Manufacturing apparatus and manufacturing method

Abstract

The present invention provides a manufacturing device that manufacturers an assembly of a plurality of conductor segments arranged in a ring shape that attaches to a stator core of a motor. The manufacturing device comprises: a jig unit having a plurality of jigs that assemble the assembly in stages, and a support on which the plurality of jigs are mounted; a conveyance device that conveys the jig unit; and a plurality of work devices arranged along the conveyance route of the jig unit. The plurality of work devices include at least one drive device that has an assembly operation performed by the work object jig to which the plurality of conductor segments are supplied by the at least one supply device, and at least one transfer device that transfers an intermediate assembly assembled by the work object jig to the jig at the next stage.

Description

Technical Field

[0001] The present invention relates to a manufacturing technology of a motor.

Background Art

[0002] As a stator coil mounted on a stator core of a motor, an assembly having a plurality of conductor segments is known. This assembly is inserted into a slot of the stator core. Patent Documents 1 to 4 disclose manufacturing technologies for assembling the assembly from a plurality of conductor segments. In these manufacturing technologies, individual conductor segments are arranged and aligned in a circular shape using jigs.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0004] In order to improve the manufacturing efficiency of the assembly, it is necessary to continuously assemble more assemblies. The conventional technology has room for improvement in terms of manufacturing efficiency.

[0005] An object of the present invention is to improve the manufacturing efficiency of an assembly of a plurality of conductor segments.

Means for Solving the Problems

[0006] According to the present invention, A manufacturing apparatus for manufacturing an assembly in which a plurality of conductor segments are annularly arranged and attached to a stator core of a motor, a jig unit having a plurality of jigs for stepwise assembling the assembly and a support on which the plurality of jigs are mounted, a transport device for transporting the jig unit, and a plurality of working devices arranged along the transport path of the jig unit by the transport device, wherein the plurality of working devices include at least one supply device for supplying a plurality of conductor segments to a jig as a work object, at least one driving device for causing an assembling operation to be performed on the jig as the work object to which the plurality of conductor segments are supplied by the at least one supply device, and at least one transfer device for transferring an intermediate assembly assembled by the jig as the work object to a jig in the next stage. mi 、 Each of the plurality of conductor segments has a pair of legs inserted into different slots of the stator core, and a connecting portion connecting between ends of the pair of legs, The assembling operation includes an operation of moving the legs for the plurality of conductor segments to align the pair of legs, The plurality of jigs include a leading jig where an intermediate assembly of the first stage is assembled, at least one subsequent jig, The leading jig includes a first inner jig and a first outer jig surrounding the first inner jig, and the first inner jig and the first outer jig are provided so as to be relatively rotatable around a first rotation center line, The first inner jig is annularly arranged around the first rotation center line and has a plurality of first inner holding portions for holding one of the pair of legs, The first outer jig is annularly arranged around the first rotation center line and has a plurality of first outer holding portions for holding the other of the pair of legs in a radially displaceable manner, The at least one subsequent jig includes a second inner jig and a second outer jig surrounding the second inner jig, and the second inner jig and the second outer jig are provided so as to be relatively rotatable around a second rotation center line, The second inner jig is annularly arranged around the second rotation center line and has a plurality of second inner holding portions for holding the assembly of the previous stage and one of the pair of legs, The second outer jig is annularly arranged around the second rotation center line and has a plurality of second outer holding portions for holding the other of the pair of legs in a radially displaceable manner, The at least one driving device is a device that performs relative rotation of the first inner jig and the first outer jig, and relative rotation of the second inner jig and the second outer jig, The at least one transfer device is a device that transfers the intermediate assembly to the plurality of second inner holding portions of the at least one subsequent jig of the next stage, A manufacturing apparatus is provided, which is characterized by the above.

Advantages of the Invention

[0007] According to the present invention, the manufacturing efficiency of an assembly of a plurality of conductor segments can be improved.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Mode for Carrying Out the Invention

[0009] Hereinafter, embodiments will be described in detail with reference to the accompanying drawings. Note that the following embodiments do not limit the invention according to the claims, and not all combinations of the features described in the embodiments are essential for the invention. Two or more of the plurality of features described in the embodiments may be arbitrarily combined. Also, the same or similar configurations are given the same reference numerals, and duplicate descriptions are omitted.

[0010] <First Embodiment> <Manufacturing System> FIG. 1 is a layout diagram schematically showing a manufacturing system 100 for manufacturing a stator of a three-phase AC motor. In each figure, arrows X and Y indicate horizontal directions orthogonal to each other, and arrow Z indicates the vertical direction. The manufacturing system 100 includes a cutting device 110, a processing device 120, a conveying device 130, a manufacturing device 1, a supply device 140, a mounting device 150, and a processing device 160. Briefly, the cutting device 110, the processing device 120, the conveying device 130, and the manufacturing device 1 manufacture an assembly 10 of stator coils, and the supply device 140 supplies a stator core 141. The mounting device 150 attaches the assembly 10 to the slots 142 of the stator core 141, and the processing device 160 performs processing such as processing the ends of the assembly 10 attached to the stator core 141.

[0011] The cutting device 110 includes a reel 111 around which a wire, which is a material for a stator coil, is wound. The wire is, for example, a metal wire (e.g., a copper wire) having a rectangular cross-section, and its surface is covered with an insulating film. The wire drawn from the reel 111 is formed into a straight shape by a shape correction device 112 and then cut into a predetermined length by a cutting device 113 to produce a rod-shaped conductor wire 114. Note that the insulating films on the surfaces of both ends of the conductor wire 114 are peeled off by a peeling device (not shown).

[0012] The conductor wire 114 is supplied to the processing device 120. The processing device 120 includes a bending device 121. The bending process is performed in two steps. In the first step, the bending device 121 bends the conductor wire 114 into a substantially U shape on the same plane. Subsequently, in the second step, bending is performed in a direction intersecting the same plane to bend a connection part C described later. Thereby, the conductor segment CS is manufactured. The conductor segment CS integrally includes a pair of leg portions F inserted into the slots 142 of the stator core 141 and a connection part C connecting between the ends of the pair of leg portions F. The pair of leg portions F extend linearly in parallel with each other. The connection part C has a roof shape or a mountain shape. Due to the bending of the connection part C, the pair of leg portions F are easily inserted into the slots 142, and an annular assembly can be obtained by assembling a plurality of conductor segments CS by a method described later.

[0013] The conveying device 130 is a device that supplies the conductor segment CS manufactured by the processing device 120 to the manufacturing device 1. The conveying device 130 includes, for example, a shooter that sequentially flows the conductor segment CS into the stocker 7 of the manufacturing device 1.

[0014] In the case of this embodiment, two sets of the cutting device 110, the processing device 120, and the conveying device 130 are provided, and are arranged one set on each side of the manufacturing line (the line in the X direction) of the manufacturing device 1. The manufacturing device 1 is a device that manufactures an assembly 10 in which a plurality of conductor segments CS are arranged in an annular shape. Details will be described later.

[0015] The supply device 140 sequentially supplies the stator core 141 to the mounting device 150. The stator core 141 has a cylindrical shape as a whole, and a plurality of slots 142 opened on the inner peripheral surface are formed radially. The mounting device 150 mounts the assembly 10 on the stator core 141 by inserting the leg portions F of each conductor segment CS of the assembly 10 into the slots 142 of the stator core 141. The pair of leg portions F of each conductor segment CS are inserted into different slots 142. The processing device 160 performs bending processing on each leg portion F protruding from the stator core 141 to the outside, welding processing between adjacent leg portions F, and the like.

[0016] <Manufacturing apparatus> With reference to FIGS. 1 to 3, the configuration of the manufacturing apparatus 1 will be described. FIG. 2 is a side view of the manufacturing apparatus 1, and FIG. 3 is a perspective view of the jig unit 2 used for assembling the assembly 10. The manufacturing apparatus 1 includes a plurality of jig units 2, a transfer device 3 that circulates the jig units 2, a plurality of working devices 4 to 6 arranged along the transfer path of the jig units 2 by the transfer device 3, and a plurality of stockers 7.

[0017] The transfer device 3 includes an upper conveyor 30 and a lower conveyor 31 arranged in two stages vertically. The conveyor 30 forms the forward path of the transfer path of the jig unit 2, and the conveyor 31 forms the return path of the transfer path of the jig unit 2.

[0018] The conveyors 30 and 31 extend in the X direction and are roller conveyors in which a plurality of rows of rollers RL are arranged in two rows spaced apart in the Y direction. As shown by the arrow in FIG. 2, the conveyor 30 conveys the jig unit 2 placed on the rollers RL in one direction in the X direction, and the conveyor 31 conveys the jig unit 2 placed on the rollers RL in the reverse direction in the X direction.

[0019] At both ends of the conveyors 30 and 31 in the X direction, moving conveyors 32 are respectively arranged. The moving conveyor 32 is a roller conveyor in which a plurality of rows of rollers RL are arranged in two rows spaced apart in the Y direction and has a length capable of placing one jig unit 2. The moving conveyor 32 is lifted and lowered by a lifting device 33 between a position continuous with the conveyor 30 (the solid line position in FIG. 2) and a position continuous with the conveyor 31 (the broken line position in FIG. 2).

[0020] After the jig unit 2 is conveyed from one end to the other end of the conveyor 30 in the X direction, it is lowered by the moving conveyor 32 and transferred to the conveyor 31. Then, after the jig unit 2 is conveyed from the other end to one end of the conveyor 31 in the X direction, it is lifted by the moving conveyor 32 and transferred to the conveyor 30. In this way, the jig unit 2 is circulated by the transfer device 3.

[0021] The jig unit 2 includes a plurality of jigs 22 and 23 for stepwise assembling the assembly 10, and a support 20 on which the jigs 22 and 23 are mounted. One assembly 10 can be manufactured by one jig unit 2. In the case of this embodiment, the support 20 has a plurality of support portions 21 on a plate-shaped main body. The jigs 22 and 23 are respectively supported by the support portions 21. The jigs 22 and 23 are arranged side by side in the X direction, and the jig 22 is the leading jig and the jig 23 is the subsequent jig when viewed in the conveying direction by the conveying device 30. In the case of this embodiment, the jigs 22 and 23 are mounted on the support 20 in the assembling order of the assembly 10 in the conveying direction of the jig unit 2 by the conveyor 30. The arrangement of the jigs 22 and 23 is not limited to the assembling order, but according to the arrangement of this embodiment, since the jigs of the work object are sequentially shifted in the conveying direction, the progress of the assembly becomes easy to understand, and the management of the assembly process and the layout of the working devices 4 to 6 are facilitated.

[0022] The jig 22 includes an inner jig 221 and an outer jig 222 surrounding the inner jig 221. In the case of this embodiment, both the inner jig 221 and the outer jig 222 have a cylindrical shape, and the outer peripheral surface of the inner jig 221 is in contact with the inner peripheral surface of the outer jig 222. The inner jig 221 and the outer jig 222 are relatively rotatable around the rotation center line 22a in the Z direction. In the case of this embodiment, the inner jig 221 is fixed to the support portion 21, and the outer jig 222 is rotatably supported by the support portion 21. However, a configuration in which the inner jig 221 is rotatably supported and the outer jig 222 is fixed may also be used.

[0023] In the case of this embodiment, the outer jig 222 has a pressed portion 223 protruding radially from its outer peripheral surface, and rotates when an external force in the Y direction acts on the pressed portion 223. However, the rotation mechanism of the outer jig 222 is not limited to this, and for example, a configuration in which the outer jig 222 is rotated by a drive source mounted on the support 20 or the support portion 21 may also be used.

[0024] The jig 23 has the same structure as the jig 22. The jig 23 has an inner jig 231 and an outer jig 232 that surrounds the inner jig 231. In the case of this embodiment, both the inner jig 231 and the outer jig 232 have a cylindrical shape, and the outer peripheral surface of the inner jig 231 is in contact with the inner peripheral surface of the outer jig 232. The inner jig 231 and the outer jig 232 are relatively rotatable around the rotation center line 23a in the Z direction. In the case of this embodiment, the inner jig 231 is fixed to the support portion 21, and the outer jig 232 is rotatably supported by the support portion 21. However, a configuration in which the inner jig 231 is rotatably supported and the outer jig 232 is fixed may also be employed.

[0025] Holding portions for holding the legs F of the conductor segment CS are respectively formed in the jigs 22 and 23. FIG. 4 is a partially enlarged view of the jigs 22 and 23 and is a plan view showing a part of the jigs 22 and 23.

[0026] A plurality of inner holding portions 224 are formed in the inner jig 221 of the jig 22, and a plurality of outer holding portions 225 are formed in the outer jig 222. In the case of this embodiment, the inner holding portion 224 is a hole having a depth in the Z direction, and in the case of this embodiment, it is a hole penetrating the inner jig 221 in the Z direction. When viewed in the cross-sectional shape in the X-Y plane, the inner holding portion 224 has a size into which one leg F can be inserted. The plurality of inner holding portions 224 are arranged annularly around the rotation center line 22a at equal pitches in the circumferential direction.

[0027] The outer holding portion 225 is a groove having a depth in the Z direction and opening on the inner peripheral surface of the outer jig 222, and in the case of this embodiment, it is a groove penetrating the outer jig 222 in the Z direction. When viewed in the cross-sectional shape in the X-Y plane, the outer holding portion 225 has a width into which one leg F can be inserted and extends in the radial direction so that the leg F can be displaced in the radial direction. The plurality of outer holding portions 225 are arranged annularly around the rotation center line 22a at equal pitches in the circumferential direction. The number of the inner holding portions 224 and the outer holding portions 225 is the same, and the pitch in the circumferential direction is also the same.

[0028] A plurality of inner holding portions 234 are formed on the inner jig 231 of the jig 23, and a plurality of outer holding portions 235 are formed on the outer jig 232. In the case of this embodiment, the inner holding portion 234 is a hole having a depth in the Z direction, and in the case of this embodiment, it is a hole penetrating the inner jig 231 in the Z direction. When viewed in the cross-sectional shape in the X-Y plane, the inner holding portion 234 has a width into which one leg portion F can be inserted, and has a length that allows a plurality of leg portions F to be inserted side by side in the radial direction. The plurality of inner holding portions 234 are arranged annularly around the rotation center line 23a at equal pitches in the circumferential direction.

[0029] The outer holding portion 235 has a depth in the Z direction and is a groove that opens on the inner peripheral surface of the outer jig 232. In the case of this embodiment, it is a groove penetrating the outer jig 232 in the Z direction. When viewed in the cross-sectional shape in the X-Y plane, the outer holding portion 235 has a width into which one leg portion F can be inserted, and is extended in the radial direction so that the leg portion F can be displaced freely in the radial direction. The plurality of outer holding portions 235 are arranged annularly around the rotation center line 23a at equal pitches in the circumferential direction. The number of the inner holding portions 234 and the outer holding portions 235 is the same, and the circumferential pitch is also the same.

[0030] With reference to FIGS. 1 and 2, the working devices 4 to 6 will be described. The working devices 4 to 6 are arranged on the side of the conveying device 3, and four working devices 4, two working devices 5, and one working device 6 are arranged for performing various operations on the jig unit 2 conveyed by the conveyor 30. However, the number and arrangement of each working device can be designed as appropriate.

[0031] The working device 4 is a multi-axis robot that moves the working head 4a in each of the X, Y, and Z directions, and supplies the conductor segments CS one by one from the stocker 7 to the jig 22 or the jig 23 that is the work target. In the case of this embodiment, the working device 4 is a vertically articulated robot, and a gripping portion 4b capable of gripping the conductor segment CS is provided at its tip. Although the working device 4 is a vertically articulated type, a horizontally articulated robot or other well-known industrial robots can be used.

[0032] The working device 5 is a driving device that causes the jig 22 or the jig 23 for the work object to perform an assembling operation. In the case of this embodiment, the working device 5 is a pusher that reciprocates the pressing portion 5a in the Y direction, and presses the pressed portion 223 of the outer jig 222 or the pressed portion 233 of the outer jig 232 to rotate the outer jig 222 or the outer jig 232. The pusher of this embodiment is an air actuator that expands and contracts the pressing portion 5a in the Y direction.

[0033] The working device 6 is a transfer device that transfers the intermediate assembly assembled by the jig 22 to the jig 23. The working device 6 includes a holding head 6a that holds the intermediate assembly, a lifting portion 6b that raises and lowers the holding head 6a, and a moving portion 6c that moves the lifting portion 6b in the X direction. The intermediate assembly of the jig 22 is held by the holding head 6a, the intermediate assembly is lifted from the jig 22 by the lifting portion 6b, the holding portion 6a and the lifting portion 6b are moved to the jig 23 by the moving portion 6c, and the holding portion 6a is lowered by the lifting portion 6b to transfer the intermediate assembly to the jig 23.

[0034] In this embodiment, a plurality of working devices 4 and 5 are provided at intervals in the conveyance direction of the jig unit 2 by the conveyor 30. Specifically, four working devices 4 and two working devices 5 are provided. Operations on a plurality of jig units 2 can be performed simultaneously, improving the manufacturing efficiency. In this embodiment, there is one working device 6, but a plurality of working devices 6 may also be provided at intervals in the conveyance direction of the jig unit 2.

[0035] <Manufacturing Method> With reference to FIGS. 1, 5 to 11, each manufacturing process of the assembly 10 will be described. In the manufacture of the assembly 10, the jig unit 2 is conveyed and stopped by the conveying device 3. While the conveyance of the jig unit 2 is stopped, operations are performed on the jig unit 2 by the working devices 4 to 6. Thereafter, the conveyance and stop of the jig unit 2 and the operations on the jig unit 2 are repeated.

[0036] The work content for the jig unit 2 will be described. The manufacturing of the assembly 10 involves performing operations on the jig 22 using two working devices 4 on the upstream side (left side in FIG. 1) and one working device 5 in the conveyance direction of the jig unit 2 in the conveyance device 30, and transferring the intermediate assembly from the jig 22 to the jig 23 using the working device 6. Further, operations are performed on the jig 23 using the working devices 4 and 5 on the downstream side (right side in FIG. 1) in the conveyance direction of the jig unit 2 in the conveyance device 30 to obtain the assembly 10.

[0037] Specifically, for example, it starts with the step of supplying a plurality of conductor segments CS to the jig 22 marked with the symbol G in FIG. 1 by the working device 4. FIG. 5 is a schematic diagram showing this step. The working device 4 takes out the conductor segments CS one by one from the stocker 7 using the gripping portion 4b and inserts them into the jig 22. When inserting, of the pair of leg portions F of the conductor segment CS, one leg portion F is inserted into the inner holding portion 224, and the other leg portion F is inserted into the outer holding portion 225. In this way, the conductor segment CS is inserted so as to straddle the inner jig 221 and the outer jig 222. By repeating such a supply operation of the conductor segment CS by the working device 4, a plurality of conductor segments CS are arranged in a circular one-round manner in the jig 22. As shown in the cross-sectional view taken along the line A-A in FIG. 5, one leg portion F of the conductor segment CS is inserted into the inner holding portion 224, and the other leg portion F is inserted into the outer holding portion 225 which is in a circumferentially different position from the inner holding portion 224 into which one leg portion F is inserted.

[0038] Next, the conveyor 30 conveys the jig unit 2 downstream in the conveyance direction, conveys the jig 22 at the position of the symbol G in FIG. 1 to the position of the symbol H, and stops it. After stopping the jig 22 at the position H, the working device 5 is driven to perform an assembling operation on the jig 22. FIG. 6 is an explanatory diagram thereof. The pressed portion 223 of the jig 22 where the insertion operation of the plurality of conductor segments CS is completed is pressed by the pressing portion 5a of the working device 5, and the outer jig 222 is rotated in the arrow direction. Thereby, the intermediate assembly 11 is manufactured. FIG. 7 is a diagram showing the assembling operation in more detail than FIG. 6.

[0039] As the outer jig 222 rotates, the leg portion F inserted into the outer holding portion 225 is displaced radially inward while being displaced in the circumferential direction of the outer jig 222. Accordingly, the connection portions C of a plurality of adjacent conductor segments CS are aligned in a ring shape. Finally, the leg portion F held by the outer holding portion 225 is displaced to a position adjacent to the leg portion F of another conductor segment CS held by the inner holding portion 224, and the intermediate assembly 11 with a pair of aligned leg portions F is completed. The intermediate assembly 11 has two layers (two rows) of leg portions F arranged in a ring shape in the radial direction.

[0040] Regarding the configuration of reversing the rotated outer jig 222 to its original position, for example, a drive source (not shown) for reversing may be provided on the support 20 or the support portion 21. Alternatively, the outer jig 222 may be reversed by another working device 5 different from the working device 5 that rotates the outer jig 222. Or, it may be reversed by a working device (not shown) during the process of transporting the jig unit 2 by the conveyor 21.

[0041] Next, the working device 6 is driven to transfer the intermediate assembly 11 assembled by the jig 22 at the position of the reference symbol H in FIG. 1 to the next-stage jig 23 at the position of the reference symbol I. FIG. 8 is a schematic diagram showing this process.

[0042] The working device 6 holds the intermediate assembly 11 of the jig 22 with the holding head 6a. The tip of the holding head 6a has a plurality of pins 6d that can be inserted radially into and detached from the intermediate assembly 11, and the intermediate assembly 11 is held by the engagement between the plurality of pins 6d and each connection part C of the intermediate assembly 11. A large number of pins 6d may be provided in the circumferential direction of the intermediate assembly 11. After the pins 6d are inserted radially from below each connection part C, when the holding head 6a starts to rise by the lifting part 6b, the intermediate assembly 11 also rises together and is pulled up from the jig 22. After pulling up the intermediate assembly 11 from the jig 22, the moving part 6c moves the holding head 6a and the lifting part 6b to the jig 23 at the position of symbol I in FIG. 1, and positions the holding head 6a above the jig 23. Next, the holding head 6a is lowered by the lifting part 6b, and the leg part F of the intermediate assembly 11 is inserted into the hole of the inner holding part 234 of the jig 23. After the insertion, the insertion of the pins 6d is released, and the transfer of the intermediate assembly 11 to the jig 23 is completed.

[0043] The leg part F of the intermediate assembly 11 is inserted into the hole of the inner holding part 234 of the inner jig 231. As shown in the partially enlarged cross-sectional view of FIG. 8, two layers (two pieces) of leg parts F are inserted into the hole of one inner holding part 234.

[0044] Next, the conveyor 30 conveys the jig unit 2 downstream in the conveying direction, conveys the jig 23 at the position of I to the position of symbol J in FIG. 1, and stops it. After stopping the jig 23 at the position of J, a plurality of conductor segments CS are supplied to the jig 23 by the working device 4. FIG. 9 is a schematic diagram showing this process. The working device 4 takes out the conductor segments CS one by one from the stocker 7 using the gripping part 4b and inserts them into the jig 23. At the time of insertion, among the pair of leg parts F of the conductor segment CS, one leg part F is inserted into the inner holding part 234, and the other leg part F is inserted into the outer holding part 235. The leg part F inserted into the inner holding part 234 is inserted outside the already inserted intermediate assembly 11.

[0045] In this way, the conductor segment CS is inserted into the inner jig 231 and the outer jig 232 so as to straddle them. By repeating the supply operation of such conductor segments CS, a plurality of conductor segments CS are arranged in a circular shape around the intermediate assembly 11 in the jig 23 for one round. In FIG. 9, as shown in the cross-sectional view taken along line B-B, one leg portion F of the conductor segment CS is inserted into the inner holding portion 234, and the other leg portion F is inserted into the outer holding portion 235 which is in a circumferentially different position from the inner holding portion 234 into which one leg portion F is inserted.

[0046] FIG. 10 is a partially enlarged cross-sectional view showing the state where the conductor segment CS is inserted into the jig 23. Two layers of leg portions F of the intermediate assembly 11 and one leg portion F of the conductor segment CS are inserted into each inner holding portion 234 of the inner jig 231. The other leg portion F of the conductor segment CS is inserted into each outer holding portion 235 of the outer jig 232.

[0047] Next, the conveyor 30 conveys the jig unit 2 downstream in the conveying direction, conveys the jig 23 located at the position J in FIG. 1 to the position K, and stops it. After stopping the jig 23 at the position K, the working device 5 is driven to perform an assembling operation on the jig 23. FIG. 11 is an explanatory view thereof. The pressed portion 233 of the jig 23 in which the insertion operation of the intermediate assembly 11 and the plurality of conductor segments CS is completed is pressed by the pressing portion 5a of the working device 5, and the outer jig 232 is rotated. Thereby, the assembly 10 which is the final assembly is manufactured.

[0048] Similar to the case of the jig 22 described with reference to FIG. 7, as the outer jig 232 rotates, the leg F inserted into the outer holding portion 235 is displaced radially inward while being displaced in the circumferential direction of the outer jig 232, and accordingly, the connection portions C of a plurality of adjacent conductor segments CS are aligned in a ring shape. Finally, the leg F held by the outer holding portion 235 is displaced to a position adjacent to the leg F of another conductor segment CS held by the inner holding portion 234, and a pair of legs F are aligned. The assembly 10 has a structure in which, on the outside of the intermediate assembly 11, it has two layers (two rows) of legs F arranged in a ring shape in the radial direction, and as a whole, it has four layers of legs F in the radial direction. After that, the conveyor 30 conveys the jig unit 2 downstream in the conveying direction, and conveys the jig 23 located at the position K in FIG. 1 to the position L where the moving conveyor 32 is located and stops it. After stopping the jig 23 at the position L, the assembly 10 is transferred to the mounting device 150 by a working device or an operator (not shown).

[0049] Regarding the configuration of reversing the rotated outer jig 232 to its original position, for example, a drive source (not shown) for reversing may be provided on the support 20 or the support portion 21. Alternatively, the outer jig 232 may be reversed by a working device 5 different from the working device 5 that rotates the outer jig 232. Or, it may be reversed by a working device (not shown) during the process of conveying the jig unit 2 by the conveyor 21.

[0050] The jig unit 2 from which the assembly 10 has been removed is lowered by the lifting device 33 from a position continuous with the conveyor 30 to a position continuous with the conveyor 31. Next, the jig unit 2 is conveyed from the other end (the right end in FIG. 1) in the X direction of the conveyor 31 to one end (the left end in FIG. 1), and then is lifted by the moving conveyor 32 to a position continuous with the conveyor 30 and transferred to the conveyor 30. In this way, the jig unit 2 is circulated by the conveying device 3, and the assembly work of the assembly 10 is continuously repeated by the working devices 4 to 6.

[0051] As described above, in the present embodiment, while the jig unit 2 is intermittently conveyed in the X direction, the assembling work of the assembly 10 is performed by the working devices 4 to 6. The line production of the assembly 10 becomes possible, and the manufacturing efficiency of the assembly 10 can be improved. Since the jig unit 2 is conveyed cyclically, the manufacturing of the assembly 10 can be continuously performed without interruption, and its manufacturing efficiency can be further improved. Further, in the manufacturing process of the assembly, there is no need to lift or lower the jig 22 or the jig 23, and there is no need to transfer the jig 22 or the jig 23 from another storage location to the assembly position. Therefore, there is no need to perform complicated management and storage of the jigs.

[0052] In the present embodiment, after the intermediate assembly 11 is transferred to the jig 23, the conductor segment CS is supplied. Conversely, after the conductor segment CS is supplied to the jig 23, the intermediate assembly 11 may be transferred.

[0053] <Second Embodiment> When the assembly 10 is used as the stator coil of a three-phase AC motor, it is necessary to perform electrical interlayer connection work for each of the three phases (U phase, V phase, W phase) between the 1-2 layer coils and the 3-4 layer coils. In the first embodiment, it is assumed that the wiring work is performed after the manufacturing of the assembly 10. However, a conductor segment for interlayer connection may be incorporated into the assembly using the same conductor segment as the conductor segment CS. Note that the conductor segment for interlayer connection may be different from the conductor segment CS. For example, the distance between a pair of leg portions F may be different, or the roof-shaped or gable-shaped configuration of the connection portion C may be different.

[0054] FIG. 12 is a layout diagram of the manufacturing apparatus 1A in the present embodiment. The manufacturing apparatus 1A manufactures the assembly 10A in which the conductor segments for connection are incorporated as the final assembly. The basic configuration of the manufacturing apparatus 1A is the same as that of the manufacturing apparatus 1, but the number and arrangement of the jig unit and the working devices 4 to 6 are different.

[0055] FIG. 13 is a perspective view of the jig unit 2A used in the present embodiment. The basic configuration of the jig unit 2A is the same as that of the jig unit 2, but the number of jigs is different. The jig unit 2A includes a plurality of jigs 22 to 24 for stepwise assembling the assembly 10, and a support 20 on which the jigs 22 to 24 are mounted. One assembly 10 can be manufactured by one jig unit 2. In the case of the present embodiment, the support 20 has a plurality of support portions 21 on a plate-shaped main body. The jigs 22 to 24 are respectively supported by the support portions 21.

[0056] The jigs 22 to 24 are arranged side by side in the X direction. When viewed from the upstream side (the left side in FIG. 12) in the conveyance direction by the conveyance device 30, the jig 22 is the leading jig, and the jigs 24 and 23 are subsequent jigs. The jig 23 is the last jig, and the jig 24 is an intermediate jig between the jig 22 and the jig 23. In the case of the present embodiment, in the conveyance direction of the jig unit 2 by the conveyor 30, the jigs 22, 24, and 23 are mounted on the support 20 in the assembling order of the assembly 10. That is, the assembly 10 is assembled in the order of operations using the jig 22, operations using the jig 24, and operations using the jig 23. The arrangement of the jigs 22, 24, and 23 is not limited to the assembling order. However, according to the arrangement of the present embodiment, the progress of the assembly with the assembly 10 becomes easy to understand, and the management of the assembly process and the layout of the working devices 4 to 6 are facilitated.

[0057] The configurations of the jigs 22 and 23 are the same as those of the jigs 22 and 23 described in the first embodiment. The configuration of the jig 24 is the same as that of the jig 23 except for the size, and includes an inner jig 241, an outer jig 242, and a pressed portion 243. The outer jig 242 is rotatable around the rotation center line 24a. Inner holding portions 244 and outer holding portions 245 similar to the inner holding portion 234 and the outer holding portion 235 of the jig 23 are formed on the inner jig 241 and the outer jig 242 (see FIG. 14).

[0058] Each manufacturing process of the assembly 10A will be described. First, in the same procedure as in the first embodiment, the conductor segment CS is supplied to the jig 22 at the position of the symbol M in FIG. 12 by the working device 4. In parallel with, or after the supply of the conductor segment CS to the jig 22, as shown in FIG. 14, the connection segment DS is supplied to the jig 24 at the position of N in FIG. 12 by the working device 4. The connection segment DS is the same segment as the conductor segment CS.

[0059] The working device 4 takes out the connection segments DS (conductor segments CS) one by one from the stocker 7 using the gripping portion 4b and inserts them into the jig 24. At the time of insertion, of the pair of legs F of the connection segment DS, one leg F is inserted into the inner holding portion 244 and the other leg F is inserted into the outer holding portion 245. In this way, the connection segment DS is inserted into the inner jig 241 and the outer jig 242 so as to straddle them. By repeating such a supply operation of the connection segment DS by the working device 4, a plurality of connection segments DS are arranged in a fan shape in the jig 24. In the present embodiment, since the number of layers between the 1-2 layer coil and the 3-4 layer coil is 2 and the number of phases is 3 (U phase, V phase, W phase), 2×3 = 6 connection segments DS are supplied to the jig 24.

[0060] In the present embodiment, a part (6 pieces) of the leg F group of the second layer and a part (6 pieces) of the leg F group of the third layer are formed by the legs F of the connection segment DS. Therefore, the conductor segment CS is supplied to the jig 22 with thinning by the amount of the connection segment DS.

[0061] Next, the conveyor 30 conveys the jig unit 2A downstream in the conveyance direction, conveys the jigs 22 and 24 at the positions of the symbols M and N in FIG. 12 to the positions of the symbols P and Q, and stops them. After stopping the jigs 22 and 24 at the positions of the symbols P and Q, the working device 5 is driven to perform an assembling operation on the jig 22.

[0062] Next, the conveyor 30 conveys the jig unit 2A downstream in the conveying direction, conveys the jigs 22 and 24 at the positions P and Q in FIG. 12 to the positions R and S, and stops them.

[0063] After stopping the jigs 22 and 24 at the positions R and S in FIG. 12, the intermediate assembly 11 is transferred from the jig 22 at the position R to the jig 24 at the position S by the working device 6. The intermediate assembly 11 is inserted into the inner jig 241 of the jig 24.

[0064] FIG. 15 is a partially enlarged cross-sectional view showing a state where the intermediate assembly 11 is transferred to the jig 24. In the illustrated example, the leg portion F of the conductor segment CS constituting the intermediate assembly 11 is indicated by reference numeral 11, and the leg portion F of the connection segment DS is indicated by reference numeral DS. At the six inner holding portions 244, two layers (two rows) of leg portions F are formed by the leg portion F of the conductor segment CS and the leg portion F of the connection segment DS. And in the inner holding portion 244 into which one leg portion F of the connection segment DS is inserted, one layer (one) of the leg portion F of the intermediate assembly 11 is inserted inside the leg portion F of the connection segment DS. In the remaining inner holding portions 244 (the inner holding portions 244 into which the leg portion F of the connection segment DS is not inserted), only two layers (two) of the leg portion F of the intermediate assembly 11 are inserted.

[0065] Next, the working device 5 is driven to cause an assembling operation on the jig 24 at the position S in FIG. 12. FIG. 16 is an explanatory diagram thereof. The pressed portion 243 of the jig 24 where the insertion operation of the six connection segments DS and the intermediate assembly 11 is completed is pressed by the pressing portion 5a of the working device 5, and the outer jig 242 is rotated. An intermediate assembly 12 with six connection segments DS added to the intermediate assembly 11 is manufactured. In the intermediate assembly 12, a third layer of leg portion F is partially formed by the six leg portions F of the connection segment DS.

[0066] Subsequently, the intermediate assembly 12 is transferred by the working device 6 from the jig 24 located at the position of symbol S in FIG. 12 to the jig 23 located at the position of symbol T. The intermediate assembly 12 is inserted into the inner jig 231 of the jig 23. Into the six inner holding portions 234, two layers (two pieces) of leg portions F and one leg portion F of the connection segment DS are inserted. Only two layers (two pieces) of leg portions F are inserted into the remaining inner holding portions 234.

[0067] Next, the conveyor 30 conveys the jig unit 2A downstream in the conveying direction, conveys the jig 23 located at the position of T to the position of U, and stops it. After the jig 23 is stopped at the position of U, in the same manner as in the first embodiment, a plurality of conductor segments CS are supplied to the jig 23 by the working device 4. The working device 4 takes out the conductor segments CS one by one from the stocker 7 using the gripping portion 4b and inserts them into the jig 23. At the time of insertion, of the pair of leg portions F of the conductor segment CS, one leg portion F is inserted into the inner holding portion 234, and the other leg portion F is inserted into the outer holding portion 235. The leg portion F inserted into the inner holding portion 234 is inserted outside the already inserted intermediate assembly 12, but the leg portion F of the connection segment DS is not inserted into the inner holding portion 234 where the leg portion F of the conductor segment CS is inserted. A plurality of conductor segments CS are arranged in a ring shape around the intermediate assembly 12 in the jig 23 for one round.

[0068] Next, the conveyor 30 conveys the jig unit 2A downstream in the conveying direction, conveys the jig 23 located at the position of U to the position of V, and stops it. After the jig 23 is stopped at the position of V, the working device 5 is driven in the same manner as in the first embodiment to perform an assembling operation on the jig 23, and the assembly 10A is completed. The assembly 10A has two layers (two rows) of leg portions F arranged in a ring shape outside the intermediate assembly 12 in the radial direction, and has a 1-2 layer coil on the radially inner side and a 3-4 layer coil on the outer side. And the leg portion F of the connection segment DS is mixed in the second layer coil and the third layer coil. The assembly 10A has a structure having four layers of leg portions F of the conductor segment CS in the radial direction as a whole.

[0069] In this way, by changing the jig unit 2 (adding the jig 24) and changing the layout of the working devices 4 to 6 with respect to the manufacturing apparatus 1A, it is possible to relatively easily obtain assemblies with different structures. In this embodiment, after supplying the connection segment DS to the jig 24, the intermediate assembly 11 is transferred. Conversely, after transferring the intermediate assembly 11 to the jig 24, the connection segment DS may be supplied.

[0070] Also, in this embodiment, after transferring the intermediate assembly 12 to the jig 23, the conductor segment CS is supplied. Conversely, after supplying the conductor segment CS to the jig 23, the intermediate assembly 12 may be transferred.

[0071] <Third Embodiment> The manufacturing apparatus 1 can also obtain further different assemblies by changing the jig unit 2 and changing the layout of the working devices 4 to 6. Hereinafter, a configuration example of the jig unit and a structural example of the assembly obtained from the jig unit will be described.

[0072] The jig unit 2B in FIG. 17 has a jig 22, a jig 23A, and a jig 23B. The jig 23A and the jig 23B each have the same configuration as the jig 23 in the first embodiment, and have an inner jig 231A, 231B corresponding to the inner jig 231 and an outer jig 232A, 232B corresponding to the outer jig 232.

[0073] An assembly with a six-layer structure can be obtained by the jig unit 2B. Briefly, an intermediate assembly similar to the intermediate assembly 11 in the first embodiment is obtained by the jig 22. This intermediate assembly is transferred to the jig 23A, and further, by supplying the conductor segment CS to the jig 23A and performing an assembly operation, a four-layer intermediate assembly similar to the final assembly 10 in the first embodiment is obtained. This intermediate assembly is transferred to the jig 23B, and further, by supplying the conductor segment CS to the jig 23B and performing an assembly operation, a six-layer final assembly is obtained.

[0074] The jig unit 2C in Fig. 17 has jigs 22, 23A to 23C. The jigs 23A to 23C each have the same configuration as the jig 23 in the first embodiment, and have inner jigs 231A, 231B, 231C corresponding to the inner jig 231 and outer jigs 232A, 232B, 232C corresponding to the outer jig 232.

[0075] An eight-layer assembly can be obtained by the jig unit 2C. Briefly, an intermediate assembly similar to the intermediate assembly 11 in the first embodiment is obtained by the jig 22. This intermediate assembly is transferred to the jig 23A, and further, a conductor segment CS is supplied to the jig 23A to perform an assembly operation, thereby obtaining a four-layer intermediate assembly similar to the final assembly 10 in the first embodiment. This intermediate assembly is transferred to the jig 23B, and further, a conductor segment CS is supplied to the jig 23B to perform an assembly operation, thereby obtaining a six-layer intermediate assembly. This intermediate assembly is transferred to the jig 23C, and further, a conductor segment CS is supplied to the jig 23C to perform an assembly operation, thereby obtaining an eight-layer final assembly.

[0076] The jig unit 2D in Fig. 17 has jigs 22, 24A, 23A, 24B, 23B. The jigs 23A and 23B each have the same configuration as the jig 23 in the first embodiment, and have inner jigs 231A, 231B corresponding to the inner jig 231 and outer jigs 232A, 232B corresponding to the outer jig 232. The jigs 24A and 24B each have the same configuration as the jig 24 in the second embodiment, and have inner jigs 241A, 241B corresponding to the inner jig 241 and outer jigs 242A, 242B corresponding to the outer jig 242.

[0077] The jig unit 2D can obtain an assembly in a six-layer structure with conductor segments (connection segments DS) for interlayer connection that connect between the coils of layers 1-2 and layers 3-4, and between the coils of layers 3-4 and layers 5-6, respectively. Generally speaking, an intermediate assembly similar to the intermediate assembly 11 of the first embodiment can be obtained by the jig 22. By supplying the connection segment DS to the jig 24A and performing the assembly operation of the jig 24A after transferring the intermediate assembly to the jig 24A, an intermediate assembly similar to the intermediate assembly 12 of the second embodiment can be obtained. By transferring this intermediate assembly to the jig 23A and further supplying the conductor segment CS to the jig 23A and performing the assembly operation, an intermediate assembly similar to the final assembly 10A of the second embodiment can be obtained.

[0078] By supplying the connection segment DS to the jig 24B and performing the assembly operation of the jig 24B after transferring the intermediate assembly to the jig 24B, an intermediate assembly with the connection segment DS arranged in the final assembly 10A of the second embodiment can be obtained. By transferring this intermediate assembly to the jig 23B and further supplying the conductor segment CS to the jig 23B and performing the assembly operation, the final assembly can be obtained. This final assembly has a six-layer structure, and the legs F of the connection segment DS are mixed in the leg F groups of the second, third, fourth, and fifth layers. That is, this final assembly is an assembly in which connection segments DS that connect between the coils of layers 1-2 and layers 3-4, and between the coils of layers 3-4 and layers 5-6 are incorporated.

[0079] Based on the above embodiments, when the number N of jigs constituting the jig unit does not incorporate connection segments for interlayer connection, N = (the number of layers of the final assembly) / 2. Also, when incorporating connection segments for interlayer connection, the number of jigs is N = (the number of layers of the final assembly) - 1.

[0080] Although the embodiments of the invention have been described above, the invention is not limited to the above embodiments, and various modifications and changes are possible within the scope of the gist of the invention.

Claims

1. A manufacturing apparatus for manufacturing an assembly in which a plurality of conductor segments are annularly arranged and attached to a stator core of a motor, comprising: A jig unit having a plurality of jigs for assembling the assembly step by step and a support on which the plurality of jigs are mounted; A transfer device for transferring the jig unit; A plurality of working devices arranged along a transfer path of the jig unit by the transfer device, The plurality of working devices include: At least one supply device for supplying a plurality of conductor segments to a jig as a work target; At least one driving device for causing an assembling operation to be performed on the jig as the work target to which a plurality of conductor segments are supplied by the at least one supply device; At least one transfer device for transferring an intermediate assembly assembled by the jig as the work target to a jig in the next stage, Each conductor segment of the plurality of conductor segments has: A pair of leg portions inserted into different slots of the stator core and a connecting portion connecting ends of the pair of leg portions; The assembling operation includes an operation of moving the leg portions for a plurality of conductor segments to align the pair of leg portions; The plurality of jigs include: A leading jig on which an intermediate assembly in the first stage is assembled; At least one subsequent jig, The leading jig includes a first inner jig and a first outer jig surrounding the first inner jig, and the first inner jig and the first outer jig are provided so as to be relatively rotatable around a first rotation center line; The first inner jig is annularly arranged around the first rotation center line and has a plurality of first inner holding portions for holding one of the pair of leg portions; The first outer jig is annularly arranged around the first rotation center line and has a plurality of first outer holding portions for holding the other of the pair of leg portions so as to be displaceable in the radial direction; The at least one subsequent jig includes a second inner jig and a second outer jig surrounding the second inner jig, and the second inner jig and the second outer jig are provided so as to be relatively rotatable around a second rotation center line; The second inner jig is annularly arranged around the second rotation center line and has a plurality of second inner holding portions for holding an intermediate assembly in the previous stage and one of the pair of leg portions; The second outer jig is annularly arranged around the second rotation center line, and has a plurality of second outer holding parts for holding the other of the pair of legs in a displaceable manner in the radial direction. The at least one driving device is a device that performs relative rotation of the first inner jig and the first outer jig, and relative rotation of the second inner jig and the second outer jig. The at least one transfer device is a device that transfers the intermediate assembly to the plurality of second inner holding parts of the at least one subsequent jig in the next stage. A manufacturing apparatus characterized by the above.

2. The manufacturing apparatus according to claim 1, wherein the transfer device circularly transfers the jig unit, and the transfer path includes an outward path and a return path where operations are performed by the plurality of working devices. A manufacturing apparatus characterized by the above.

3. The manufacturing apparatus according to claim 1, comprising at least one subsequent jig, wherein the leading jig assembles an intermediate assembly having two layers of legs in the radial direction, the second inner jig of the subsequent jig holds the two-layer intermediate assembly, and the subsequent jig assembles a final assembly having four layers of legs in the radial direction. A manufacturing apparatus characterized by the above.

4. The manufacturing apparatus according to claim 1, wherein the plurality of conductor segments include a plurality of connection segments for interlayer connection, and the at least one subsequent jig includes a jig in which the plurality of connection segments are held by the second inner jig and the second outer jig. A manufacturing apparatus characterized by the above.

5. The manufacturing apparatus according to claim 1, wherein the at least one subsequent jig includes a first subsequent jig and a second subsequent jig, the plurality of conductor segments include a plurality of connection segments for interlayer connection, the leading jig assembles an intermediate assembly having two layers of legs in the radial direction, the second inner jig of the first subsequent jig holds the two-layer intermediate assembly, the plurality of connection segments are held by the second inner jig and the second outer jig of the first subsequent jig, the first subsequent jig assembles an intermediate assembly having two layers in the radial direction and having the plurality of connection segments, and the second inner jig of the second subsequent jig holds the intermediate assembly having the plurality of connection segments. By the second subsequent jig, a final assembly having the plurality of connection segments and the legs radially arranged in four layers is assembled. A manufacturing apparatus characterized by this.

6. The manufacturing apparatus according to claim 1, wherein the plurality of jigs are mounted on the support in the assembly order of the assembly in the conveyance direction of the jig unit. A manufacturing apparatus characterized by this.

7. The manufacturing apparatus according to claim 1, wherein a plurality of the at least one supply device and the at least one drive device are provided respectively. A manufacturing apparatus characterized by this.

8. A manufacturing method for manufacturing an assembly in which a plurality of conductor segments are annularly arranged and attached to a stator core of a motor, including a conveyance step of conveying a jig unit, and a working step of performing work on the jig unit conveyed by the conveyance step, wherein the jig unit has a plurality of jigs for stepwise assembling the assembly and a support on which the plurality of jigs are mounted, and the working step includes a supply step of supplying a plurality of conductor segments to a jig as a work target, a drive step of causing an assembling operation to be performed on the jig as the work target to which the plurality of conductor segments have been supplied by the supply step, and a transfer step of transferring an intermediate assembly assembled by the jig as the work target to a jig in the next stage, wherein each conductor segment of the plurality of conductor segments has a pair of legs inserted into different slots of the stator core and a connection portion connecting ends of the pair of legs, and the assembling operation includes an operation of moving the legs for the plurality of conductor segments to align the pair of legs, and the plurality of jigs include a leading jig on which a first-stage intermediate assembly is assembled, and at least one subsequent jig, wherein the leading jig includes a first inner jig and a first outer jig surrounding the first inner jig, and the first inner jig and the first outer jig are provided so as to be relatively rotatable around a first rotation center line, the first inner jig is annularly arranged around the first rotation center line and has a plurality of first inner holding portions for holding one of the pair of legs, and the first outer jig is annularly arranged around the first rotation center line and has a plurality of first outer holding portions for holding the other of the pair of legs so as to be displaceable in the radial direction. The at least one subsequent jig includes a second inner jig and a second outer jig surrounding the second inner jig, and the second inner jig and the second outer jig are provided so as to be relatively rotatable around a second rotation center line. The second inner jig is annularly arranged around the second rotation center line and has a plurality of second inner holding portions for holding the assembly of the previous stage and one of the pair of legs. The second outer jig is annularly arranged around the second rotation center line and has a plurality of second outer holding portions for holding the other of the pair of legs so as to be displaceable in the radial direction. In the driving step, relative rotation of the first inner jig and the first outer jig or relative rotation of the second inner jig and the second outer jig is performed. In the transfer step, the intermediate assembly is transferred to the plurality of second inner holding portions of the at least one subsequent jig of the next stage. A manufacturing method characterized by the above.

9. A manufacturing method according to claim 8, In the conveying step, the jig unit is circulatedly conveyed in a forward path and a return path. The working step is performed on the jig unit conveyed in the forward path. A manufacturing method characterized by the above.

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