Stator manufacturing device and manufacturing method

Abstract

A stator manufacturing device and method are provided that can be applied to stators in which the radial distance between a pair of lead ends to be connected or the distance between rows of lead ends is narrow. [Solution] The device comprises a pair of comb clamps (12) arranged axially overlapping each other and supported so as to be movable radially, each having comb teeth (16) inserted between a pair of lead ends (11) to be joined; side clamps (20) arranged radially and inserted between rows of the lead ends arranged at a predetermined interval in the circumferential direction, each wedge-shaped and narrowing in the inward radial direction, and moving in the inward radial direction to abut on both sides of each lead end; a comb clamp drive device that moves the pair of comb clamps radially independently; a side clamp drive device that moves the side clamps radially; and an axial movement device that moves the comb clamps and the side clamps axially.

Description

[Technical Field]

[0001] The present invention relates to a manufacturing device and a manufacturing method for a stator that is inserted into the stator core of a rotating electric machine and that forms a coil by joining lead ends of segment coils arranged in the radial direction of the stator core. [Background technology]

[0002] Conventionally, a rectangular wire is bent into a hairpin shape, both ends of which are inserted into two predetermined slots in a stator core, the lead ends that protrude from the slots are formed into a predetermined shape, and the pair of lead ends to be connected are arranged so that they are adjacent in the radial direction. In this state, the pair of lead ends to be connected are held together with a jig and welded to form a continuous coil.

[0003] For example, Patent Document 1 listed below describes a method of using a jig consisting of a pair of restraining members each having a radially extending rod portion and teeth protruding at a predetermined interval from one side of the rod portion, inserting the teeth of each restraining member between a pair of lead ends to be connected, moving one restraining member in either radial direction, and moving the other restraining member to the opposite radial direction, and welding the lead ends to be connected in a state where they are clamped between the teeth. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-35922 Summary of the Invention [Problem to be solved by the invention]

[0005] In the coil joining method described in Patent Document 1, a pair of restraint members are positioned at the same height and are positioned so as to sandwich the lead terminals on both sides. This means that the teeth protruding from the pair of restraint members need to be inserted between the pair of lead ends to be connected, and restraint members that hold the lead terminals in adjacent rows need to be arranged side by side between the rows of lead terminals that are aligned radially. This means that the radial spacing between the pair of lead ends to be connected and the spacing between the rows need to be wide, which poses a problem in that this method is difficult to apply to the manufacture of compact stators with narrow spacing.

[0006] Therefore, an object of the present invention is to provide a stator manufacturing apparatus and method that can position a pair of lead ends to be connected, clamp them from both radial sides, and hold them so that they can be welded, even in a stator where the radial spacing between the pair of lead ends to be connected or the spacing between rows of lead ends is narrow. [Means for solving the problem]

[0007] In order to achieve the above object, one aspect of the present invention is a rotating electric motor. Machine In a stator manufacturing apparatus, a coil is formed by joining lead ends of segment coils that are inserted into a stator core and arranged in the radial direction of the stator core, a pair of comb clamps each having comb teeth inserted between a pair of lead ends to be joined among the lead ends arranged in the radial direction, the comb clamps being arranged overlapping each other in the axial direction, and each supported so as to be movable in the radial direction; The comb-shaped clamps are arranged offset in the axial direction, arranged radially, and inserted between rows of the lead ends arranged at predetermined intervals in the circumferential direction, and have wedge-shaped plates that narrow in the inward radial direction, and move in the inward radial direction to abut on both sides of each lead end; and a comb clamp drive device that moves the pair of comb clamps independently in the radial direction; a side clamp driving device that moves the side clamp in a radial direction; The present invention provides a stator manufacturing apparatus comprising an axial movement device that moves the comb clamp and the side clamp in the axial direction.

[0008] According to the above-described stator manufacturing apparatus, the axial movement device brings the comb clamps and side clamps close to the end face of the stator core, so that the comb teeth of the comb clamps can be inserted between the radially arranged lead ends and the side clamps can be inserted between the rows of radially arranged lead ends.

[0009] In this state, a pair of comb clamps arranged overlapping each other in the axial direction can be moved radially in opposite directions by a comb clamp drive device, thereby bringing the pair of lead ends to be joined close together radially and pressing them together to position them radially.

[0010] Furthermore, by moving the side clamps inwardly by the side clamp driving device, both sides of the lead ends aligned in the radial direction can be clamped by the side clamps, thereby positioning them in the circumferential direction.

[0011] By welding the lead ends thus positioned and pressed together in the radial direction, the pair of lead ends to be joined can be reliably joined together to form a coil.

[0012] After welding is completed, the comb clamps are moved in the opposite direction by the comb clamp drive device to separate them from the welded lead end, and the side clamps are moved radially outward by the side clamp drive device to separate them from both sides of the welded lead end. In this state, the axial movement device is used to separate the comb clamps and side clamps from the end face of the stator core, allowing each clamp to be easily removed.

[0013] Furthermore, because the comb clamps are arranged overlapping in the axial direction, the comb teeth do not interfere with each other, and even if the spacing between the lead ends arranged radially is narrow, the comb teeth can be inserted as long as there is a gap large enough for one comb tooth to fit.

[0014] In addition, the side clamps are also positioned axially offset from the comb clamps, and the wedge-shaped plates inserted between the rows of lead terminals come into contact with the lead terminals in the rows on both sides, so that the side clamps can be positioned even if the spacing between the rows of lead terminals is narrow.

[0015] As a result, the present invention can be easily applied to stators in which the radial distance between a pair of lead ends to be connected or the distance between rows of lead terminals is narrow.

[0016] Furthermore, by moving the comb-shaped clamps arranged overlapping in the axial direction in opposite radial directions, the lead ends can be pressed from the surface direction and pressure-welded, thereby more reliably pressure-welding the lead ends together.

[0017] In the stator manufacturing apparatus of the present invention, the comb clamp that is closest to the end face of the stator core in the axial direction is moved inwardly, and the comb clamp that is farther from the end face of the stator core in the axial direction is moved inwardly, thereby pressing together a pair of lead ends to be joined among the lead ends arranged in the radial direction, and it is preferable that the side clamps are positioned offset in the axial direction from the comb clamps in a direction away from the end face of the stator core.

[0018] According to the above aspect, the comb clamp that is closest to the end face of the stator core in the axial direction is moved inwardly, and the comb clamp that is farther from the end face of the stator core in the axial direction is moved inwardly, thereby pressing the pair of lead ends to be joined together.When the side clamps are moved inwardly to clamp both sides of the lead ends with the side clamps, the inner diameter movement of the side clamps causes the lead end that is arranged axially and that is to be connected, and that is located on the inner diameter side, to rub against the side clamp and move inwardly, preventing the lead ends from separating.

[0019] In addition, in the stator manufacturing apparatus of the present invention, it is preferable that earth clamps are provided to press the inner diameter side end and the outer diameter side end of the side clamp against earthed components, respectively.

[0020] According to the above aspect, by pressing the inner diameter side end and outer diameter side end of the side clamps that clamp both sides of the lead end against the parts that are grounded by the earth clamps, earthing can be achieved in both radial directions, which causes the arc to spread evenly, resulting in a good shape for the welding ball and more effectively suppressing interference with the welding ball when each clamp is removed.

[0021] Furthermore, in the stator manufacturing apparatus of the present invention, the comb clamps and the side clamps are respectively provided for multiple rows of lead ends aligned radially and spaced at predetermined intervals in the circumferential direction, and it is preferable that the comb clamp driving device and the side clamp driving device are configured to move the comb clamps and the side clamps corresponding to each row of the lead ends simultaneously in an interlocked manner.

[0022] According to the above aspect, positioning and clamping can be performed simultaneously for multiple rows of lead ends arranged in the radial direction, thereby improving workability.

[0023] Another aspect of the present invention is a manufacturing method for a stator that is inserted into a stator core of a rotating electric machine and that forms a coil by joining lead ends of segment coils that are arranged in the radial direction of the stator core, comprising: a pair of comb clamps each having comb teeth inserted between a pair of lead ends to be joined among the lead ends arranged in the radial direction, the comb clamps being arranged overlapping each other in the axial direction, and each supported so as to be movable in the radial direction; The comb clamps are arranged axially offset, aligned radially, and inserted between rows of the lead ends arranged at predetermined intervals in the circumferential direction, and have wedge-shaped plates that narrow inwardly, and side clamps that move inwardly to abut on both sides of each lead end, a first step of bringing the comb clamp and the side clamp close to an end face of the stator core in an axial direction of the stator core, inserting the comb teeth between the pair of lead ends to be joined, and inserting the side clamp between rows of the lead ends aligned in a radial direction; a second step of moving the pair of comb clamps, which are arranged overlapping in the axial direction, in opposite radial directions to bring the pair of lead ends to be joined closer together in the radial direction and pressing them together; a third step of clamping both sides of the lead ends arranged in the radial direction with the side clamps by moving the side clamps in an inward radial direction; a fourth step of welding the pair of lead ends pressed together by the pair of comb clamps; a fifth step of moving the pair of comb clamps radially in a direction opposite to that of the second step and moving the side clamps radially outward to release the clamps; and a sixth step of axially moving the comb clamp and the side clamp away from the end face of the stator core and removing them from the lead end.

[0024] According to the stator manufacturing method of the present invention, welding is performed while the lead ends are pressed together radially by a pair of comb-shaped clamps and are sandwiched on both sides by side clamps, so that the pair of lead ends to be joined can be reliably joined to form a coil.

[0025] Furthermore, in the sixth step, when the comb clamps and the side clamps are moved in the axial direction away from the end face of the stator core and removed from the lead end, each clamp can be easily removed.

[0026] Furthermore, because the comb clamps are arranged overlapping in the axial direction, the comb teeth do not interfere with each other, and even if the spacing between the lead ends arranged radially is narrow, the comb teeth can be inserted as long as there is a gap large enough for one comb tooth to fit.

[0027] In addition, the side clamps are also positioned axially offset from the comb clamps, and the wedge-shaped plates inserted between the rows of lead terminals come into contact with the lead terminals in the rows on both sides, so that the side clamps can be positioned even if the spacing between the rows of lead terminals is narrow.

[0028] As a result, the present invention can be easily applied to stators in which the radial distance between a pair of lead ends to be connected or the distance between rows of lead terminals is narrow.

[0029] Furthermore, by moving the comb-shaped clamps arranged overlapping in the axial direction in opposite radial directions, the lead ends can be pressed from the surface direction and pressure-welded, thereby more reliably pressure-welding the lead ends together. [Effects of the Invention]

[0030] According to the present invention, a pair of lead ends to be joined can be reliably joined to form a coil, and the present invention can be easily applied to stators in which the radial spacing between the pair of lead ends to be connected or the spacing between rows of lead terminals is narrow. [Brief explanation of the drawings]

[0031] [Figure 1] 1 is a perspective view showing an embodiment of a stator manufacturing apparatus of the present invention, in which a support frame is raised. FIG. [Figure 2] FIG. 2 is a perspective view showing the manufacturing apparatus with a support frame lowered. [Figure 3] FIG. 3 is a partially enlarged perspective view showing the lead ends of the segment coils, the comb clamps, and the side clamps in FIG. 2. [Figure 4] FIG. 2 is an exploded perspective view showing a comb clamp and a side clamp of the manufacturing apparatus. [Figure 5] FIG. 2 is a perspective view showing a comb clamp driving device of the manufacturing apparatus. [Figure 6] This is a partially enlarged oblique view showing the state in which a pair of lead ends to be connected of a segment coil are clamped by a comb-shaped clamp in the same manufacturing apparatus. [Figure 7] 10 is a partially enlarged oblique view showing the state in which both sides of the lead ends of the segment coil are held by side clamps in the manufacturing apparatus. FIG. [Figure 8] 10 is a perspective view showing the state in which both radial ends of the side clamp are pressed by a pressing plate connected to a ground wire in the manufacturing apparatus. FIG. [Figure 9] 10 is a partially enlarged perspective view showing a state in which a pair of lead ends to be connected to a segment coil have been welded by welding in the manufacturing apparatus. FIG. [Figure 10] FIG. 10 is a partially enlarged perspective view showing the state in which the comb clamps and side clamps are released after welding is completed in the manufacturing apparatus. [Figure 11] This is a partially enlarged oblique view showing the state in which, after welding is completed, the clamps of the comb clamps and side clamps are raised and removed from the lead ends of the segment coil in the same manufacturing apparatus. DETAILED DESCRIPTION OF THE INVENTION

[0032] Hereinafter, one embodiment of the present invention will be described with reference to the drawings, but the present invention is not limited to this embodiment.

[0033] As shown in Figure 1, this stator manufacturing apparatus 10 forms coils by welding radially aligned lead ends 11 of segment coils that are inserted into predetermined slots (not shown) in a stator core 18 and protrude from one end face. Note that in the drawing, only the outline of the stator core 18 is shown with imaginary lines, and the slots and the overall shape of the segment coils are omitted because they are well known. The lead ends 11 are aligned radially and arranged in rows at predetermined intervals around the circumference.

[0034] This stator manufacturing apparatus 10 has a support frame 17 that can be raised and lowered by a lifting device (not shown). On this support frame 17, comb clamps 12 and side clamps 20 shown in FIG. 4 are mounted.

[0035] First, we will explain the comb clamp 12. The comb clamp 12 is made up of a first comb clamp 12a and a second comb clamp 12b, which are arranged overlapping and offset in the axial direction of the stator core 18. In the axial direction of the stator core 18, the first comb clamp 12a is arranged on the side farther away from the end face of the stator core 18.

[0036] The first comb clamp 12a and the second comb clamp 12b each have a base 13, a pin mounting hole 14 provided at the base end of the base 13, a radial extension 15 extending radially inward from the base 13, and a plurality of comb teeth 16 protruding from one side of the radial extension 15. In this embodiment, three notches 19 into which a pair of lead ends 11 are inserted are formed between the comb teeth 16.

[0037] With respect to base 13, radially extending portion 15 extends radially inward of stator core 18 from a position shifted in the axial direction of stator core 18 in a direction away from the end face of stator core 18 via a step formed at the tip end of base 13. In addition, base 13 is formed thicker than radially extending portion 15.

[0038] Next, the side clamp 20 will be described. The side clamp 20 has a base 21, a wedge-shaped plate 22 that extends from the tip of the base 21 in the radially inward direction of the stator core 18 and narrows in width as it goes in the radially inward direction, and a pin mounting hole 23 provided in a portion of the base 21 close to the wedge-shaped plate 22. The base 21 is formed thicker than the wedge-shaped plate 22, and the base 21 protrudes in a direction closer to the end face of the stator core 18 than the wedge-shaped plate 22.

[0039] When the side clamp 20, the first comb clamp 12a, and the second comb clamp 12b are stacked in the axial direction of the stator core 18, the base 21 of the side clamp 20, the base 13 of the first comb clamp 12a, and the base 13 of the second comb clamp 12b overlap, and the wedge-shaped plate 22 of the side clamp 20, the radial extension 15 of the first comb clamp 12a, and the radial extension 15 of the second comb clamp 12b overlap.

[0040] As shown in FIG. 2, when the support frame 17 is lowered in a direction approaching the end face of the stator core 18, a pair of lead ends 11 consisting of a first lead end 11a and a second lead end 11b are inserted into the notches 19 formed between the comb teeth 16, as shown in FIG. 3, and a wedge-shaped plate 22 is positioned between the rows of lead ends 11.

[0041] 5 shows a comb clamp drive device 30 that independently moves the first comb clamp 12a and the second comb clamp 12b. The comb clamp drive device 30 has a first slide plate 31 that moves the first comb clamp 12a and a second slide plate 32 that moves the second comb clamp 12b.

[0042] The first comb clamp 12a has a pin 33 attached to the pin mounting hole 14. The first slide plate 31 has a flat shape with a fan-shaped inner diameter side and a narrow outer diameter side. A plurality of pin engagement holes 36 are formed at predetermined intervals in the circumferential direction in the fan-shaped portion of the first slide plate 31. The pins 33 of a plurality of first comb clamps 12a arranged in the circumferential direction are inserted into each pin engagement hole 36. In addition, a drive pin engagement hole 34 is formed in the outer diameter end of the first slide plate 31, and a drive pin 35 of a drive mechanism (not shown) is inserted into this hole.

[0043] When the drive pin 35 moves toward the outer diameter of the stator core 18 by a drive mechanism not shown, each of the first comb-shaped clamps 12a is pulled toward the outer diameter via the first slide plate 31 and pin 33, and when the drive pin 35 moves toward the inner diameter of the stator core 18, each of the first comb-shaped clamps 12a is pushed toward the inner diameter via the first slide plate 31 and pin 33, and moves.

[0044] The second slide plate 32 also has a similar structure to that described above, with multiple second comb clamps 12b connected via pins 33, and is provided with a drive mechanism similar to that described above. When the second slide plate 32 is moved toward the inner diameter side by the drive mechanism (not shown), each of the second comb clamps 12b is pushed toward the inner diameter side and moves, and when the second slide plate 32 is moved toward the outer diameter side, each of the second comb clamps 12b is pulled toward the outer diameter side and moves.

[0045] As shown in Figure 6, when a pair of lead ends 11 consisting of a first lead end 11a and a second lead end 11b are inserted into the notches 19 of the first comb clamp 12a and the second comb clamp 12b, and the first comb clamp 12a moves in the outer radial direction A and the second comb clamp 12b moves in the inner radial direction B, the second lead end 11b is pushed toward the outer radial direction by the comb teeth 16 of the first comb clamp 12a, and the first lead end 11a is pushed toward the inner radial direction by the comb teeth 16 of the second comb clamp 12b, so that the tips of the first lead end 11a and the second lead end 11b are pressed against each other and held in place.

[0046] Also, as shown in FIG. 10, when the first comb clamp 12a moves in the inner radial direction B and the second comb clamp 12b moves in the outer radial direction A, the comb teeth 16 of the first comb clamp 12a move away from the second lead end 11b, and the comb teeth 16 of the second comb clamp 12b move away from the first lead end 11a, thereby releasing the clamp.

[0047] FIG. 7 shows a side clamp drive device 40 for moving the side clamps 20 in the radial direction of the stator core 18. Pins 43 are attached to the pin mounting holes 23 (see FIG. 4) of the side clamps 20. An arc-shaped cam plate 41 is provided so as to overlap the arrangement of the pins 43 of the side clamps 20, which are arranged at predetermined intervals in the circumferential direction. The arc-shaped cam plate 41 is provided with slit-like cam grooves 42 extending obliquely relative to the radial direction, corresponding to each pin 43, and the pins 43 are inserted into the corresponding cam grooves 42. As shown in FIGS. 1 and 2, a side clamp drive bracket 72 is connected to the arc-shaped cam plate 41, and the side clamp drive bracket 72 is connected to a rod 71 of an air cylinder for driving the side clamps. By pushing and pulling the rod 71, the arc-shaped cam plate 41 can reciprocate in the circumferential direction around the axis of the stator core 18.

[0048] In this embodiment, when the arc-shaped cam plate 41 moves in the direction of arrow C in Fig. 7, the pins 43 attached to each side clamp 20 are pushed inward by the cam grooves 42, and the side clamps 20 are pushed inward as indicated by arrow D. As a result, the wedge-shaped plates 22 are pressed against the lead ends 11 on both sides, and the lead ends 11 are sandwiched between the wedge-shaped plates 22 arranged on both sides, positioning them in the circumferential direction and establishing electrical continuity between the lead ends 11 and the wedge-shaped plates 22.

[0049] 7, the pins 43 attached to each side clamp 20 are pushed outward by the cam grooves 42, causing the side clamps 20 to move outward in the direction opposite to the direction of arrow D. As a result, both sides of the wedge-shaped plate 22 move away from the lead end 11, creating an unclamped state where the wedge-shaped plate 22 and the lead end 11 are no longer in contact with each other.

[0050] As shown in FIGS. 1 and 2, a first pressure plate 51 is disposed on the support frame 17 so as to cover the leading ends of the wedge-shaped plates 22 arranged in the circumferential direction, with the leading ends of the wedge-shaped plates 22 inserted below the first pressure plate 51. The first pressure plate 51 is normally maintained in a raised position away from the wedge-shaped plates 22. A first earth wire 52 is connected to the first pressure plate 51 by a fixing bolt 53. Two lift guide shafts (not shown) are provided that pass through the first pressure plate 51, and a lever 54 is rotatably attached to each lift guide shaft via a support shaft 55. An air cylinder connector 57 is provided at the end of the lever 54 to which an operating rod of an air cylinder (not shown) is connected. The outer periphery of the part of lever 54 where support shaft 55 is inserted forms eccentric cam portion 56, and as shown in Figure 8, when lever 54 is rotated so as to fall by an air cylinder (not shown), first pressing plate 51 is pushed downward by eccentric cam portion 56 against an elastic member (not shown), pressing the tip of wedge-shaped plate 22 toward support frame 17, ensuring electrical continuity between wedge-shaped plate 22 and first earth wire 52.

[0051] 2 and 8, a second presser plate 61 made of an arc-shaped plate is disposed on the support frame 17 so as to cover the bases 21 of the side clamps 20 arranged in the circumferential direction, and the bases 21 of the side clamps 20 are inserted below the second presser plate 61. The second presser plate 61 is normally maintained in a raised state away from the bases 21 by an elastic member (not shown). A second ground wire 62 is connected to the second presser plate 61 by a fixing bolt 63. Two lift guide shafts (not shown) are provided that penetrate the second presser plate 61, and a lever 64 is rotatably attached to each lift guide shaft via a support shaft 65. An air cylinder connecting portion 67 to which an operating rod of an air cylinder (not shown) is connected is provided at the end of the lever 64. The outer periphery of the portion of the lever 64 where the support shaft 65 is inserted forms an eccentric cam portion 66, and as shown in Figure 8, when the lever 64 is rotated so as to fall down by an air cylinder (not shown), the second pressing plate 61 is pressed downward by the eccentric cam portion 66 against an elastic member (not shown), pressing the base 21 of the side clamp 20 toward the support frame 17, ensuring electrical continuity between the base 21 and the second earth wire 62.

[0052] In addition, a welding device (not shown) is placed above the lead end 11, and a high voltage is applied between the lead end 11, which is earthed via the wedge-shaped plate 22, base 21, first pressure plate 51, second pressure plate 61, first earth wire 52, and second earth wire 62, so that the tips of the first lead end 11a and second lead end 11b, which are pressed and held by the comb teeth 16 of the first comb clamp 12a and second comb clamp 12b, can be welded.

[0053] Next, an embodiment of a method for manufacturing a stator according to the present invention using the stator manufacturing apparatus 10 will be described.

[0054] (1st step) As shown in Fig. 1, the support frame 17 is raised, and then lowered by an axial movement device (not shown) as shown in Fig. 2. Then, as shown in Fig. 3, a pair of lead ends 11 consisting of a first lead end 11a and a second lead end 11b is inserted into the notches 19 formed between the comb teeth 16 of the first comb clamp 12a and the second comb clamp 12b, and wedge-shaped plates 22 of the side clamps 20 are disposed on both sides of the lead end 11. In this state, one tooth 16 of the first comb clamp 12a and the second comb clamp 12b is inserted between the pair of radially arranged lead ends 11, and the comb teeth 16 of the first comb clamp 12a and the second comb clamp 12b overlap so as to be substantially aligned, and the lead end 11 does not come into contact with the radially extending portion 15 or the comb teeth 16. Moreover, the side clamp 20 is retracted to the outer diameter side, and the lead end 11 and the wedge-shaped plate 22 are not in contact with each other.

[0055] (2nd process) 5 moves the first slide plate 31 of the comb clamp driver 30 toward the outer diameter of the stator core 18 and the second slide plate 32 toward the inner diameter, thereby moving the first comb clamp 12a toward the outer diameter as indicated by arrow A and the second comb clamp 12b toward the inner diameter as indicated by arrow B, as shown in FIG. 6. As a result, the comb teeth 16 of the first comb clamp 12a press the second lead end 11b toward the outer diameter, and the comb teeth 16 of the second comb clamp 12b press the first lead end 11a toward the inner diameter, thereby pressing and holding the tips of the first lead end 11a and the second lead end 11b to be connected. Note that the comb clamp driver 30 simultaneously moves the multiple first comb clamps 12a and second comb clamps 12b via the first slide plate 31 and the second slide plate 32, thereby simplifying the drive mechanism and improving operability.

[0056] (3rd step) As shown in FIG. 7, the arcuate cam plate 41 of the side clamp driver 40 is rotated in the direction of arrow C, causing the cam groove 42 to press the pin 43 toward the inner diameter of the stator core 18, moving the side clamp 20 in the inner diameter direction and forcing the wedge-shaped plate 22 between the rows of lead ends 11. As a result, both sides of the lead end 11 are clamped by the wedge-shaped plates 22, accurately maintaining the circumferential position of the lead end 11. In this embodiment, as shown in FIG. 6, the comb teeth 16 of the first comb clamp 12a, which is located on the side away from the end face of the stator core 18, press the second lead end 11b located on the inner diameter side. Therefore, even if the wedge-shaped plate 22 moves in the inner diameter direction and rubs the second lead end 11b, the second lead end 11b can be prevented from moving in the inner diameter direction and separating from the first comb clamp 12a. Furthermore, by rotating the arc-shaped cam plate 41 of the side clamp drive device 40, multiple side clamps 20 can be moved simultaneously, which simplifies the drive mechanism and improves workability.

[0057] (4th step) 8, an air cylinder (not shown) rotates lever 54 downward, causing eccentric cam portion 56 to press down first pressing plate 51 and bring it into pressure contact with wedge-shaped plate 22 of side clamp 20, thereby establishing electrical continuity between wedge-shaped plate 22 and first earth wire 52 via first pressing plate 51. Note that wedge-shaped plate 22 holds both sides of first lead end 11a and second lead end 11b, so first lead end 11a and second lead end 11b are also electrically connected to first earth wire 52.

[0058] Similarly, lever 64 is rotated downward by an air cylinder (not shown), causing eccentric cam portion 66 to press second presser plate 61 down and bring it into pressure contact with base portion 21 of side clamp 20, thereby establishing electrical continuity between base portion 21 and second earth wire 62 via second presser plate 61. Note that wedge-shaped plate 22 of side clamp 20 holds both sides of first lead end 11a and second lead end 11b, so first lead end 11a and second lead end 11b are also electrically connected to second earth wire 62.

[0059] In this state, a high voltage is applied to the pair of lead ends 11 to be connected, consisting of the first lead end 11a and the second lead end 11b, using a welding device (not shown), to weld the tips of the first lead end 11a and the second lead end 11b. As a result, as shown in Fig. 9, a molten ball 73 is formed at the tips of the first lead end 11a and the second lead end 11b, and the tips of the first lead end 11a and the second lead end 11b to be connected are joined. At this time, the wedge-shaped plate 22 of the side clamp 20 is electrically connected to the first ground wire 52 via the first holding plate 51, and the base 21 of the side clamp 20 is electrically connected to the second ground wire 62 via the second holding plate 61. This allows for grounding in both radial directions via the side clamp 20, thereby suppressing deflection due to electromagnetic force and improving the shape of the molten ball 73.

[0060] (5th step) 10, the comb clamp driver 30 moves the first comb clamp 12a in the radially inward direction indicated by arrow B, and moves the second comb clamp 12b in the radially outward direction indicated by arrow A, returning them to their initial state in which the comb teeth 16 of the first comb clamp 12a and the second comb clamp 12b are substantially aligned and overlapped. As a result, the first lead end 11a and the second lead end 11b are no longer in contact with the comb teeth 16 and the radially extending portion 15, and the radial clamping is released.

[0061] 7, the arc-shaped cam plate 41 of the side clamp driving device 40 is rotated in the direction opposite to the arrow C shown in FIG. 7, and the pin 43 is pressed toward the outer diameter of the stator core 18 via the cam groove 42, moving the side clamp 20 toward the outer diameter. As a result, the wedge-shaped plates 22 of the side clamp 20 move away from both sides of the lead end 11, and the circumferential clamping is released.

[0062] (6th step) As shown in FIG. 1, the support frame 17 is raised by an axial movement device (not shown), and as shown in FIG. 11, the first lead end 11a and the second lead end 11b joined by the molten ball 73 are extracted from the notch 19 between the comb teeth 16, and the stator manufacturing apparatus 10 is returned to the initial position shown in FIG. 1.

[0063] At this time, as described above, the shape of the molten ball 73 joining the first lead end 11a and the second lead end 11b is formed well, so that the molten ball 73 can be extracted without getting caught on the comb teeth 16 or the wedge-shaped plate 22.

[0064] In addition, with this stator manufacturing apparatus 10, as shown in Figures 3, 6, 10, and 11, the first comb clamp 12a, the second comb clamp 12b, and the side clamp 20 are arranged so that they overlap in the axial direction. Therefore, it is sufficient that the comb teeth 16 of the first comb clamp 12a and the second comb clamp 12b are inserted one by one between each pair of lead ends 11 to be connected, with the teeth 16 overlapping, and it is sufficient that one wedge plate 22 of the side clamp 20 is inserted between each row of lead ends 11 aligned in the radial direction. Therefore, even if the radial spacing between each pair of lead ends 11 to be connected or the circumferential spacing between rows of lead ends 11 aligned in the radial direction is narrow, this apparatus can be applied, and a compact stator can be manufactured.

[0065] Furthermore, when laser welding is used as the welding method, the first earth wire 52 and the second earth wire 62 are not necessary. [Explanation of symbols]

[0066] 10 Stator manufacturing equipment 11 Lead end 11a First lead end 11b Second lead end 12 Comb clamp 13 Base 14 Pin mounting hole 15 Radial extension 16 Comb Teeth 17 Support frame 18 stator core 19 Notch 12a First comb clamp 12b Second comb clamp 20 Side Clamp 21 Base 22 Wedge Plate 23 Pin mounting hole 30 Comb clamp drive device 31 First slide plate 32 Second slide plate 33 pin 34 Drive pin engagement hole 35 Drive pin 36 Pin engagement hole 40 Side clamp drive unit 41 Arc-shaped cam plate 42 Cam groove 43 pin 51 First presser plate 52 First ground wire 53 Fixing bolt 54 Lever 55 Spindle 56 Eccentric cam part 57 Air cylinder connection part 61 Second presser plate 62 Second earth wire 63 Fixing bolt 64 Lever 65 Spindle 66 Eccentric cam part 67 Air cylinder connection part 71 Side clamp drive air cylinder rod 72 Side clamp drive bracket 73 Molten ball

Claims

1. A manufacturing apparatus for a stator that is inserted into a stator core of a rotating electric machine and that joins lead ends of segment coils arranged in the radial direction of the stator core to form a coil, a pair of comb clamps each having comb teeth inserted between a pair of lead ends to be joined among the lead ends arranged in the radial direction, the comb clamps being arranged overlapping each other in the axial direction, and each supported so as to be movable in the radial direction; The comb-shaped clamps are arranged offset in the axial direction, arranged radially, and inserted between rows of the lead ends arranged at predetermined intervals in the circumferential direction, and have wedge-shaped plates that narrow in the inward radial direction, and move in the inward radial direction to abut on both sides of each lead end; and a comb clamp drive device that moves the pair of comb clamps independently in the radial direction; a side clamp driving device that moves the side clamp in a radial direction; an axial movement device that moves the comb clamp and the side clamp in the axial direction, each of the pair of comb clamps has a base, a radially extending portion extending from the base in the radial direction of the stator core, and a plurality of comb teeth protruding from one side of the radially extending portion, and has a shape in which notches are formed between the comb teeth into which a pair of lead terminals are inserted; The side clamp has a base and the wedge-shaped plate extending from the base in the inner radial direction of the stator core, A stator manufacturing apparatus, characterized in that the radially extending portions of the pair of comb-shaped clamps and the wedge-shaped plates of the side clamps are arranged to overlap in the axial direction.

2. 2. The stator manufacturing apparatus according to claim 1, wherein the comb clamp drive device is configured to press-contact a pair of radially arranged lead ends to be joined together by moving the comb clamp that is closest to the end face of the stator core in the axial direction in the inner radial direction and moving the comb clamp that is farther from the end face of the stator core in the axial direction in the outer radial direction, and the side clamp is positioned offset in the axial direction from the comb clamp in the direction away from the end face of the stator core.

3. 3. The stator manufacturing apparatus according to claim 1, further comprising earth clamps for pressing inner diameter side ends and outer diameter side ends of the side clamps against grounded components, respectively.

4. 3. The stator manufacturing apparatus according to claim 1, wherein the comb clamps and the side clamps are respectively provided for a plurality of rows of lead ends aligned radially and arranged at predetermined intervals in the circumferential direction, and the comb clamp driving device and the side clamp driving device are configured to move the comb clamps and the side clamps corresponding to each row of the lead ends in an interlocked manner simultaneously.

5. A method for manufacturing a stator that is inserted into a stator core of a rotating electric machine and that forms a coil by joining lead ends of segment coils that are arranged in the radial direction of the stator core, comprising: a pair of comb-shaped clamps each having a base, a radially extending portion extending from the base in the radial direction of the stator core, and a plurality of comb teeth protruding from one side of the radially extending portion, with notches formed between the comb teeth into which a pair of lead terminals to be joined are inserted, and each supported so as to be movable in the radial direction; a side clamp having a base and a wedge-shaped plate extending from the base in a radially inward direction of the stator core and narrowing in width as it goes in the radially inward direction, the wedge-shaped plate being inserted between rows of the lead ends that are aligned radially and spaced apart in the circumferential direction, and configured to move in the radially inward direction so that the wedge-shaped plate comes into contact with both sides of each of the lead ends; The radially extending portions of the pair of comb clamps and the wedge-shaped plates of the side clamps are arranged so as to overlap in the axial direction, a first step of bringing the comb clamp and the side clamp close to the end face of the stator core in the axial direction of the stator core, inserting the comb teeth between the pair of lead ends to be joined, and inserting the wedge plates of the side clamps between rows of the lead ends aligned in the radial direction; a second step of moving the pair of comb-shaped clamps, which are arranged overlapping in the axial direction, in opposite radial directions to bring the pair of lead ends to be joined closer together in the radial direction and press them together; a third step of clamping both sides of the lead ends arranged in the radial direction with wedge-shaped plates of the side clamps by moving the side clamps in a radially inward direction; a fourth step of welding the pair of lead ends pressed together by the pair of comb clamps; a fifth step of moving the pair of comb clamps radially in a direction opposite to that of the second step and moving the side clamps radially outward to release the clamps; and a sixth step of axially moving the comb clamps and the side clamps away from the end face of the stator core and removing them from the lead end.

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