064] In step S21, the stator 1A for powder coating is preheated in the heating furnace 20. At this time, shutters 22 and 23 are closed. In step S22, as shown in Figure 24, shutter 22 rises and the outlet of the heating furnace 20 opens, and in step S23, as shown in Figure 25, the stator 1A is transported into the heat-insulating space (inside the cover member 50-3). After the stator 1A has been transported inside the cover member 50-3, in step S24, as shown in Figure 26, shutter 22 descends and closes. This isolates the stator 1A and prevents it from being affected by the outside air. Subsequently, when it is time to perform powder coating in the powder tank 40, in step S25, as shown in Figure 27, shutter 23 rises and the stator 1A is transported out of the cover member 50-3. In other words, the stator 1A is released from the cover member 50-3.

[0065] When the stator 1A moves to a predetermined position, in step S26, the arm 32 of the transport device 30, recognizing that the stator 1A has been transported outside the cover member 50-3, moves the chuck 31 closer to the stator 1A, as shown in Figure 28, and the chuck 31 holds the stator 1A. The subsequent operations from steps S27 to S29 are the same as those described in steps S6 to S8.

[0066] As described above, in the third embodiment, a fixed heat-insulating space can be formed using the cover member 50-3, and a mechanism can be constructed to prevent a temperature drop in the stator 1A. By providing a heat-insulating space between the heating furnace 20 and the powder coating process, and sealing the heat-insulating space using shutters 22 and 23, the temperature inside the space can be maintained, and a temperature drop in the stator 1A can be suppressed, thereby improving the quality of powder coating. Since a heat-insulating space can be easily added by replacing a part of the heating furnace 20 with the cover member 50-3, or by providing the cover member 50-3 to a part of the heating furnace 20, effects such as improved energy efficiency, system simplification, or increased productivity can be obtained.

[0067] The third embodiment of this disclosure may be combined with the second embodiment and its modifications. In this case, for example, as shown in Figure 28, the arm 32 of the transport device 30, upon recognizing that the stator 1A has been transported outside the cover member 50-3, approaches the stator 1A, and the two chucks 31a and 31b move closer to each other. As a result, the cover member 50-2 is placed over the stator 1A, as shown in Figure 16.

[0068] Furthermore, the first embodiment and its modifications of this disclosure may be combined with the second embodiment and its modifications. In this case, for example, as shown in Figure 8, the arm 32 of the transport device 30, upon recognizing that the stator 1A has been transported outside the cover member 50-1, approaches the stator 1A, and the two chucks 31a and 31b move closer to each other. As a result, the cover member 50-2 is placed over the stator 1A, as shown in Figure 16.

[0069] In the embodiments described above, an example was given in which a heating furnace 20 is used as the heating device, but this is merely one example, and an induction heating device or an electrostatic heating device may also be used.

[0070] The following additional information is disclosed regarding the above-described embodiments.

[0071] (Note 1) The stator, which includes the core and the coil provided on the core, is heated by a heating device. The cover member surrounding the stator isolates the stator after it has been discharged from the heating device, thereby keeping the stator warm. Stator manufacturing method. (Note 2) The stator manufacturing method according to Appendix 1, wherein the heated stator is isolated with the cover member, the cover member is removed, and then the stator is transported to an insulating coating process for the joint portion of the coil. (Note 3) A stator manufacturing method according to Appendix 1 or 2, wherein the cover member is placed over the stator in conjunction with the opening and closing mechanism of the heating device, and the cover member is removed when the stator is transported to the insulating coating process. (Note 4) The stator manufacturing method according to any one of the appendices 1 to 3, wherein the opening and closing mechanism is a shutter that opens and closes the outlet of the stator of the heating device in the vertical direction. (Note 5) A stator manufacturing method according to any one of the appendices 1 to 4, wherein when the shutter closes, a drive device linked to the shutter lowers the cover member. (Note 6) A stator manufacturing method according to any one of the appendices 1 to 5, wherein the cover member provided on a chuck of a hand that transports the stator is placed over the heated stator, and the hand transports the stator to an insulating coating process for the joint portion of the coil. (Note 7) The cover member includes a first member and a second member facing the radially outer surface of the stator, A method for manufacturing a stator according to any one of the appendices 1 to 6, wherein when the chuck grips the radially outer surface of the core, the first member and the second member move closer to each other so that the first member and the second member cover the periphery of the stator. (Note 8) The stator manufacturing method according to any one of the appendices 1 to 7, wherein the first member and the second member include lids for opening and closing the upper and lower parts of the first member and the second member, respectively. (Note 9) The stator manufacturing method according to any one of the appendices 1 to 8, wherein the first member and the second member cover the periphery of the stator in conjunction with the operation of the chuck. (Note 10) A stator manufacturing method according to any one of the appendices 1 to 9, wherein the first member and the second member operate independently of the operation of the chuck to cover the periphery of the stator. (Note 11) The stator manufacturing method according to any one of appendices 1 to 10, wherein the cover member is formed in a box shape. (Note 12) The stator manufacturing method according to any one of the appendices 1 to 11, wherein the cover member includes a heating section for heating the stator. (Note 13) A stator manufacturing method according to any one of the appendices 1 to 12, wherein the heated stator is isolated with the cover member, and the stator, released from the cover member, is transported to an insulating coating process for the joint portion of the coil. (Note 14) A stator manufacturing method according to any one of the appendices 1 to 13, wherein after opening a shutter that opens and closes the outlet for the stator of the heating device, the stator discharged from the heating device is isolated with the cover member. (Note 15) A stator manufacturing method according to any one of the appendices 1 to 14, wherein when the stator is transported to the insulating coating process, a shutter that opens and closes the outlet of the cover member in the vertical direction is opened, and then the stator is transported out of the cover member. (Note 16) The stator manufacturing method according to any one of the appendices 1 to 15, wherein the cover member is in communication with the discharge port of the heating device. (Note 17) A heating device for heating a stator including a core and a coil provided on the core, A cover member that surrounds the stator, the cover member that isolates the stator after it has been removed from the heating device, A conveying device for transporting the stator, which has been released from the cover member, to a powder tank in which powder coating is flowing, A stator manufacturing system, including a stator manufacturing system. [Explanation of Symbols]

[0072] 1 core 1a slot 1A Stator 2 coils 2a Tip 10 Conveyor device 20 Furnace 21, 22, 23 Shutter 30 Conveying device 31, 31a, 31b Chuck 31c Base 32 Arms 40 Powder tank 41 Powder coating 50-1, 50-2, 50-21, 50-3 Cover components 50a First member 50a1 opening 50a2 bottom 50a3 side part 50a31 Top lid 50a32 Lower lid 50b Second Member 50b1 opening 50b2 bottom 50b3 Side part 50b31 Top lid 50b32 Lower lid 60, 60A, 60B1, 60B2 Mobile device 61 Support member 100-1, 100-2, 100-3 Stator Manufacturing System AX center axis AXD Axial direction CD circumferential direction RD radial direction

Claims

1. The stator, which includes the core and the coil provided on the core, is heated by a heating device. The cover member surrounding the stator isolates the stator after it has been discharged from the heating device, thereby keeping the stator warm. Stator manufacturing method.

2. A method for manufacturing a stator according to claim 1, wherein the heated stator is isolated with the cover member, the cover member is removed, and then the stator is transported to an insulating coating process for the joint portion of the coil.

3. The method for manufacturing a stator according to claim 2, wherein the cover member is placed over the stator in conjunction with the opening and closing mechanism of the heating device, and the cover member is removed when the stator is transported to the insulating coating process.

4. The method for manufacturing a stator according to claim 3, wherein the opening and closing mechanism is a shutter that opens and closes the outlet of the stator of the heating device in the vertical direction.

5. The stator manufacturing method according to claim 4, wherein when the shutter closes, a drive device linked to the shutter lowers the cover member.

6. The method for manufacturing a stator according to claim 1, wherein the cover member provided on a chuck of the hand that transports the stator is placed over the heated stator, and the hand transports the stator to an insulating coating process for the joint portion of the coil.

7. The cover member includes a first member and a second member facing the radially outer surface of the stator, The stator manufacturing method according to claim 6, wherein when the chuck grips the radially outer surface of the core, the first member and the second member move closer to each other so that the first member and the second member cover the periphery of the stator.

8. The method for manufacturing a stator according to claim 7, wherein the first member and the second member include lids for opening and closing the upper and lower parts of the first member and the second member, respectively.

9. The stator manufacturing method according to claim 7, wherein the first member and the second member cover the periphery of the stator in conjunction with the operation of the chuck.

10. The method for manufacturing a stator according to claim 7, wherein the first member and the second member operate independently of the operation of the chuck to cover the periphery of the stator.

11. The stator manufacturing method according to claim 1, wherein the cover member is formed in a box shape.

12. The stator manufacturing method according to claim 1, wherein the cover member includes a heating section for heating the stator.

13. A method for manufacturing a stator according to claim 1, wherein the heated stator is isolated by the cover member, and the stator, which has been released from the cover member, is transported to an insulating coating process for the joint portion of the coil.

14. The method for manufacturing a stator according to claim 13, wherein after opening the shutter that opens and closes the outlet for the stator of the heating device, the stator discharged from the heating device is isolated with the cover member.

15. The method for manufacturing a stator according to claim 14, wherein when the stator is transported to the insulating coating process, the shutter that opens and closes the outlet of the cover member is opened, and then the stator is transported out of the cover member.

16. The stator manufacturing method according to claim 13, wherein the cover member is in communication with the discharge port of the heating device.

17. A heating device for heating a stator including a core and a coil provided on the core, A cover member that surrounds the stator, the cover member that isolates the stator after it has been removed from the heating device, A conveying device for transporting the stator, which has been released from the cover member, to a powder tank in which powder coating is flowing, A stator manufacturing system, including a stator manufacturing system.

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