Stator manufacturing method and device

Abstract

Provided is a manufacturing method for a stator that can easily form a power line by bending a coil end portion. The manufacturing method for a stator 1 includes bending a first coil end portion 9Aa at the outermost periphery among a plurality of coil end portions 9 of a segment coil 7 held in a stator core 3 to form a power line 11, bending a second coil end portion 9b adjacent to the inside of the first coil end portion 9Aa in the radial direction of the stator core 3 so that a base end portion 10b is inclined radially outward and a tip portion 10a is aligned in the axial direction, and the first coil end portion 9Aa is held in a tilted state along the inclination of the base end portion 10b of the second coil end portion 9b, and the tip portion 10a of the inclined first coil end portion 9Aa is grasped and displaced to bend the first coil end portion 9Aa to form the power line 11.

Description

[Technical field]

[0001] The present invention relates to a manufacturing method and apparatus for a stator in which the coil end portions of segment coils held in a stator core are bent to form power lines. [Background technology]

[0002] Conventional methods for manufacturing a stator include one that uses a plurality of deformation jigs, as described in Patent Document 1, for example.

[0003] In this manufacturing method, a base is first placed on the outside of the coil end portion (power line), which will be the power line. Next, a blade is driven between the power line and the adjacent coil end portion, and the power line is tilted outward with the base as a fulcrum.

[0004] A block-shaped first deformation jig is inserted between the inclined power line and the adjacent coil end portion, and the first deformation jig is moved radially outward while the power line is sandwiched between the first deformation jig and the base.

[0005] Thereafter, a second deformation jig, which is made of a roller arranged on the outside of the base, is moved parallel to the adjacent coil end portion to bend the tip portion of the power line along the axial direction.

[0006] This manufacturing method can reliably bend the power line into a crank shape, but it requires controlling the blade and the first and second deformation jigs in coordination, making the formation of the power line by bending the coil end portion complicated. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent No. 6269514 Summary of the Invention [Problem to be solved by the invention]

[0008] The problem to be solved is that the formation of the power lines by bending the coil end portions is complicated. [Means for solving the problem]

[0009] The present invention relates to a segment coil held in a stator core. Arranged along the radial direction The present invention provides a method for manufacturing a stator in which a first coil end portion at the outermost periphery among a plurality of coil end portions is bent to form a power line. The manufacturing method includes the steps of: The above A second coil end portion adjacent to the inside of the first coil end portion in the radial direction Together with the first coil end portion Inclined radially outward The second coil end The tip is aligned along the axial direction. The second coil end Bend and separating the inclined tip of the first coil end portion from the tip of the second coil end. , the above Separated The tip of the first coil end portion is grasped and displaced, thereby bending the first coil end portion to form the power line.

[0010] The present invention also provides a manufacturing device for a stator in which a first coil end portion at the outermost periphery among a plurality of coil end portions of a segment coil held by a stator core is bent to form a power line. The manufacturing device includes a tooth that can be inserted between adjacent coil end portions, a pusher that can move in a direction intersecting the insertion direction relative to the tooth inserted between the coil end portions, a gripping portion that can grip a tip end of the first coil end portion, and a controller that controls the tooth, the pusher, and the gripping portion. The tooth is inserted in the axial direction between the coil end portions that are radially inner than a second coil end portion adjacent to the inner side of the first coil end portion in the radial direction of the stator core, so that the first coil end portion and the second coil end portion are inclined from a state along the axial direction, the tip end of the second coil end portion is pressed against the tooth by the pusher, the tip end of the second coil end portion is aligned with the axial direction, and the gripping portion that grips the inclined tip end of the first coil end portion is displaced to bend the first coil end portion to form the power line. Effect of the Invention

[0011] According to the present invention, the power lines can be easily formed by bending the coil end portions. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a schematic perspective view showing a stator according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is an enlarged cross-sectional view partially showing the stator of FIG. [Diagram 3] FIG. 3 is a side view showing the manufacturing apparatus of the stator according to the first embodiment. [Figure 4] FIG. 4 is an enlarged side view showing a state before bending the coil end portion of a slot without a power line in accordance with the manufacturing method of the stator of the first embodiment. [Diagram 5]FIG. 5 is an enlarged side view showing a state at the start of bending the coil end portion of a slot without a power line, in accordance with the manufacturing method of the stator of the first embodiment. [Figure 6] FIG. 6 is an enlarged side view showing a portion of FIG. [Figure 7] FIG. 7 is an enlarged side view showing an inclined state of a bending jig with respect to a coil end portion of a slot having no power line, in accordance with the manufacturing method of the stator of the first embodiment. [Figure 8] FIG. 8 is an enlarged side view showing a portion of FIG. [Figure 9] FIG. 9 is an enlarged side view showing a state in which a coil end portion of a slot having no power lines is being bent in the manufacturing method of the stator according to the first embodiment. [Figure 10] FIG. 10 is an enlarged side view showing a portion of FIG. [Figure 11] FIG. 11 is an enlarged side view showing a state after bending of a coil end portion of a slot having no power line is completed in accordance with the manufacturing method of the stator according to the first embodiment. [Figure 12] FIG. 12 is an enlarged side view showing a portion of FIG. [Figure 13] FIG. 13 is an enlarged side view showing a state at the start of bending the coil end portion of a slot containing a power line, in accordance with the manufacturing method of the stator of the first embodiment. [Figure 14] FIG. 14 is an enlarged side view showing a state in which a coil end portion of a slot carrying a power line is being bent in the manufacturing method of the stator according to the first embodiment. [Figure 15] FIG. 15 is an enlarged side view showing a portion of FIG. [Figure 16] FIG. 16 is an enlarged side view showing a state where bending of a coil end portion other than the power lines in a slot with a power line is completed in accordance with the manufacturing method of the stator of the first embodiment. [Figure 17] FIG. 17 is an enlarged side view showing a portion of FIG. [Figure 18] FIG. 18 is an enlarged side view showing a state before the power lines are bent in the manufacturing method of the stator according to the first embodiment. [Figure 19] FIG. 19 is an enlarged side view showing a portion of FIG. [Figure 20] FIG. 20 is an enlarged side view showing a state at the start of bending the power line in accordance with the manufacturing method of the stator of the first embodiment. [Figure 21] FIG. 21 is an enlarged side view showing a portion of FIG. [Figure 22] FIG. 22 is an enlarged side view showing a state where bending of the power lines is completed in the manufacturing method of the stator according to the first embodiment. [Diagram 23] FIG. 23 is a front view showing a bending jig of the stator manufacturing apparatus according to the second embodiment. [Figure 24] FIG. 24 is a rear view showing the bending jig of FIG. [Diagram 25] FIG. 25 is a side view showing the bending jig of FIG. [Figure 26] FIG. 26 is a front view showing a bending jig of a stator manufacturing apparatus according to a modified example of the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The objective of easily forming a power line by bending the coil end portion is achieved by tilting the first coil end portion in accordance with the inclination of the base end portion associated with the bending of the adjacent second coil end portion, and by grasping the tip end portion of the tilted first coil end portion and bending it.

[0014] As shown in the figure, the manufacturing method of the stator 1 includes bending the outermost first coil end portion 9Aa of the multiple coil end portions 9 of the segment coil 7 held by the stator core 3 to form the power line 11.

[0015] In this manufacturing method, the second coil end portion 9b adjacent to the inside of the first coil end portion 9Aa in the radial direction of the stator core 3 is bent so that the base end portion 10b is inclined radially outward and the tip end portion 10a is aligned along the axial direction. The first coil end portion 9Aa is held in an inclined state along the inclination of the base end portion 10b of the second coil end portion 9b. The tip end portion 10a of the inclined first coil end portion 9Aa is then grasped and displaced to bend the first coil end portion 9Aa into the power line 11.

[0016] In this manufacturing method, any suitable technique can be used to grip the tip end 10a of the inclined first coil end portion 9Aa. In one embodiment, the tip end 10a of the inclined first coil end portion 9Aa is positioned and gripped between a pair of walls 25a and 29. One of the pair of walls 29 is positioned between the first coil end portion 9Aa and the second coil end portion 9b, and the first coil end portion 9Aa is pressed against a curved surface 29a provided at the tip of one of the pair of walls 29, thereby bending the first coil end portion 9Aa.

[0017] The second coil end portion 9b can be bent by any suitable method, but in one embodiment, teeth 25a and pusher 21 may be used. In this case, teeth 25a are inserted in the axial direction between adjacent coil end portions 9 radially inward from second coil end portion 9b, and first coil end portion 25a is tilted from the axial direction together with second coil end portion 9b. Then, tip portion 10a of second coil end portion 9b is pressed against teeth 25a by pusher 21 to align with the axial direction.

[0018] Before being bent, the first coil end portion 9Aa may be axially shorter than the second coil end portion 9b, and the pusher 21 may press the second coil end portion 9b against the teeth 25a within the range that protrudes axially from the first coil end portion 9Aa.

[0019] The manufacturing device 15 for the stator 1 includes the teeth 25a, a pusher 21, a gripping unit 27, and a controller 31. The teeth 25a are members that can be inserted between adjacent coil end portions 9. The pusher 21 is configured to be movable in a direction intersecting the insertion direction with respect to the teeth 25a inserted between the coil end portions 9. The gripping unit 27 is configured to be able to grip the tip portion 10a of the first coil end portion 9Aa. The controller 31 controls the teeth 25a, the pusher 21, and the gripping unit 27.

[0020] The controller 31 inserts the teeth 25a in the axial direction between the coil end portions 9 radially inside the second coil end portion 9b adjacent to the inside of the first coil end portion 9Aa in the radial direction of the stator core 3, and tilts the first coil end portion 9Aa together with the second coil end portion 9b from a state along the axial direction. The controller 31 also presses the tip portion 10a of the second coil end portion 9b against the teeth 25a using the pusher 21, and aligns the tip portion 10a of the second coil end portion 9b in the axial direction. The controller 31 then displaces the gripping portion 27 gripping the tip portion 10a of the tilted first coil end portion 9Aa, thereby bending the first coil end portion 9Aa to form the power line 11.

[0021] The gripping portion 27 may include a pair of walls 25a and 29 that position the tip 10a of the inclined first coil end portion 9Aa between them and grip the tip 10a, and a curved surface 29a that is provided at the tip of one of the pair of walls 25a and 29 that is located between the first coil end portion 9Aa and the second coil end portion 9b when gripping, and is pressed against the first coil end portion 9Aa to bend it.

[0022] The teeth 25 a and the gripper 27 may be arranged on a folding fixture 19 that is displaceable by a robotic manipulator 17 . EXAMPLES

[0023] [Stator] Fig. 1 is a schematic perspective view showing a stator according to a first embodiment of the present invention, and Fig. 2 is an enlarged cross-sectional view showing a part of the stator in Fig. 1.

[0024] 1 and 2 constitute a rotating electric machine together with a rotor (not shown). The rotating electric machine is constituted, for example, as a three-phase (U-phase, V-phase, W-phase) eight-pole AC permanent magnet synchronous motor that drives the drive wheels of an electric vehicle (not shown) and generates electricity by the regenerative braking force from the drive wheels.

[0025] 1 and 2 show the state in which the stator coil 5 is assembled into the stator core 3. In the state shown in FIG. 1, the tip end 10a of the coil end portion 9 of each segment coil 7 constituting the stator coil 5 is aligned along the axial direction. The axial direction refers to the axial direction of the stator core 3.

[0026] 1, the coil end portions 9 are bent in the circumferential direction and then joined by welding to form the stator coil 5. Thereafter, terminals 8a of the coil end portions 9 are coated with insulating paint, and the stator coil 5 is sealed with resin to form the stator 1 for the rotating electric machine. In the following explanation, for convenience, the one shown in FIG. 1 will be described as the stator 1.

[0027] As described above, the stator 1 includes the stator core 3 and the stator coil 5. The stator core 3 is formed, for example, by laminating a plurality of annular electromagnetic steel plates. The stator core 3 includes a plurality of slots 3a at equal intervals in the circumferential direction.

[0028] The stator coil 5 is provided on the stator core 3 for three phases and configured to have a wave-wound shape. The stator coil 5 is configured with a plurality of segment coils 7.

[0029] Each segment coil 7 is, for example, a rectangular wire having a rectangular cross section formed into a U-shape, for example, a hairpin shape. The cross-sectional shape of the segment coil 7 is not particularly limited. The multiple segment coils 7 are combined with the stator core 3 in the circumferential direction.

[0030] Each segment coil 7 has its legs 8, including terminals 8a without an insulating layer, inserted into slots 3a of the stator core 3. This allows the segment coil 7 to be held in the stator core 3. The insulating layer is formed on the entire portion of the segment coil 7 except for the terminals 8a.

[0031] The leg 8 of the segment coil 7 penetrates the stator core 3. As a result, the coil end portion 9 of the leg 8, including the terminal 8a, protrudes in the axial direction from the stator core 3. Note that Figs. 1 and 2 show a state in which the leg 8 of the segment coil 7 is pushed into the stator core 3 from below and protrudes upward. Protrusion here means that the tip and base ends of the coil end portion 9 are misaligned in the axial direction.

[0032] The coil end portions 9 are arranged in a row in the radial direction within each slot 3a. In this embodiment, according to the phase of the stator coil 5, the first coil end portion 9a on the outermost periphery to the sixth coil end portion 9f on the innermost periphery are positioned within the slot 3a.

[0033] Note that the first coil end portion 9a (and the first coil end portion 9Aa described below) to the innermost sixth coil end portion 9f refer to the coil end portions 9 within the same slot 3a, and are used specifically to identify the coil end portions 9 within each slot 3a.

[0034] In the slot 3a having the power line 11, the power line 11 is formed by bending the first coil end portion 9Aa for the power line, and the second coil end portion 9b to the sixth coil end portion 9f are positioned together with the power line 11 within the slot 3a.

[0035] A radial gap 13 is formed between the tip ends 10a of the coil end portions 9 of adjacent layers. This gap 13 makes it easier to bend the coil end portions 9 in the circumferential direction.

[0036] To form the gaps 13, the first to fourth coil end portions 9a to 9d each include a tip portion 10a along the axial direction and a base portion 10b inclined relative to the axial direction (see FIG. 12). The base portion 10b is inclined so as to be gradually biased radially outward toward the tip portion 10a.

[0037] Here, the tip portion 10a refers to the portion that ultimately follows the axial direction. The tip portion 10a does not need to be strictly aligned with the axial direction, and may be slightly inclined. The base portion 10b refers to the portion located on the stator core 3 side of the tip portion 10a. When the tip portion 10a is slightly inclined with respect to the axial direction, the inclination of the base portion 10b refers to the inclination of the base portion 10b relative to the tip portion 10a, which is more inclined than the tip portion 10a.

[0038] The power line 11 has a shape bent into a crank shape. The power line 11 includes a tip end 11a along the axial direction and a base end 11b inclined with respect to the axial direction. The base end 11b is inclined so as to be gradually biased radially outward toward the tip end 11a. The inclination angle of the base end 11b with respect to the axial direction is greater than the inclination angles of the base ends 10b of the first to fourth coil end portions 9a to 9d with respect to the axial direction.

[0039] [Stator manufacturing device and method] FIG. 3 is a side view showing the manufacturing apparatus of the stator according to the first embodiment.

[0040] In this embodiment, the stator 1 is manufactured using a manufacturing apparatus 15 for the stator 1 shown in Fig. 3. The manufacturing apparatus 15 includes a robot manipulator 17, a bending jig 19, a clamp 20, a pusher 21, and a controller 31.

[0041] The robot manipulator 17 is, for example, a six-axis vertical articulated robot. A bending jig 19 serving as an end effector is attached to the end of the robot manipulator 17. Although only one robot manipulator 17 is shown in FIG. 3, the present invention is not limited to this, and multiple robot manipulators 17 may be provided in the circumferential direction of the stator 1.

[0042] The bending jig 19 is used to form the gaps 13 between the coil end portions 9 of adjacent layers and to form the power lines 11. Note that the formation of the gaps 13 and the formation of the power lines 11 may be performed separately using different jigs, etc.

[0043] The bending jig 19 includes a main body 23, comb teeth 25, and a gripping portion 27. The main body 23 is, for example, a plate made of metal. The comb teeth 25 and the gripping portion 27 are provided on one side surface 23a of the main body 23.

[0044] The comb teeth 25 include a plurality of teeth, three teeth 25a, 25b, and 25c in this embodiment, arranged at intervals in the axial direction of the sixth axis A6 of the robot manipulator 17. The teeth 25a, 25b, and 25c are formed in a plate shape.

[0045] The teeth 25a, 25b, and 25c extend in a direction away from the sixth axis A6, and have a single-edged pointed tip. The teeth 25a, 25b, and 25c are arranged along the axial direction of the stator core 3, and the inclined surface of the single-edged surface faces radially outward with the arrangement direction coinciding with the radial direction of the stator 1 in which the coil end portions 9 are arranged within the slots 3a. In this state, the teeth 25a, 25b, and 25c are successively shorter in the axial direction from the radially inner tooth 25c to the outer tooth 25a.

[0046] The clamp 20 is formed into a plate shape, for example, from metal, and holds the base end of the coil end portion 9 in the slot 3a from inside and outside in the radial direction. This holding protects the insulating paper 22 between the slot 3a and the coil end portion 9 and also forms the starting point for bending the coil end portion 9.

[0047] The pusher 21 is columnar and made of resin etc. The pusher 21 is movable toward and away from the teeth 25a on the outside in the direction along the sixth axis A6 of the robot manipulator 17.

[0048] The movement direction of the pusher 21 is the radial direction, which is perpendicular to the axial direction, which is the direction in which the teeth 25a are inserted between the coil end portions 9. However, the movement direction of the pusher 21 may be a direction inclined with respect to the radial direction and the sixth axis A6. The movement of the pusher 21 may be performed by an appropriate actuator such as a linear actuator. The pusher 21 can be supported by the robot manipulator 17 or another member.

[0049] The gripping portion 27 is capable of gripping the tip portion 10a of the first coil end portion 9Aa for the power line 11. The gripping portion 27 of this embodiment has a pair of walls, that is, teeth 25c and a wall portion 29. In this embodiment, the teeth 25c are used as one of the walls, but a separate wall portion may be provided.

[0050] The wall portion 29 is aligned with the tooth 25c at a distance in the axial direction of the sixth axis A6. The gripper 27 is configured to grip the tip portion 10a of the first coil end 9Aa by inserting it between the tooth 25c and the wall portion 29. However, the gripper 27 may be configured by a robot hand or the like. The wall portion 29 has a curved surface 29a at the corner where the tip portion facing away from the sixth axis A6 faces the tooth 25c (see FIG. 6).

[0051] The controller 31 is composed of a computer having a processor, a memory, etc. In Fig. 3, the controller 31 is only conceptually shown. The controller 31 controls the bending jig 19, i.e., the teeth 25a, 25b, and 25c and the gripper 27 through the robot manipulator 17, and also controls the pusher 21. Through this control, the manufacturing method of the stator 1 is realized.

[0052] Hereinafter, a method for manufacturing the stator 1 will be described with reference to the control of the manufacturing apparatus 15 by the controller 31.

[0053] In the manufacturing method of the stator 1, inter-layer expansion is performed. Inter-layer expansion is performed by expanding the gap between the coil end portions 9 of adjacent layers in the slot 3a to form a gap 13, as shown in Figures 1 and 2. Inter-layer expansion is performed for both the slots 3a without the power lines 11 and the slots 3a with the power lines 11.

[0054] In slots 3a without power lines 11, the coil end portions 9 are bent except for the innermost layer in the radial direction of the stator core 3. It is also possible to bend the coil end portions 9 of the innermost layer as well. The coil end portions 9 are bent so that the base ends 10b of the coil end portions 9 are inclined radially outward and the tip ends 10a are aligned in the axial direction.

[0055] FIG. 4 is an enlarged side view showing a state before bending the coil end portion of a slot without a power line in accordance with the manufacturing method of the stator of the first embodiment.

[0056] 3 and 4, in this embodiment, the stator 1 is first held in a predetermined position and the axial direction of the stator core 3 is arranged along the vertical direction. At this time, the base ends of the first coil end 9a to the sixth coil end 9f are gripped by the clamps 20. Note that before bending, the first coil end 9a to the sixth coil end 9f are aligned along the axial direction as a whole, and the axial length gradually shortens from the first coil end 9a to the sixth coil end 9f within each slot 3a.

[0057] In the portion where the power line 11 is formed, the axial length of the first coil end 9Aa is the shortest, and the axial length of the remaining coil ends, from the second coil end 9b to the sixth coil end 9f, gradually becomes shorter in the same manner as described above (see Figure 3).

[0058] A bending jig 19 is positioned above the stator 1 by a robot manipulator 17. At this time, the teeth 25a, 25b, and 25c of the comb teeth 25 of the bending jig 19 are aligned along the axial direction, and the inclined surface of one edge faces outward in the radial direction of the stator core 3.

[0059] The tips of teeth 25a, 25b, and 25c of comb tooth 25 are arranged to radially face coil end portions 9 located radially inward of each layer, in this embodiment, second, fourth, and sixth coil end portions 9b, 9d, and 9f, respectively. This arrangement is made based on the difference in axial length between teeth 25a, 25b, and 25c and the difference in axial length between coil end portions 9.

[0060] Fig. 5 is an enlarged side view showing a state at the start of bending the coil end portion of a slot without a power line, and Fig. 6 is an enlarged side view showing a part of Fig. 5.

[0061] 5 and 6, the bending jig 19 is moved in the radial direction by the robot manipulator 17. As a result, the tips of the teeth 25a, 25b, and 25c of the comb teeth 25 are brought into radial contact with the opposing coil end portions 9 (the second, fourth, and sixth coil end portions 9b, 9d, and 9f), respectively.

[0062] As a result, the tips of teeth 25a, 25b, and 25c of comb tooth 25 are positioned between the coil end portions 9 of adjacent layers. Specifically, tooth 25a is positioned between the second and third coil end portions 9b and 9c, and tooth 25b is positioned between the fourth and fifth coil end portions 9d and 9e. In addition, tooth 25c is positioned radially inward of sixth coil end portion 9f.

[0063] Fig. 7 is an enlarged side view showing the inclination of the bending jig with respect to the coil end portion of a slot without a power line, and Fig. 8 is an enlarged side view showing a part of Fig. 7.

[0064] 7 and 8, the bending jig 19 is further moved in the axial direction toward the stator core 3 by the robot manipulator 17. As a result, the teeth 25a and 25b of the comb teeth 25 are inserted between the coil end portions 9 of adjacent layers, that is, between the second and third coil end portions 9b and 9c, and between the fourth and fifth coil end portions 9d and 9e.

[0065] During this insertion, the bending jig 19 is tilted around an axis perpendicular to the radial direction of the stator core 3, which is the arrangement direction of the teeth 25a, 25b, and 25c, and the axial direction of the stator core 3, in this embodiment, around the fifth axis A5 of the robot manipulator 17. As a result, the teeth 25a, 25b, and 25c of the comb teeth 25 are tilted. Therefore, the tips of the teeth 25a, 25b, and 25c of the comb teeth 25 are not in contact with the insulating layer of the coil end portion 9.

[0066] Fig. 9 is an enlarged side view showing a state in which the coil end portion of a slot without a power line is being bent. Fig. 10 is an enlarged side view showing a part of Fig. 9. Fig. 11 is an enlarged side view showing a state when the bending of the coil end portion is completed. Fig. 12 is an enlarged side view showing a part of Fig. 11.

[0067] As shown in Figs. 9 and 10, in the process of inserting the teeth 25a, 25b, and 25c, the bending jig 19 is displaced by the robot manipulator 17 so that the teeth 25a, 25b, and 25c are again aligned along the axial direction.

[0068] When the teeth 25a, 25b, and 25c of the comb teeth 25 are fully inserted, the third and fourth coil end portions 9c and 9d are bent between the teeth 25a and 25b, and the fifth and sixth coil end portions 9e and 9f are accommodated between the teeth 25b and 25c without being bent. As a result, the third and fourth coil end portions 9c and 9d are in a state where the base ends 10b are inclined radially outward and the tip ends 10a are aligned along the axial direction.

[0069] On the other hand, the first and second coil end portions 9a and 9b, which are the outermost layers, are inclined overall because there are no teeth of the comb teeth 25 on the radially outer side. The inclined tip portions 10a of the first and second coil end portions 9a and 9b are pressed against the teeth 25a from the radially outer side by a pusher 21, as shown in Figures 11 and 12. As a result, the base ends 10b of the tip portions 10a of the first and second coil end portions 9a and 9b also incline radially outward, and the tip portions 10a are aligned in the axial direction.

[0070] Thereafter, the pusher 21 is removed from the tip portions 10a of the first and second coil end portions 9a and 9b, and the bending jig 19 is raised by the robot manipulator 17. This causes the teeth 25a and 25b of the comb teeth 25 to be pulled out from between the coil end portions 9 of the adjacent layers. This completes the spacing expansion in the slots 3a where there are no power lines 11.

[0071] On the other hand, in the slot 3a where the power line 11 is located, the interlayer expansion is also performed by bending the coil end portion 9 so that the base end portion 10b of the coil end portion 9 is inclined radially outward and the tip end portion 10a is aligned in the axial direction, as shown in Figures 1 and 2.

[0072] FIG. 13 is an enlarged side view showing the state at the start of bending the coil end portion of a slot containing a power line.

[0073] 13, similarly to slot 3a without power line 11, bending jig 19 is moved axially and radially by robot manipulator 17. As a result, teeth 25a and 25b of comb teeth 25 are inserted between coil end portions 9 of adjacent layers, that is, between second and third coil end portions 9b and 9c, and between fourth and fifth coil end portions 9d and 9e.

[0074] During this insertion, the comb teeth 25 are also inclined, so that the tips of the teeth 25a, 25b, and 25c of the comb teeth 25 are not in contact with the insulating layer of the coil end portion 9, similarly to FIG.

[0075] Fig. 14 is an enlarged side view showing a state in which the coil end portion of a slot containing a power line is being bent, and Fig. 15 is an enlarged side view showing a part of Fig. 14.

[0076] When the teeth 25a and 25b of the comb teeth 25 are fully inserted, the third and fourth coil end portions 9c and 9d are bent between the teeth 25a and 25b, and the fifth and sixth coil end portions 9e and 9f are accommodated between the teeth 25b and 25c without being bent, as shown in Figures 14 and 15. Meanwhile, the first and second coil end portions 9Aa and 9b, which are the outermost layers, are inclined as a whole.

[0077] As a result, in this embodiment, the teeth 25a are inserted axially between adjacent coil end portions 9 radially inward from the second coil end portion 9b, thereby tilting the first coil end portion 9Aa together with the second coil end portion 9b from its axially aligned state.

[0078] Depending on the configuration of the stator coil 5, the teeth 25a of the comb teeth 25 may be omitted and the first and second coil end portions 9a and 9b may be inclined together with the third and fourth coil end portions 9c and 9d by the teeth 25b. In other words, the space between adjacent coil end portions 9 radially inward from the second coil end portion 9b may not only be between the second and third coil end portions 9b and 9c, but may also be between other coil end portions 9, for example, between the fourth and fifth coil end portions 9d and 9e.

[0079] Fig. 16 is an enlarged side view showing a state when bending of the coil end portion other than the power line in the slot where the power line is present is completed. Fig. 17 is an enlarged side view showing a part of Fig. 16.

[0080] As shown in Figs. 16 and 17, of the inclined first and second coil end portions 9a and 9b, a tip portion 10a of the second coil end portion 9b is pressed against teeth 25a from the radially outer side by a pusher 21.

[0081] This pressing is performed at a position where the pusher 21 does not come into contact with the first coil end portion 9Aa. In this embodiment, the pusher 21 presses the second coil end portion 9b against the teeth 25a within the range that protrudes axially from the first coil end portion 9Aa. As long as the pusher 21 is within this range, its axial position can be fixed between the slots 3a with the power line 11 and the slots 3a without the power line 11.

[0082] This pressing causes the base end 10b of the second coil end portion 9b to be bent so that the base end 10b is inclined radially outward and the tip end 10a is bent along the axial direction. Meanwhile, the first coil end portion 9Aa abuts against the base end 10b of the second coil end portion 9b and is held in an inclined state following the inclination of the base end 10b.

[0083] In this way, the first coil end portion 9Aa is separated from the second coil end portion 9b. This separation can be achieved by the same inter-layer expansion as in the slot 3a where no power line 11 is present, as described above.

[0084] Thereafter, the pusher 21 is moved away from the tip 10a of the second coil end portion 9b, and the bending jig 19 is raised by the robot manipulator 17, whereby the teeth 25a and 25b of the comb teeth 25 are pulled out from between the coil end portions 9 of adjacent layers.

[0085] Next, the tip end 10a of the inclined first coil end portion 9Aa is grasped and displaced, so that the first coil end portion 9Aa is bent to form the power line 11.

[0086] Fig. 18 is an enlarged side view showing a state before the power line is bent, and Fig. 19 is an enlarged side view showing a part of Fig. 18.

[0087] 18 and 19, in this embodiment, the bending jig 19 is positioned radially outward of the group of coil end portions 9 by the robot manipulator 17. At this time, the bending jig 19 is tilted so that the pair of wall portions, the teeth 25c and the wall portion 29, match the inclination of the tip portion 10a of the first coil end portion 9Aa. This causes the space between the teeth 25c and the wall portion 29 to be oriented toward the tip portion 10a of the first coil end portion 9Aa. This inclination can be performed by rotating the robot manipulator 17 about the fifth axis A5, similar to when tilting the comb teeth 25.

[0088] Fig. 20 is an enlarged side view showing a state at the start of bending the power line, and Fig. 21 is an enlarged side view showing a part of Fig. 20.

[0089] With the teeth 25c and the wall portion 29 inclined in this manner, the bending jig 19 is displaced to grip the tip portion 10a of the first coil end portion 9Aa between the teeth 25c and the wall portion 29, as shown in FIGS.

[0090] At this time, the inclination of the bending jig 19, i.e., the teeth 25c and the wall portion 29, is increased. Increasing the inclination means increasing the inclination angle with respect to the axial direction. This increase in inclination makes it possible to smoothly grip the tip portion 10a of the first coil end portion 9Aa. However, increasing the inclination of the bending jig 19 may be omitted.

[0091] During this gripping, one of a pair of walls, wall portion 29, is positioned between first coil end portion 9Aa and second coil end portion 9b. Wall portion 29 has a curved surface 29a at its tip, and so has a greater plate thickness than teeth 25c, etc. In this embodiment, by separating first coil end portion 9Aa from second coil end portion 9b as described above, tip portion 10a of first coil end portion 9Aa can be smoothly gripped by gripping portion 27 even if wall portion 29 is thick.

[0092] FIG. 22 is an enlarged side view showing the state when the bending of the power line is completed.

[0093] 22, while holding the tip portion 10a of the first coil end portion 9Aa, the bending jig 19 is displaced by the robot manipulator 17 so as to move radially outward and axially closer to the stator core 3. At this time, the inclination of the bending jig 19 is returned so that the wall portion 29 is aligned along the axial direction.

[0094] As a result, the first coil end portion 9Aa is pressed against the curved surface 29a of the wall portion 29, and the first coil end portion 9Aa is bent.

[0095] As described above, in the manufacturing method of the stator core 3 of this embodiment, the second coil end portion 9b adjacent to the inside of the first coil end portion 9Aa in the radial direction of the stator core 3 is bent so that the base end portion 10b is inclined radially outward and the tip end portion 10a is aligned along the axial direction. The first coil end portion 9Aa is held in an inclined state along the inclination of the base end portion 10b of the second coil end portion 9b. Then, the tip end portion 10a of the inclined first coil end portion 9Aa is grasped and displaced to bend the first coil end portion 9Aa to form the power line 11.

[0096] Therefore, in this embodiment, the first coil end portion 9Aa and the second coil end portion 9b are separated by bending the second coil end 9b, and the tip portion 10b of the first coil end portion 9Aa can be easily and reliably gripped. Then, by displacing the gripped tip portion 10b of the first coil end portion 9Aa, the first coil end portion 9Aa can be easily and reliably bent.

[0097] In this manner, in this embodiment, the power line 11 can be easily formed by bending the first coil end portion 9Aa.

[0098] In this embodiment, the tip 10a of the inclined first coil end portion 9Aa is positioned and gripped between a pair of walls, namely, teeth 25c and wall portion 29. At this time, wall portion 29, one of the pair of walls, is positioned between the first coil end portion 9Aa and the second coil end portion 9b. Then, the first coil end portion 9Aa is pressed against a curved surface 29a provided at the tip of wall portion 29 to bend it.

[0099] Therefore, in this embodiment, the first coil end portion 9Aa can be bent more easily. With this configuration, the wall portion 29 cannot be made as thin as the tooth 25c because it has the curved surface 29a. However, since the first coil end portion 9Aa is separated from the second coil end portion 9b, the first coil end portion 9Aa can be easily and reliably gripped between the tooth 25c and the wall portion 29.

[0100] In addition, in this embodiment, teeth 25a are inserted axially between adjacent coil end portions 9 radially inward from the second coil end portion 9b to tilt the first coil end portion 9Aa together with the second coil end portion 9b from a state aligned in the axial direction, and the tip portion 10a of the second coil end portion 9b is pressed against the teeth 25a by a pusher 21 to align it in the axial direction.

[0101] Therefore, in this embodiment, the first coil end portion 9Aa and the second coil end portion 9b can be easily tilted simply by inserting the teeth 25a. Moreover, the first coil end portion 9Aa and the second coil end portion 9b can be easily separated by bending the tip portion 10a of the second coil end portion 9b along the axial direction.

[0102] Before being bent, the first coil end portion 9Aa is axially shorter than the second coil end portion 9b, and the pusher 21 presses the second coil end portion 9b against the teeth 25a within the range that protrudes axially from the first coil end portion 9Aa.

[0103] Therefore, in this embodiment, the axial position of the pusher 21 can be fixed between the case where the power line 11 is formed and the case where the power line 11 is not formed, thereby simplifying the structure and control of the manufacturing apparatus 15 and the steps of the manufacturing method, etc.

[0104] The manufacturing apparatus 15 for the stator 1 in this embodiment includes a tooth 25a that can be inserted between adjacent coil end portions 9, a pusher 21 that can move relative to the tooth 25a inserted between the coil end portions 9 in a direction intersecting the direction of insertion, a holding portion 27 that can hold the tip portion 10a of the first coil end portion 9Aa, and a controller 31 that controls the tooth 25a, the pusher 21, and the holding portion 27.

[0105] Therefore, the manufacturing apparatus 15 for the stator 1 realizes the manufacturing method of this embodiment and can easily form the power lines 11 by bending the first coil end portions 9Aa. Furthermore, the manufacturing apparatus 15 does not require complex control of the teeth 25a, the pusher 21, and the gripping portion 27, and the structure and control can be simplified.

[0106] The teeth 25a and the gripping portion 27 are disposed on a bending jig 19 that can be displaced by a robot manipulator. Therefore, the operations of the teeth 25a and the gripping portion 27 can be standardized, and the structure and control of the manufacturing device 15 can be simplified. EXAMPLES

[0107] Fig. 23 is a front view showing a bending jig of a stator manufacturing apparatus according to Example 2 of the present invention. Fig. 24 is a rear view of the bending jig of Fig. 23. Fig. 25 is a side view of the bending jig of Fig. 23. Note that, since Example 2 has a basic configuration in common with Example 1, the same reference numerals are used for configurations corresponding to those of Example 1, and duplicated explanations will be omitted.

[0108] 23 to 25, in Example 2, the position of the gripping portion 27 of the bending jig 19 is changed from that in Example 1. That is, the bending jig 19 has comb teeth 25 on one side surface 23a of the main body portion 23, and has a gripping portion 27 on the other side surface 23b of the main body portion 23. The rest is the same as in Example 1.

[0109] FIG. 26 is a front view showing a bending jig according to a modified example.

[0110] In this modification, the bending jig 19 has comb teeth 25 and a gripping portion 27 on one side 23a of the main body 23, but the gripping portion 27 and the comb teeth 25 are provided on opposite ends in the longitudinal direction of the main body 23. The rest is the same as in the first embodiment.

[0111] In this embodiment as well, it is possible to achieve the same effects as in embodiment 1. In addition, since it is not necessary to provide the gripping portion 27 in parallel with the comb teeth 25, it is possible to reduce the dimensions of the bending jig 19. The position of the gripping portion 27 can be set to various positions on the main body 23 as long as the tip portion 10a of the first coil end portion 9Aa for the power line 11 can be gripped by controlling the posture of the bending jig 19.

[0112] The gripping portion 27 does not necessarily have to be integral with the bending jig 19, but may be provided on a separate jig. [Explanation of symbols]

[0113] 1 Stator 3 Stator core 5 Stator coil 7 Segment Coil 9 Coil end 9a to 9f 1st to 6th coil end portions 9Aa First coil end 10a Tip 10b Base end 11 Power line 15 Manufacturing equipment 17 Robot Manipulator 19 Bending jig 21 Pusher 25a, 25b, and 25c teeth 27 Gripping part 29 Wall 29a Curved surface

Claims

1. A method for manufacturing a stator in which a first coil end portion at an outermost periphery is bent among a plurality of coil end portions arranged along a radial direction of a segment coil held by a stator core to form a power line, the method comprising the steps of: a second coil end portion adjacent to an inner side of the first coil end portion in the radial direction of the stator core is inclined toward an outer side in the radial direction together with the first coil end portion; bending the second coil end so that a tip end of the second coil end is along an axial direction to separate a tip end of the inclined first coil end portion from a tip end of the second coil end; a tip end portion of the separated first coil end portion is gripped and displaced to bend the first coil end portion to form the power line; A method for manufacturing a stator.

2. A method for manufacturing the stator of claim 1, comprising the steps of: The tip end of the separated first coil end portion is positioned between a pair of wall portions and gripped, one of the pair of wall portions is located between the first coil end portion and the second coil end portion, The first coil end portion is pressed against a curved surface provided at the tip of one of the pair of wall portions to perform the bending. A method for manufacturing a stator.

3. A method for manufacturing a stator in which a first coil end portion at the outermost periphery is bent to form a power line among a plurality of coil end portions arranged along the radial direction of a segment coil held in a stator core, comprising: a second coil end portion adjacent to the inside of the first coil end portion in the radial direction of the stator core is inclined from a state along the axial direction together with the first coil end portion toward the outside in the radial direction by inserting teeth in the axial direction between adjacent coil end portions located radially inside the second coil end portion, a tip end portion of the second coil end portion is pressed against the teeth by a pusher to be aligned along the axial direction, and the first coil end portion is held in an inclined state along the inclination of the base end portion of the second coil end portion, a tip end portion of the inclined first coil end portion is gripped and displaced to bend the first coil end portion to serve as the power line; A method for manufacturing a stator.

4. A method for manufacturing a stator according to claim 3, comprising the steps of: the first coil end portion is shorter in the axial direction than the second coil end portion before being bent; the pusher presses the second coil end portion against the teeth within a range protruding from the first coil end portion in the axial direction. A method for manufacturing a stator.

5. A manufacturing device for a stator in which a first coil end portion at an outermost periphery is bent out of a plurality of coil end portions arranged along a radial direction of a segment coil held by a stator core to form a power line, the device comprising: A tooth insertable between adjacent coil end portions; a pusher movable in a direction intersecting a direction of the insertion of the teeth between the coil end portions; a gripping portion capable of gripping a tip end portion of the first coil end portion; a controller for controlling the teeth, the pusher, and the gripping portion; The controller, the teeth are inserted in the axial direction between the coil end portions that are radially inward of a second coil end portion adjacent to an inner side of the first coil end portion in the radial direction of the stator core, thereby tilting the first coil end portion together with the second coil end portion from a state along the axial direction; The pusher presses the tip end of the second coil end portion against the teeth, and aligns the tip end of the second coil end portion in the axial direction. a gripping portion gripping the tip end of the inclined first coil end portion is displaced to bend the first coil end portion to serve as the power line; Stator manufacturing equipment.

6. An apparatus for manufacturing a stator in which a first coil end portion at the outermost periphery is bent out of a plurality of coil end portions arranged along the radial direction of a segment coil held in a stator core to form a power line, A tooth insertable between adjacent coil end portions; a pusher movable in a direction intersecting a direction of the insertion of the teeth between the coil end portions; a gripping portion capable of gripping a tip end portion of the first coil end portion; a controller for controlling the teeth, the pusher, and the gripping portion; The controller, the teeth are inserted in the axial direction between the coil end portions that are radially inward of a second coil end portion adjacent to an inner side of the first coil end portion in the radial direction of the stator core, thereby tilting the first coil end portion together with the second coil end portion from a state along the axial direction; The pusher presses the tip end of the second coil end portion against the teeth, and aligns the tip end of the second coil end portion in the axial direction. a gripping portion gripping the tip end of the inclined first coil end portion is displaced to bend the first coil end portion to serve as the power line; the gripping portion includes a pair of wall portions that position the tip end portion of the inclined first coil end portion between them and grip the tip end portion of the inclined first coil end portion, and a curved surface that is provided at the tip end of one of the pair of wall portions that is positioned between the first coil end portion and the second coil end portion during the gripping and is pressed against the first coil end portion to perform the bending. Stator manufacturing equipment.

7. The stator manufacturing apparatus according to claim 6, The teeth and the gripping portion are arranged on a bending jig that can be displaced by a robot manipulator. Stator manufacturing equipment.

Images