Coil manufacturing apparatus, coil manufacturing method, stator manufacturing method, and rotating electric machine manufacturing method

Abstract

Provided is a coil manufacturing device for manufacturing a coil (5) by winding, around a core (11), a magnet wire (2) drawn from a bobbin (1), the coil manufacturing device comprising a defect detection device (200) that detects a defect in the magnet wire before being wound, and a defect location recording device (310) that calculates the location of the defect on the coil after being wound, and records the location as defect location data (313). Thus, it is possible to obtain a coil manufacturing device that reduces excessive determinations due to faults in the magnet wire (2) in a method of manufacturing the coil (5), and to reduce the amount of waste due to faults.

Description

[Technical field]

[0001] The present application relates to a coil manufacturing apparatus, a coil manufacturing method, a stator manufacturing method, and a rotating electric machine manufacturing method. [Background technology]

[0002] The magnet wire wound around the coil of a rotating electric machine or a transformer is generally coated with varnish to provide electrical insulation. If there are defects such as scratches, air bubbles, or pinholes in the varnish layer, these become electrically weak spots and can become the starting points of breakdown when voltage is applied. Magnet wire is inspected for defects in the insulating coating and shipped wound on a bobbin, but it is difficult to completely prevent defects in the insulating coating, and the locations where defects occur in the insulating coating vary.

[0003] If the insulating layer of the magnet wire of a rotating electric machine has defects such as scratches or pinholes, the insulation between the magnet wire and the core and between the magnet wire and the ground will be reduced, and insulation breakdown will occur between adjacent magnet wires in the coil, which may cause problems such as reduced performance of the rotating electric machine, burning, and electric leakage. Therefore, it is necessary to inspect the magnet wire for defects in rotating electric machines. Furthermore, to detect defects in the coils of rotating electric machines or transformers, a voltage test is conducted on the coil in its final shape after winding (the stator in the case of rotating electric machines) to guarantee quality. If the performance is not met at this point, the coil is discarded, and the amount of waste increases especially when the quality of the magnet wire is poor.

[0004] For example, Patent Document 1 discloses a manufacturing method in which a mark is applied to the defective portion of a delivered magnet wire to indicate the presence of a defect in the insulating coating, the magnet wire is prepared in a state of being wound around a bobbin, and when the bobbin is used in the coil manufacturing process, the defective portion is inspected based on the mark and the defective portion is cut off. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 6252865 Summary of the Invention [Problem to be solved by the invention]

[0006] With such conventional coil manufacturing methods, the delivered magnet wire must be rewound onto a bobbin, resulting in poor production efficiency. In addition, the coils must be inspected for performance after production, and if a defect occurs at that point, the amount of waste increases. The present application has been made to solve the above-mentioned problems, and aims to provide a coil manufacturing apparatus that can suppress excessive detection of defective magnet wires in a coil manufacturing process and reduce the amount of waste due to defects. [Means for solving the problem]

[0007] Original Application of The coil manufacturing apparatus is a coil manufacturing apparatus that manufactures a coil by winding a magnet wire drawn from a bobbin around a core, To the core It is equipped with a defect detection device that detects defects in the magnet wire before it is wound, and a defect position recording device that calculates the position of the defect on the coil after it is wound and records it as defect position data. Effect of the Invention

[0008] The magnet wire is checked for defects before it is wound, and the position data of the defect on the wound coil is calculated and recorded for the position of the defect, so that the quality of the wound coil can be judged based on the position of the defect on the coil. Even if the magnet wire has a defect, it can be used if it does not affect the performance of the coil. Therefore, excessive judgments due to defects in the magnet wire can be suppressed, and the amount of waste due to defects can be reduced. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic diagram showing a coil manufacturing apparatus according to a first embodiment. [Diagram 2] 1 is a schematic diagram showing a defect detection device of a coil manufacturing apparatus according to a first embodiment. [Diagram 3] 2 is a block diagram showing a control device of the coil manufacturing apparatus according to the first embodiment. FIG. [Figure 4] 1 is a perspective view showing a coil winding state of the coil manufacturing apparatus according to the first embodiment. FIG. [Diagram 5] FIG. 2 is a perspective view showing a stator according to the first embodiment. [Figure 6] FIG. 11 is a schematic diagram showing the configuration of a defect position recording device of a coil manufacturing apparatus according to a second embodiment. [Figure 7] 1 is a block diagram showing a defect position recording device of a coil manufacturing apparatus according to a first embodiment. [Figure 8] 4 is a schematic diagram showing the process of a defect position recording device of the coil manufacturing apparatus according to the first embodiment. FIG. [Figure 9] 4 is a flowchart showing the operation of a defect position recording device of the coil manufacturing apparatus according to the first embodiment. [Figure 10] 2 is a perspective view showing a method of determining whether a coil is good or bad in the coil manufacturing apparatus according to the first embodiment. FIG. [Figure 11] FIG. 11 is a perspective view showing a method of determining whether a coil is good or bad in the coil manufacturing apparatus according to the second embodiment. [Figure 12]FIG. 11 is a perspective view showing a method for determining whether a stator is good or bad according to the third embodiment. [Figure 13A] 11 is a flowchart showing a procedure for determining whether or not the annular coil set according to the third embodiment is good. [Figure 13B] 11 is a flowchart showing a procedure for determining whether or not the annular coil set according to the third embodiment is good. [Figure 13C] 11 is a flowchart showing a procedure for determining whether or not the annular coil set according to the third embodiment is good. [Figure 14A] FIG. 11 is a perspective view showing a method for manufacturing a stator according to a fourth embodiment. [Figure 14B] FIG. 11 is a perspective view showing a method for manufacturing a stator according to a fourth embodiment. [Figure 15] FIG. 13 is a schematic diagram showing a coil manufacturing apparatus according to a fifth embodiment. [Figure 16] FIG. 13 is a perspective view showing a pressing member of a coil manufacturing apparatus according to a fifth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Embodiment 1 Fig. 1 is a schematic diagram showing a coil manufacturing apparatus according to the first embodiment. In Fig. 1, in the coil manufacturing apparatus 100, a magnet wire 2, which is a material, is drawn out from a bobbin 1 placed so that its axial direction is perpendicular to the ground, and the drawn magnet wire 2 passes through a tensioner 3 and a nozzle 4, and is wound into a coil 5. At this time, the magnet wire 2 in the section from the tensioner 3 to the coil 5 is kept at a predetermined tension by the tensioner 3, and a defect detection device 200 for detecting defects in the insulating coating of the magnet wire 2 is disposed in the region between the tensioner 3 and the nozzle 4, and is installed at a location where the flow line of the magnet wire 2 crosses. The control of these devices, signal processing, data recording, etc. are performed by a control device 300.

[0011] The magnet wire 2 has a conductor and an insulating coating covering the conductor, and is prepared in a state of being wound around a bobbin 1. This magnet wire 2 has defective parts that are not removed and remains, and is wound around a bobbin with a predetermined winding amount. Examples of materials for forming this conductor include copper or copper alloy, aluminum or aluminum alloy, etc. Examples of materials for forming the insulating coating include polyimide resin, polyamide-imide resin, polyester-imide resin, etc. The shape of the conductor can be various shapes, such as a circular, elliptical, or racetrack cross-sectional shape, or a polygonal shape such as a triangular or rectangular shape. Representative examples include a round wire with a circular cross-sectional shape and a rectangular wire with a rectangular cross-sectional shape. The coil manufacturing apparatus 100 can be applied to any of the winding methods, which are mainly classified into spindle winding, flyer winding, and nozzle winding methods.

[0012] The defect detection device 200 is a device for inspecting defects in an insulating coating. Examples of defects in an insulating coating include bulges, peeling, and pinholes in the coating. Depending on the object to be detected, the defect detection device 200 may be a combination of multiple inspection devices. Inspection methods for defects in an insulating coating include, for example, detecting bulges and peeling of the coating by capturing an image of the winding surface with a CCD camera or the like and processing the captured image with an image processing device, and detecting the thickness of the insulating coating formed on the surface of the winding by measuring with a laser displacement meter. In addition, in the case of pinholes, the magnet wire 2 is installed so as to be electrically connected through the end of the bobbin 1 at the winding start side, and detecting partial discharge.

[0013] FIG. 2 shows the configuration of the defect detection device 200 used in the description of the first embodiment. The defect detection device 200 is provided with a liquid tank 201, which is filled with a conductive liquid 202. Rectangular wet electrodes 203a and 203b made of soft and hygroscopic felt material are provided on the upper part of the liquid tank 201, and the magnet wire 2 is disposed between the wet electrodes 203a and 203b. The wet electrodes 203a and 203b are pressed against and held by a clamp 204 fixed to the coil manufacturing device 100 or the liquid tank 201. That is, the rectangular wet electrodes 203a and 203b are in contact with the magnet wire 2 so as to sandwich the magnet wire 2. The lower parts of the wet electrodes 203a and 203b are immersed in the conductive liquid 202. The wet electrodes 203a and 203b are hygroscopic and are therefore wet with the conductive liquid 202. Furthermore, because the wet electrodes 203a and 203b are soft, they are pressed against the magnet wire 2 by the clamp 204, and are in contact with the entire circumference of the magnet wire 2 in the region of electrode width D1. (Hereinafter, the wet electrodes 203a and 203b will be referred to as 203 without distinction.) That is, in the region of electrode width D1, the conductive liquid 202 is in contact with the entire circumference of the magnet wire 2. With this configuration, the conductive liquid 202 can be brought into contact with the surface of the magnet wire 2 efficiently.

[0014] The magnet wire 2 moves while maintaining a contact area of ​​electrode width D1 with the wet electrode 203 due to the winding operation into the coil 5 in the coil manufacturing apparatus 100. A power source V connects an end of the magnet wire 2 to earth in order to apply a voltage to the measurement range, and is also connected to apply a voltage to the end of the measurement range. The partial discharge detector 205 measures the discharge charge or discharge current of the magnet wire 2, and when it detects a measured value equal to or greater than a threshold value, it outputs a detection signal to the control device 300, indicating that a defect in the insulator layer has been detected.

[0015] The lower part of the metal electrode 206 connected to the power source V and the partial discharge detector 205 is immersed in the conductive liquid 202, and the power source V, which is an AC voltage, is applied to the conductive liquid 202. Since the wet electrode 203 is wetted with the conductive liquid 202, by connecting the power source V, a voltage is applied to the entire circumference of the magnet wire 2 in the region of the electrode width D1. With this configuration, electrical defects in the insulating layer of the magnet wire 2 can be detected non-destructively and continuously.

[0016] As shown in FIG. 3, the control device 300 is composed of a processor 301 and a storage device 302. Although not shown, the storage device includes a volatile storage device such as a random access memory and a non-volatile auxiliary storage device such as a flash memory. Also, instead of the flash memory, a hard disk auxiliary storage device may be included. The processor 301 executes a program input from the storage device 302, and performs part or all of the configuration related to the functional blocks described in FIG. 7 and the operation of the flowchart described in FIG. 9. In this case, the program is input from the auxiliary storage device to the processor 301 via the volatile storage device. Also, the processor 301 may output data such as input / output signals, intermediate values ​​of calculations, and calculation results to the volatile storage device of the storage device 302, or may store data in the auxiliary storage device via the volatile storage device. Also, in addition to the processor 301 and the storage device 302, a logic circuit and an analog circuit may be used in combination.

[0017] 1 shows the control device 300 provided inside the coil manufacturing apparatus 100, it may be provided separately from the coil manufacturing apparatus 100, in which case it is connected to the coil manufacturing apparatus 100 by a communication cable or the like. Also, the control device 300 may be provided in a distributed manner with different roles, with one provided inside the coil manufacturing apparatus 100 and one provided separately.

[0018] 4 shows the state of the coil 5 being wound. The magnet wire 2 that has passed through the wet electrode 203 passes through the nozzle 4 and is wound around the core 11 that is installed in the winding section. The core 11 is insulated from the coil 5 by an insulator 12 and is fixed on a rotating table. By rotating the rotating table in the rotation direction R, the magnet wire 2 is wound around the core 11 to form the coil 5. The shapes and sizes of the core 11 and insulator 12 to be formed are predetermined and are recorded as coil shape data in the control device 300. The magnet wire 2 is wound as the coil 5 around the teeth of the core 11 in a predetermined shape and size.

[0019] Core 11 shown in this embodiment 1 is a portion that becomes a divided core for constituting stator 500 that forms rotating electric machine 600, and completed stator 500 is shown in Fig. 5. In Fig. 5, coils 5 wound around core 11 are arranged in the circumferential direction so that core back portions 18 are connected in an annular shape, terminals of coils 5 are connected to conductive connecting members 17 via conductive coil terminals 16 to connect coils 5 that are separated by two or more coils in the circumferential direction, and adjacent coils 5 are connected with crossover wires 15, thereby forming stator 500. Thereafter, a withstand voltage test and a surge test are performed in the intermediate inspection on the stator 500. In the present application, since insulation defects caused by pinholes or the like in the magnet wire 2 during winding before the intermediate inspection can be detected, insulation defects in the intermediate inspection can be reduced, and the number of steps in the intermediate inspection can be reduced.

[0020] In addition, in a product assembly process after the intermediate inspection, a rotor (not shown) is rotatably arranged on the inner diameter side of the stator 500 via a gap, thereby manufacturing the rotating electric machine 600. Thereafter, a voltage resistance test is performed on the stator 500 in the final inspection. In the present application, since insulation defects caused by pinholes or the like in the magnet wire 2 can be detected during winding before the final inspection, insulation defects caused by pinholes can be reduced even in the final inspection, and process defects in the final inspection can be reduced.

[0021] Fig. 6 shows the configuration of a defect position recording device that calculates the position on coil 5 of a defect detected by defect detection device 200. Encoder 400 is installed between wet electrode 203 and nozzle 4 of defect detection device 200, and a distance (length) is calculated from the speed at which magnet wire 2 passes through encoder 400. As shown in the block diagram of Fig. 7, defect position recording device 310 provided in control device 300 is executed by a program. According to the measurement flow, defect position recording device 310 controls wet electrode 203, partial discharge detector 205, and encoder 400 to measure the position of the defect.

[0022] 7, control device 300 has defect position recording device 310 as a functional block operated by a program, and defect position recording device 310 has functional blocks of defect position calculation processing unit 311, coil shape data 312, and defect position data 313. The distance L1 between the wet electrode 203 of the defect detection device 200 in FIG. 6 and the nozzle 4, the distance L2 from the tip of the nozzle 4 to the coil 5, the short-side length T1 and long-side length T2 of the coil 5, and the elongation rate of the magnet wire 2 under winding tension are determined in advance, and these data are recorded in the coil shape data 312. The defect position calculation processing unit 311 receives a signal from the partial discharge detector 205 and a signal from the encoder 400 , and records the winding distance as defect position data 313 , taking the distance at the start of winding of the coil 5 as the zero point.

[0023] As described above, a power source V is connected and an AC voltage is applied to the outer surface of the magnet wire 2 in the region of electrode width D1. If a defect such as a pinhole penetrating the insulator is present in the measurement region of electrode width D1, the conductive liquid 202 comes into direct contact with the conductor on the inside of the insulator layer, so that a current is detected when a voltage is applied, and an insulation defect can be detected in the electrode width D1 region of the wet electrode 203. Furthermore, when the winding operation is performed in the coil manufacturing apparatus 100, the magnet wire 2 always passes through the electrode width D1 area of ​​the defect detection apparatus 200, so that all of the magnet wires 2 wound into coils 5 as products can be inspected for defects in their entirety.

[0024] 8 is a schematic diagram showing the processing of the defect position recording device 310. A defect in the magnet wire 2 can be detected at the position of the wet electrode 203 by a detection signal from the partial discharge detector 205. From the winding distance E1 recorded by taking in the signal from the encoder 400 and taking the distance at the start of winding the coil 5 as the zero point, the known distances (lengths) L1, L2, T1, and T2, and the elongation rate of the magnet wire 2 according to the winding tension, it is possible to accurately calculate which turn and where on the coil 5 the defect is located. Therefore, by measuring the distance from the position that is the starting point of the coil 5 in the winding to the wet electrode 203 where the defect was detected, it is possible to determine, based on the detected position, at what position in the coil 5 the defect, which is a defective coating of the magnet wire 2, will be wound and positioned when the coil 5 is formed. In addition, by setting the distance at the time the defect is detected as zero and calculating the winding distance E2 from the wet electrode 203, even if a defect remains in the magnet wire 2 after winding of the coil 5 is completed, it is possible to record this as the position of the defect in the coil 5, which will be the next workpiece.

[0025] FIG. 9 is a flowchart showing the operation of the defect position recording device 310. First, the coil manufacturing device 100 resets the distances E1 and E2 to 0 at the same time as starting winding, and starts counting the distance E1 of the encoder 400 (step S1). Next, defect detection begins, and a defect is detected at the position of the wet electrode 203 (step S2). If no defect is detected, step S2, which is the detection of a defect, is repeated until the winding distance E1 reaches the distance Lt at which the coil winding ends (step S13). If no defect is detected at the end of winding, the work is replaced to start the next winding (step S14). In replacing the work, the magnet wire 2 is cut at the end position, the wound coil 5 is removed, a new core 11 is set on the winding table, and the cut magnet wire 2 is set at the winding start position of the new coil 5.

[0026] When a defect is detected (step S2), the count distance E1 at the time of detection is obtained and stored in the defect position recording device 310 (step S3). At the same time as obtaining the distance E1, a new count is started to obtain the distance E2 to the next defect detection point (step S4). The total distance Lt of the magnet wire 2 required to complete winding is compared with the distance E1 at which the defect was detected (step S5). When comparing, the known distances L1 and L2 at the start of winding are subtracted from the total distance Lt (see the relationship between the distances in FIG. 8). These distances are calculated taking into account the type of electric wire and the elongation rate set according to the tension applied to the electric wire.

[0027] When the distance E1 is smaller than the total distance Lt-(distance L1+distance L2) (step S5), a defective portion is wound around the wound coil 5. The position of the defective portion on the coil 5 according to the distance E1+distance L1+distance L2 is calculated and recorded in the defective portion position recording device 310 (step S6). The distance E1 at which the defective portion was detected is added to the distance E2 from when the defective portion was detected to the present, thereby obtaining the distance E1 from the start of winding to the present (step S7), and the count of the distance E1 is continued. At this time, the distance E2 is reset (step S8). After that, the process returns to step S2 to detect the next defective portion.

[0028] When the distance E1 is equal to or greater than the total distance Lt-(distance L1+distance L2), wait until the winding distance E1 at the end of the winding becomes the distance Lt at the end of the coil winding (step S9), and obtain the distance E2 (step S10). In this case, it is estimated that a defect X exists at any position in the range from the end of the winding to a point that is distance L1+distance L2 back, and together with replacing the coil 5 (step S11), the position of the defect on the coil 5 corresponding to L1+L2-E2 is calculated (see the relationship of each distance in FIG. 8) and recorded in the defect position recording device 310 (step S12). This record is for the new coil 5 after replacement. After recording, return to step S1 and start winding the new coil 5 after replacement. Since the distance count is reset each time the coil 5 is replaced, the discrepancy between the distance read by the encoder 400 and the actual feed amount of the magnet wire 2 does not increase as the production of the coils 5 progresses.

[0029] Next, the quality of the coil 5 is judged according to the positions of the defects on the coil 5 recorded in the defect position recording device 310. Fig. 10 shows a perspective view for explaining the quality judgment when there is a defect position on the outermost circumference of the coil. Fig. 10 is an enlarged view of the core back portion of the core 11 and the upper part of the insulator 12 as seen from the coil side, which corresponds to the upper right part of the perspective view of the coil 5 shown in Fig. 4. Based on the defect position data 313 obtained by the measurement flow of the defect position in FIG. 9 described above, the distance L3 from the defect X to the end of the insulator 12 is calculated. In addition, by using the distance L4 from the insulator 12 to the exposed part of the core 11, which is determined according to the product, it is possible to grasp the distance from the position of the defect to the exposed part of the core 11. If the distance L3+L4 exceeds the insulation distance threshold value determined for the product, it can be determined that no insulation failure will occur even if there is a defect on the magnet wire 2. In this way, the quality of the coil 5 can be determined based on the defect position data 313, and the wound coil 5 is selected.

[0030] Since the coils 5 are sorted as described above, it is possible to prevent excessive judgments from being made regarding product functionality based on the judgment results obtained by detecting defective parts of the magnet wire 2. Also, in the past, an insulation test was performed as a performance evaluation on the stator 500 assembled into a ring with the coils 5, and the assembled stator 500 was discarded if poor insulation was detected. However, since it is possible to judge the quality of the stator 500 during its production, it is expected that the amount of waste can be reduced.

[0031] Embodiment 2 11 is a schematic diagram for explaining a method for judging the coil 5 when there are multiple defects between the layers of the coil 5 according to the embodiment 2. The positions of the defects in the magnet wire 2 on the coil 5 are calculated before winding, and the distance between the positions of the defects in the magnet wire 2 between the layers of the coil is calculated to judge the superiority or inferiority of the motor coil. Based on the defect position data 313 obtained by the measurement flow of the defect position in Fig. 9 described above, the distance L5 between layers between the positions of the defect parts X on the magnet wire 2 of the coil 5 is calculated. If the distance L5 exceeds the insulation distance threshold value set for the product, it can be determined that no insulation failure will occur even if there is a defect on the magnet wire 2.

[0032] This makes it possible to prevent excessive judgments regarding product functionality based on the judgment results obtained by detecting defective parts of the magnet wire 2. Also, in the past, an insulation test was conducted on stator 500, which is assembled into a ring with coils 5, as a performance evaluation, and if insulation defects were detected, the assembled stator 500 was discarded. However, since it is possible to judge the quality of stator 500 during its production, it is expected that the amount of waste will be reduced.

[0033] Embodiment 3 12 is a perspective view showing a method for determining the quality of a stator 500 according to the third embodiment. A method for determining whether a coil 5 has a defect X at the outermost circumference will be described. The position of the defect X in the magnet wire 2 on the coil 5 is calculated before winding, and the distance between the defect positions in the magnet wire 2 of adjacent coils 5 of the stator 500 is calculated to determine the quality of the stator 500.

[0034] Based on the defect position data 313 obtained by the measurement flow of the defect position in FIG. 9 described above, the center position of the ring when the coils 5 are assembled into a ring is set as the origin, and the position of the defect X on the magnet wire 2 of the coil 5 is converted into the origin coordinates by performing coordinate conversion. In this case, in the case of the coils 5 on the outermost side and adjacent to each other, when the coils 5 are assembled into a ring, the distance L6 between the positions of the defect X is calculated from the defect position data 313 coordinate-converted from the center position of the ring. If the distance L6 exceeds the insulation distance threshold value set for the product, it can be determined that no insulation failure will occur even if there is a defect X on the magnet wire 2. In addition, since the quality of the stator 500 can be judged during the manufacturing process, the amount of waste can be reduced.

[0035] Next, a series of flows from coil manufacturing by a coil manufacturing device to before the stator is manufactured (before the coils are assembled into an annular shape) will be described with reference to the flowcharts in Figures 13A to 13C. When n coils 5 prepared to configure a stator 500 are annular coil sets C1 to Cn, the winding procedure for a representative annular coil set Ci will be described with reference to Figure 13A. The detailed operation is as explained in Figure 9, but here, the flow required for coil manufacturing will be mainly explained.

[0036] First, the core 11 that is to become the i-th annular coil set Ci is set on the rotating table as a workpiece, the coil number Ci is recorded in the defect part position data 313 of the defect part position recording device 310, and winding is started. The number of defects is set to j, and counting starts from j=0 (step S21). The presence or absence of detection of defects in the magnet wire 2 is checked (step S22). If no defects are detected, this detection step, step S22, is repeated until the end of the coil winding (step S26). If a defect is detected, the number of defects j is counted up (step S23), and the winding distance is acquired (step S24). From this distance, position information of the defect is calculated using the coil shape data 312, and the defect part position coordinate Xij (the j-th defect part position coordinate of the annular coil set Ci) is calculated and recorded in the defect part position data 313 (step S25). In this case, the position information is three-dimensional (x, y, z) coordinate information with the position of the specific shape of the core 11 as the origin. At the same time, the position of the defect in the coil and the number of turns may also be recorded. After that, the process returns to step S22 and repeats the detection of new defects until the end of the winding (step S26). When the end of the winding is reached (step S26), the process proceeds to the next circular coil set Ci+1 by replacing the work (step S27).

[0037] If a defect exists in the magnet wire that is first wound before the winding starts, steps S21 to S22 are skipped and the process proceeds to step S23. If the winding is completed without detecting any defect (j=0), a record of no defect is recorded in the defect position data 313. In that case, impossible coordinates such as (0,0,0) may be recorded as the defect position information Xi0.

[0038] When the winding is completed up to the annular coil set Cn, proceed to FIG. 13B. In FIG. 13B, coordinates are extracted to calculate the linear distance of the defect between the coils when the annular coil sets C1 to Cn are assembled in an annular shape. First, start with i=1 (S31). Read out the position information of all the defect parts of the defect part position coordinate Xij of the annular coil set Ci from the defect part position data 313 (step S32). From the read defect part position coordinates, only the defect part position coordinate wound on the outermost circumference is extracted, and the defect part position coordinate Xi is calculated by converting it into a three-dimensional coordinate (x, y, z) with the center position of the assembled annular ring as the origin, and recorded in the defect part position data 313 (step S33). Next, advance the count i of the annular coil set (step S34), and repeat steps S32 and S33 until the annular set is completed (i=n) (step S35). When the annular set is completed, proceed to FIG. 13C. In step S33, if there are multiple defect position coordinates Xi wound around the outermost circumference, select one on each side that is closest to the adjacent coils on both sides. If there is no defect position coordinate Xi, set it to a coordinate value that is not included in the comparison of defect position coordinates between the positions of adjacent annular coil sets.

[0039] In Fig. 13C, the quality of the annular coil sets C1 to Cn is judged according to the flow chart. First, based on the position coordinates converted in Fig. 13B, the defective part position coordinate X1 of the annular coil set C1 is read from the defective part position data 313 (step S101). Next, the defective part position coordinate X2 of the adjacent annular coil set C2 is read (step S102). The linear distance between these defective part position coordinates X1 and X2 is calculated as the distance Lc1 between the positions of the defective parts between the adjacent annular coil sets (step S103). Similarly, for the other annular coil sets C2 to Cn, the distances Lc2 to Lcn between the adjacent annular coil sets are calculated (corresponding to steps S121 to S1n3). As explained in step S33 of FIG. 13B, when there are two defect position coordinates Xi, the distance Lci is calculated using the defect position coordinate Xi with the smaller Lci.

[0040] When all the results of these calculation steps are available, the calculated distances Lc1 to Lcn between the positions of the defects between adjacent annular coil sets are compared to see if they all exceed the insulation distance threshold value defined for the product (step S201). If all the distances Lc1 to Lcn exceed the insulation distance threshold value, the annular coil sets C1 to Cn are deemed to have passed the test and proceed to the next process, the annular assembly process (step S202). If any of the distances Lc1 to Lcn are equal to or smaller than the insulation distance threshold value, these annular coil sets C1 to Cn are rejected to the defective line as defective annular coil sets before being circularly assembled (step S203). However, if any of the annular coil sets rejected as defective do not have defects on the outermost periphery side, they may be incorporated into another annular coil set and reused.

[0041] As described above, it is possible to judge the quality of the annular coil set before entering the annular assembly process of the annular coil set. It is possible to suppress excessive judgments on the product function based on the judgment results obtained by detecting defects in the magnet wire 2, and also, in the past, an insulation test was performed as a performance evaluation on the stator 500 assembled into a ring with the coil 5, and the assembled stator 500 was discarded if insulation defects were detected, but by being able to judge the quality of the stator 500 during its manufacture, it is expected that the amount of waste will be reduced. It is also possible to eliminate the extra annular assembly process and the effort of performing insulation tests after annular assembly. The insulation test referred to here refers to a withstand voltage test and a surge test that are carried out in an intermediate inspection after the assembly of a stator and in a final inspection after the assembly of a rotating electrical machine.

[0042] Embodiment 4 14A and 14B are perspective views showing a manufacturing method of a stator 500 according to embodiment 4. A method of selecting adjacent coils 5 of a motor coil having a defective portion X located at the outermost periphery of the coil 5 will be described. Based on the defect position data 313 obtained by the measurement flow of the defect position in Fig. 9 described above, the center position of the ring when each coil 5 is assembled into a ring is set as the origin, and the position of the defect X on the magnet wire 2 of each coil 5 is converted to the origin coordinate by performing coordinate conversion. In this case, in the case of the coils 5 on the outermost side and adjacent to each other, when each coil 5 is assembled into a ring, the distance L7 between the positions of the defect X is calculated from the defect position data 313 coordinate-converted from the center position of the ring, and if the distance L7 is equal to or less than the insulation distance threshold value set for the product, the positions of the defect X on the magnet wire 2 are not adjacent to each other, or are combined so as to exceed the insulation distance threshold value set for the product. In Fig. 14A, the distance L7 is shortened by the adjacent coils 5a and 5b, but the distance L7 can be increased by changing the order to coils 5b and 5a as shown in Fig. 14B.

[0043] This makes it possible to prevent excessive judgments regarding product functionality based on the judgment results obtained by detecting defective parts of the magnet wire 2. Also, in the past, an insulation test was conducted on stator 500, which is assembled into a ring with coils 5, as a performance evaluation, and if insulation defects were detected, the assembled stator 500 was discarded. However, since it is possible to judge the quality of stator 500 during its production, it is expected that the amount of waste will be reduced.

[0044] Embodiment 5. 15 is a schematic diagram showing a coil manufacturing apparatus according to the fifth embodiment. A defective portion of the magnet wire 2 can be detected at the position of the wet electrode 203 by a detection signal from a partial discharge detector 205. By obtaining the moving distance of the magnet wire 2 from the point when this defective portion is detected by an encoder 400, a repair device 410 applies insulating protection paint to the defective portion of the magnet wire 2 before winding into a coil 5. The repair device 410 is composed of a spray gun 411 and a pressing member 412. A signal received when a defective portion is detected is used as a trigger, and the control device 300 gives a signal to the spray gun 411 to apply a repair material while taking into consideration the winding speed and the position of the defective portion, and applies the coating agent to a predetermined position of the magnet wire 2 through which the defective portion passes. In Fig. 15, the spray guns 411 are shown installed at two positions slightly apart in the vertical direction. The arrangement and number of the spray guns 411 are not limited to this, and the number and positions can be selected arbitrarily as long as they can coat the entire circumference of the magnet wire 2.

[0045] It is preferable that the coating material is quick-drying so as not to affect the winding speed. An example is a fluorine coating agent, but other materials can be used as long as the coating agent has the required insulation performance and film thickness. The coating method is to supply the coating material to a spray gun 411, and operate the spray gun 411 at the timing of passing the defective part described above. Figure 16 shows a schematic diagram of the holding member. The magnet wire 2 is sent in the direction F in the figure, and the excess coating agent applied to the defective part 413 is removed by the holding member 412, thereby suppressing the required dimensions of the magnet wire 2 and uneven coating. The holding member 412 is semicircular in shape, and by pressing at two points, it is possible to suppress excessive tension on the magnet wire 2.

[0046] In the coil manufacturing apparatus of embodiment 5, defective portions of the magnet wire 2 are repaired by a repair device 410 before winding the coil 5 around the core 11, so that even magnet wire 2 in which a defective portion has been detected can be reused, and it is expected that the amount of waste caused by defective portions of the magnet wire 2 will be reduced. Moreover, such repairs to defective parts can be regarded as temporary repairs for maintenance, and the defective parts after repair can also be recorded in defective part position data 313 as shown in the above-mentioned embodiments 1 to 4, and this data can be used to judge the coils and stators. In this case, even coils and stators that are judged to be defective in the pass / fail judgment using defective part position data 313 may be able to be restored at the insulation test stage, making it possible to further reduce the amount of waste due to defects.

[0047] Although various exemplary embodiments and examples are described in this application, various features, aspects, and functions described in one or more embodiments are not limited to application in a specific embodiment, but can be applied to the embodiments alone or in various combinations. Therefore, countless modifications not illustrated are expected within the scope of the technology disclosed in this specification. For example, the modification, addition, or omission of at least one component, and the extraction and combination of at least one component with components of other embodiments are included. [Explanation of symbols]

[0048] 1 bobbin, 2 magnet wire, 3 tensioner, 4 nozzle, 5, 5a, 5b coil, 11 core, 12 insulator, 15 jumper, 16 conductive coil terminal, 17 conductive connection member, 18 core back portion, 100 coil manufacturing device, 200 defect detection device, 201 liquid tank, 202 conductive liquid, 203, 203a, 203b wet electrodes, 204 clamp, 205 partial discharge detector, 206 metal electrode, 300 control device, 301 processor, 302 storage device, 310 defect position recording device, 311 defect position calculation processing unit, 312 coil shape data, 313 defect position data, 400 encoder, 410 repair device, 411 spray gun, 412 holding member, 413 excessive application location, 500 stator, 600 rotating electric machine.

Claims

1. A coil manufacturing apparatus for manufacturing a coil by winding a magnet wire drawn from a bobbin around a core, comprising: a defect detection device for detecting defects in the magnet wire before it is wound around the core; a defect position recording device that calculates the position of the defect on the coil after it has been wound and records the calculated position as defect position data; A coil manufacturing apparatus comprising:

2. 2. The coil manufacturing apparatus according to claim 1, wherein the defect detection device detects an insulation defect in an insulating coating of the magnet wire as the defect.

3. The coil manufacturing apparatus according to claim 2, characterized in that the defect detection device detects the insulation failure by clamping the magnet wire with wet electrodes and measuring partial discharge caused by a voltage applied between the wet electrodes and an end of the magnet wire.

4. A coil manufacturing apparatus for manufacturing a coil by winding a magnet wire drawn from a bobbin around a core, comprising: a defect detection device for detecting defects in the magnet wire before it is wound around the core; a defect position recording device that calculates the position of the defect on the coil after it has been wound and records the calculated position as defect position data; Equipped with The defect position recording device is a detection signal of the defect in the magnet wire before being wound around the core by the defect detection device; A passing speed of the magnet wire measured by an encoder; and Shape data of the coil to be wound; and calculating a position of the defective portion of the magnet wire on the coil after winding and recording the position as the defective portion position data.

5. 5. The coil manufacturing apparatus according to claim 1, further comprising a repair device that repairs the defective portion of the magnet wire detected by the defect detection device before the magnet wire is wound.

6. A coil manufacturing apparatus for manufacturing a coil by winding a magnet wire drawn from a bobbin around a core, comprising: a defect detection device for detecting defects in the magnet wire before it is wound around the core; a defect position recording device that calculates the position of the defect on the coil after it has been wound and records the calculated position as defect position data; a repair device that repairs the defective portion of the magnet wire detected by the defect detection device before the magnet wire is wound; Equipped with The repair device is a coil manufacturing apparatus characterized in that it has a spray gun that applies repair material to the defective portion, and a restraining portion that removes excess paint that occurs at the defective portion of the magnet wire after the repair material has been applied.

7. A coil manufacturing method, comprising: determining whether the coil manufactured by the coil manufacturing apparatus according to any one of claims 1 to 4 is good or bad based on the defect position data recorded by the defect position recording device.

8. A coil manufacturing method for manufacturing a coil by winding a magnet wire drawn from a bobbin around a core, comprising: a defect detection step for detecting a defect in the magnet wire; a defect position recording step of calculating the position of the defect on the coil after winding and recording the calculated position as defect position data; a sorting step of determining whether the wound coil is good or bad based on the defect position data recorded in the defect position recording step; A coil manufacturing method comprising:

9. A defect detection device for detecting defects in a magnet wire before it is wound around a core; a defect position recording device that calculates the position of the defect on the wound coil and records it as defect position data; A coil manufacturing method for manufacturing a coil by winding a magnet wire drawn from a bobbin around the core using a coil manufacturing apparatus comprising: A coil manufacturing method characterized in that the quality of the coil is determined by calculating the distance from the defect to the exposed surface of the core around which the magnet wire is wound, using the defect position data recorded by the defect position recording device.

10. A coil manufacturing method for manufacturing a coil by winding a magnet wire drawn from a bobbin around a core, comprising: a defect detection step for detecting a defect in the magnet wire; a defect position recording step of calculating the position of the defect on the coil after winding and recording the calculated position as defect position data; a sorting step of determining whether the wound coil is good or bad based on the defect position data recorded in the defect position recording step; having A coil manufacturing method characterized in that the defect position data is used to calculate the distance from the defect to the exposed surface of the core around which the magnet wire is wound, thereby determining whether the coil is good or bad.

11. A defect detection device for detecting defects in a magnet wire drawn from a bobbin before being wound around a core; a defect position recording device that calculates the position of the defect on the coil after it has been wound around the core and records the position as defect position data; A coil manufacturing method for manufacturing a coil by winding a magnet wire drawn from a bobbin around the core using a coil manufacturing apparatus comprising: A coil manufacturing method characterized in that, when there are multiple defects in the magnet wire on the coil after winding around the core, the distance between the multiple defects on the coil is calculated from the defect position data recorded by the defect position recording device corresponding to the defects, and the quality of the coil is determined.

12. A coil manufacturing method for manufacturing a coil by winding a magnet wire drawn from a bobbin around a core, comprising: a defect detection step for detecting a defect in the magnet wire; a defect position recording step of calculating the position of the defect on the coil after winding and recording the calculated position as defect position data; a sorting step of determining whether the wound coil is good or bad based on the defect position data recorded in the defect position recording step; having A coil manufacturing method characterized in that the magnet wire has multiple defects on the coil after winding, and the defect position data recorded corresponding to the defects is used to calculate the distance between the multiple defects on the coil, thereby determining whether the coil is good or bad.

13. 6. A method for manufacturing a coil manufactured by the coil manufacturing apparatus according to claim 5, characterized in that an insulation test is further conducted on the coil determined to be defective in a pass / fail judgment based on the defect position data to determine whether the coil is pass / fail.

14. A defect detection device for detecting defects in a magnet wire drawn from a bobbin before being wound around a core; a defect position recording device that calculates the position of the defect on the coil after it has been wound around the core and records the position as defect position data; a coil manufacturing method for manufacturing a stator, comprising: combining and arranging a plurality of coils manufactured by a coil manufacturing method in which a magnet wire drawn from a bobbin is wound around the core to manufacture a coil, the method being characterized in that the distance between the defective portions of the plurality of coils on the stator is calculated based on the defective portion position data, and the quality of the stator is determined.

15. A defect detection step for detecting defects in a magnet wire drawn from a bobbin and wound around a core; a defect position recording step of calculating the position of the defect on the wound coil and recording the calculated position as defect position data; a sorting step of determining whether the wound coil is good or bad based on the defect position data recorded in the defect position recording step; A method for manufacturing a stator by combining and arranging a plurality of the coils manufactured by the coil manufacturing method having the steps of: A stator manufacturing method comprising: calculating the distance between the defective portions of a plurality of the coils on the stator based on the defective portion position data; and determining whether the stator is good or bad.

16. The stator manufacturing method according to claim 14 or 15, characterized in that for a set of coils before the coils are configured into a ring, a distance on the stator is calculated before the coils are assembled into a ring, and the quality of the stator is determined.

17. The method for manufacturing a stator according to claim 16, further comprising the step of: conducting an insulation test on the stator when the stator is determined to be a pass / fail product.

18. A defect detection device for detecting defects in a magnet wire drawn from a bobbin before being wound around a core; a defect position recording device that calculates the position of the defect on the coil after it has been wound around the core and records the position as defect position data; A stator manufacturing method in which a plurality of coils manufactured by a coil manufacturing method in which a magnet wire drawn from a bobbin is wound around the core to manufacture a coil using a coil manufacturing apparatus comprising: a combination of the coils in the stator is determined and arranged based on the defect position data.

19. A defect detection step for detecting defects in a magnet wire drawn from a bobbin and wound around a core; a defect position recording step of calculating the position of the defect on the wound coil and recording the calculated position as defect position data; a sorting step of determining whether the wound coil is good or bad based on the defect position data recorded in the defect position recording step; A method for manufacturing a stator by combining and arranging a plurality of the coils manufactured by the coil manufacturing method having the steps of: A stator manufacturing method comprising: determining a combination of the coils selected based on the defect position data; and arranging the combination on a stator.

20. A method for manufacturing a rotating electric machine, comprising assembling a rotor to the stator manufactured by the stator manufacturing method described in any one of claims 14, 15, 18 and 19.

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