Stator manufacturing device and stator manufacturing method

Abstract

To provide a stator manufacturing device capable of holding a strip-like coil in a wound state before expansion in a stable shape.SOLUTION: Provided is a stator manufacturing device in which a plurality of linear portions of the strip-shaped coil are inserted into the plurality of slots by expanding a strip-shaped coil in a wound state disposed in a shaft hole with respect to a stator core having a plurality of slots opening toward a shaft hole at the center. The stator manufacturing device includes a coil winding jig which is configured to be insertable into the shaft hole of the stator core and winds the strip-shaped coil around an outer circumference. The coil winding jig has: a plurality of comb-shaped grooves which accommodates the plurality of linear portions and around which the strip-shaped coil can be wound; and a pressing member which can press at least a part of the plurality of linear portions accommodated in the plurality of comb-shaped grooves from the inside of the strip-shaped coil in the wound state toward the outside in a radial direction.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a stator manufacturing apparatus and a stator manufacturing method. [Background technology]

[0002] A conventional technique is known in which a strip-shaped coil wound around the outer periphery of a jig is placed in an axial hole in the center of a stator core, and the straight portion of the strip-shaped coil is inserted into a slot in the stator core by expanding the strip-shaped coil (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 3982446 Summary of the Invention [Problem to be solved by the invention]

[0004] When a wound strip coil is attached to a stator core by expanding it, if the shape of the wound strip coil varies, each straight portion of the strip coil cannot be accommodated in the appropriate position within the slot, and some straight portions may protrude from the slot toward the axial hole of the stator core. Therefore, it is desirable to maintain a stable shape of the wound strip coil until the strip coil wound on the jig is expanded. However, the above-mentioned prior art does not disclose how to stabilize the shape of the wound strip coil.

[0005] An object of the present invention is to provide a stator manufacturing apparatus and a stator manufacturing method that can maintain a stable shape of a wound strip coil before expansion. [Means for solving the problem]

[0006] (1) A stator manufacturing apparatus according to the present invention is a manufacturing apparatus (for example, a stator manufacturing apparatus) for a stator (for example, a stator 200 described later) that expands a wound strip-shaped coil (for example, a strip-shaped coil 100 described later) that is arranged in a stator core (for example, a stator core 2 described later) having a plurality of slots (for example, slots 22 described later) that open toward a central axial hole (for example, a axial hole 20 described later) to insert a plurality of straight portions (for example, straight portions 101 described later) of the strip-shaped coil into the plurality of slots. 1), and includes a coil winding jig (for example, coil winding jig 4 described later) configured to be insertable into the axial hole of the stator core and winding the strip-shaped coil around the outer periphery, and the coil winding jig has a plurality of comb-tooth grooves (for example, comb-tooth grooves 43 described later) that can accommodate the plurality of straight portions of the strip-shaped coil, and a pressing member (for example, pressing member 45 described later) that can press at least some of the straight portions accommodated in the plurality of comb-tooth grooves from the inside of the wound strip-shaped coil toward the outside in the radial direction.

[0007] (2) In the stator manufacturing apparatus described in (1) above, the strip coil has a portion at at least one end in the longitudinal direction that is thinner than other portions of the strip coil in the longitudinal direction (for example, the leading end 104 described below), and in the coil winding jig, the pressing member is provided at a position where it can press at least the straight portions of the strip coil that are located in the thinner portions of the strip coil, among the plurality of straight portions accommodated in the plurality of comb-tooth grooves.

[0008] (3) In the stator manufacturing apparatus described in (1) or (2) above, the pressing member is provided so as to press the linear portion inside the comb-tooth-shaped groove.

[0009] (4) In the stator manufacturing apparatus described in (3) above, the pushing member is composed of a leaf spring having one end which is a fixed end (e.g., fixed end 45a described later) fixed to the coil winding jig and the other end which is a free end (e.g., free end 45b described later) which can be positioned inside the comb-tooth groove.

[0010] (5) A method for manufacturing a stator according to the present invention is a method for manufacturing a stator (for example, a stator 200 described later) in which a wound strip-shaped coil (for example, a strip-shaped coil 100 described later) is expanded in a stator core (for example, a stator core 2 described later) having a plurality of slots (for example, slots 22 described later) opening toward a central axial hole (for example, a axial hole 20 described later) to insert a plurality of straight portions (for example, straight portions 101 described later) of the strip-shaped coil into the plurality of slots, After the strip-shaped coil is wound around the outer periphery of a coil winding jig (e.g., coil winding jig 4 described later) that is configured to be insertable into the axial hole of A and has a plurality of comb-tooth grooves (e.g., comb-tooth grooves 43 described later) that can accommodate the plurality of straight portions of the strip-shaped coil, at least some of the straight portions accommodated in the plurality of comb-tooth grooves are pressed radially outward from the inside of the wound strip-shaped coil by a pressing member (e.g., pressing member 45 described later) until the wound strip-shaped coil is expanded.

[0011] (6) In the method for manufacturing a stator described in (5) above, the strip coil has a portion at at least one end in the longitudinal direction that is thinner than other portions in the longitudinal direction of the strip coil (for example, the leading end portion 104 described below), and the pressing member presses at least the straight portions of the plurality of straight portions accommodated in the plurality of comb-tooth grooves that are located in the thinner portions of the strip coil.

[0012] (7) In the method for manufacturing a stator according to (5) or (6) above, the pressing member presses the linear portion inside the comb-tooth groove.

[0013] (8) In the method for manufacturing a stator described in (7) above, the pushing member is composed of a leaf spring having one end which is a fixed end (e.g., fixed end 45a described later) fixed to the coil winding jig and the other end which is a free end (e.g., free end 45b described later) which can be positioned inside the comb-tooth groove. [Effects of the Invention]

[0014] According to the above (1) and (5), the strip coil wound on the coil winding jig is continuously pressed from the inside of the wound strip coil toward the outside in the radial direction, which prevents the shape of the wound strip coil from being distorted toward the inside in the radial direction, and therefore the wound strip coil before expansion can be maintained in a stable shape.

[0015] According to (2) and (6) above, the thinner parts of the wound strip coil, which are prone to shape distortion, are pressed, so that the shape of the wound strip coil before expansion can be more stably maintained.

[0016] According to (3) and (7) above, the pressing member is guided from both sides in the circumferential direction by the comb-tooth groove, so that the straight portion accommodated in the comb-tooth groove can be reliably pressed radially outward.

[0017] According to the above (4) and (8), the linear portion accommodated in the comb-tooth groove can be reliably pressed by a pressing member having a simple structure. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 2 is a perspective view showing a stator manufacturing apparatus. [Figure 2] 1 is an exploded perspective view showing a stator core fixing jig having a stator core and a coil winding jig on which a strip-shaped coil has been wound. FIG. [Figure 3] FIG. 4 is an enlarged view showing a part of the stator core fixing jig. [Figure 4] FIG. 2 is an enlarged perspective view showing a slot of the stator core. [Figure 5] 4 is an enlarged view showing a state in which a coil winding jig is inserted into a stator core. FIG. [Figure 6] FIG. 2 is a perspective view showing a coil winding jig. [Figure 7] FIG. 2 is a plan view showing a coil winding jig. [Figure 8]FIG. 2 is a front view showing a part of the strip-shaped coil. [Figure 9] FIG. 9 is a cross-sectional view taken along line AA in FIG. 8. [Figure 10] 1A to 1C are diagrams illustrating a manufacturing process of a strip-shaped coil. [Figure 11] FIG. 9 is a cross-sectional view taken along line BB in FIG. 8. [Figure 12] FIG. 10 is a plan view showing how a strip-shaped coil is wound around a coil winding jig. [Figure 13] FIG. 10 is a plan view showing a coil winding jig on which a strip-shaped coil has been wound. [Figure 14] FIG. 10 is a perspective view showing a coil winding jig on which a strip-shaped coil has been wound. [Figure 15] FIG. 2 is an enlarged perspective view showing a part of a coil winding jig on which a strip-shaped coil has been wound. [Figure 16] FIG. 10 is a cross-sectional view showing a coil winding jig on which a strip-shaped coil has been wound. [Figure 17] 10 is a side view of the stator manufacturing apparatus showing in cross section how a coil expansion mechanism is attached to a coil winding jig inserted into a stator core. FIG. [Figure 18] FIG. 10 is a perspective view showing the coil expansion mechanism in a contracted state. [Figure 19] 10 is a side view showing the coil expansion portion of the coil expansion mechanism in a contracted state. FIG. [Figure 20] FIG. 10 is a front view showing the coil expansion portion of the coil expansion mechanism in a contracted state. [Figure 21] FIG. 10 is a perspective view showing the coil expansion mechanism in an expanded state. [Figure 22] 10 is a side view showing the coil extension portion of the coil extension mechanism in an extended state. FIG. [Figure 23] FIG. 10 is a front view showing the coil extension portion of the coil extension mechanism in an extended state. [Figure 24] FIG. 10 is an enlarged view showing the state in which the cuff guide supports the insulating paper in the slot. [Figure 25] FIG. 10 is an enlarged view showing the expanded strip coil inserted into the slot of the stator core. [Figure 26]FIG. 2 is an enlarged view showing a stator of the stator core fixing jig. [Figure 27] 10 is a cross-sectional view showing a part of a stator in which the straight portion of the strip-shaped coil is housed in a proper position. FIG. [Figure 28] 10 is a graph showing the relationship between the presence or absence of a pressing member of a coil winding jig and the amount of deviation of a straight portion of a strip-shaped coil. [Figure 29] 29 is a diagram for explaining the slot positions in the strip coil in FIG. 28. FIG. [Figure 30] FIG. 10 is a diagram illustrating the amount of deviation of a straight line portion. [Figure 31] FIG. 10 is a perspective view showing a part of a coil winding jig in which the shape of the strip-shaped coil is distorted. [Figure 32] 10 is a cross-sectional view showing a part of a stator in which a straight portion of a strip-shaped coil having a disordered shape is housed. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0019] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. Fig. 1 shows a stator manufacturing apparatus 1 according to this embodiment. The stator manufacturing apparatus 1 includes a stator core 2 (see Figs. 2 and 3), a stator core fixing jig 3 that fixes the stator core 2, a coil winding jig 4 that is inserted into an axial hole 20 (see Figs. 2 and 3) of the stator core 2 and that winds a strip-shaped coil 100 into an annular shape, and a coil expansion mechanism 5 that expands the wound strip-shaped coil 100 wound around the coil winding jig 4.

[0020] As shown in Figures 2 and 3, the stator core 2 has an annular portion 21 made of, for example, a laminated body in which a plurality of thin core plates are stacked. An axial hole 20 is provided at the center of the annular portion 21, penetrating in the axial direction. The stator core 2 has a plurality of slots 22 that penetrate the stator core 2 in the axial direction. The slots 22 are arranged radially at regular intervals along the circumferential direction of the annular portion 21. The slots 22 have openings 22a that open toward the axial hole 20. Six ears 23 are provided on the outer periphery of the annular portion 21 of the stator core 2, protruding at regular intervals.

[0021] 1 to 3, the stator core fixing jig 3 has a hexagonal prism shape with an axial dimension substantially equal to the axial dimension of the stator core 2. A stator core insertion hole 31 into which the stator core 2 can be inserted is provided in the center of the stator core fixing jig 3. In the stator manufacturing apparatus 1 of this embodiment, the stator core fixing jig 3 is fixed to the center of the base 11 of the stator manufacturing apparatus 1 so that the axial direction of the stator core 2 fixed in the stator core insertion hole 31 is horizontal.

[0022] The stator core fixing jig 3 fixes the stator core 2 in a predetermined position and posture within the stator core insertion hole 31. More specifically, as shown in FIGS. 2 and 3 , the stator core fixing jig 3 has six core holding blocks 32 corresponding to the positions of the six ears 23 of the stator core 2. Each core holding block 32 is provided movably so as to protrude into and retract from the stator core insertion hole 31. After the stator core 2 is inserted into the stator core insertion hole 31, the core holding blocks 32 are driven by an actuator such as a cylinder (not shown) to protrude into the stator core insertion hole 31 and grip the ears 23 of the stator core 2. In this way, the stator core fixing jig 3 fixes the stator core 2 in the stator core insertion hole 31 in a predetermined position and posture.

[0023] 3 and 4, insulating paper 24 is fitted into each slot 22 of the stator core 2 and is folded to fit the inner surface shape of the slot 22. As shown in Fig. 4, the insulating paper 24 has cuffs 24a that protrude from the slot 22 at a predetermined height in the axial direction of the stator core 2. The cuffs 24a protrude from the slot 22 to both outer sides in the axial direction of the stator core 2.

[0024] As shown in Fig. 2, a plurality of cuff guides 33 are attached to each of the axial end faces 3a, 3a of the stator core fixing jig 3 so as to be radially arranged at regular intervals along the circumferential direction. The cuff guides 33 are provided so as to be movable along the radial direction of the stator core 2 by driving an actuator such as a cylinder (not shown). Note that in Fig. 3, the cuff guides 33 are not shown to facilitate understanding of the explanation of the core pressing block 32.

[0025] The cuff guide 33 is formed as a long, thin plate extending along the radial direction of the stator core 2. As shown in FIG. 5 , a guide groove 331 is provided along the longitudinal direction of the cuff guide 33 on the inner end 33a side of the cuff guide 33. The guide groove 331 opens toward the inside of the stator core fixing jig 3 and supports the cuff portion 24a of the insulating paper 24 from both sides. The guide groove 331 is cut out in a U-shape with a notch width slightly narrower than the circumferential width of the slot 22 of the stator core 2. An elongated hole 332 that restricts the radial movement range of the cuff guide 33 is provided on the outer end 33b side of the guide groove 331 of the cuff guide 33.

[0026] An inner diameter side restriction pin 34a and an outer diameter side restriction pin 34b are provided on both end faces 3a, 3a of the stator core fixing jig 3. The inner diameter side restriction pin 34a and the outer diameter side restriction pin 34b are provided in pairs corresponding to the cuff guides 33. The pair of inner diameter side restriction pin 34a and outer diameter side restriction pin 34b engages with the inside of an elongated hole 332 of the cuff guide 33.

[0027] When the cuff guide 33 moves radially inward of the stator core fixing jig 3, the inner diameter side restricting pin 34a comes into contact with the outer end 332b of the elongated hole 332. This positions the cuff guide 33 at the radially innermost guide position. At this time, the inner end 33a of the cuff guide 33 is positioned radially outward of the coil winding jig 4 (see FIG. 24).

[0028] When the cuff guide 33 moves radially outward from the stator core fixing jig 3, the outer diameter side restriction pin 34b comes into contact with the inner end 332a of the elongated hole 332. This positions the cuff guide 33 at the radially outermost non-guiding position. At the non-guiding position, the inner end 33a of the cuff guide 33 is positioned radially outward from the stator core insertion hole 31 (see FIG. 25).

[0029] The stator core 2 is inserted into the stator core insertion hole 31 of the stator core fixing jig 3 from either one side in the axial direction. Therefore, the inner end 33a of the cuff guide 33, which is arranged on the side opposite to the insertion side of the stator core 2, may be arranged so as to interfere with the annular portion 21 of the stator core 2, as shown in FIG. 5. However, the inner diameter side restriction pin 34a and the outer diameter side restriction pin 34b may be configured to be able to selectively protrude or recess into the surface of the stator core fixing jig 3 by an advancing / retracting mechanism (not shown) provided inside the stator core fixing jig 3. If necessary, the inner diameter side restriction pin 34a and the outer diameter side restriction pin 34b may be recessed into the surface of the stator core fixing jig 3, thereby moving the cuff guide 33 further radially outward and completely retracting from the annular portion 21 of the stator core 2, as shown in FIG. 2.

[0030] When the cuff guide 33 is moved radially inward of the stator core fixing jig 3 and positioned at the guide position, the circumferential separation distance between adjacent cuff guides 33, 33 on the inner end 33a side is positioned so as to match the cutout width of the guide groove 331 of the cuff guide 33.

[0031] Next, the coil winding jig 4 will be described with reference to Figures 6 and 7. The coil winding jig 4 has a substantially cylindrical jig body 41, a plurality of comb-tooth portions 42 protruding radially from the outer periphery of the jig body 41, a plurality of comb-tooth grooves 43 between adjacent comb-tooth portions 42, 42 in the circumferential direction, an axial hole 44 opening in the center of the jig body 41, and a plurality of pressing members 45 attached to the outer periphery of the jig body 41.

[0032] The comb tooth portions 42 and comb tooth-shaped grooves 43 are provided at both axial ends of the jig body 41. The phases of the comb tooth portions 42 and comb tooth-shaped grooves 43 at both ends of the jig body 41 are aligned in the axial direction. The number of comb tooth-shaped grooves 43 arranged in the circumferential direction of the jig body 41 matches the number of slots 22 provided in the stator core 2. The coil winding jig 4 can be inserted into the axial hole 20 of the stator core 2. In other words, the outer diameter of the coil winding jig 4, which is determined by the positions of the tips of the comb tooth portions 42, is the same as or slightly smaller than the inner diameter of the stator core 2.

[0033] The pressing member 45 is made of an elastic member attached to the jig body 41, and is disposed between the jig body 41 and the strip coil 100 to be wound around the coil winding jig 4. The pressing member 45 elastically presses the wound strip coil 100 from the inside of the strip coil 100 toward the outside in the radial direction. The pressing member 45 shown in this embodiment is made of a leaf spring formed in the shape of a thin, long plate.

[0034] One longitudinal end of the pressing member 45, which is made of a leaf spring, is a fixed end 45a, and the other longitudinal end is a free end 45b. The fixed end 45a is fixed to the outer peripheral surface 41a of the jig body 41 by a screw. More specifically, the fixed end 45a is fixed to the outer peripheral surface 41a of the jig body 41 near the comb-tooth grooves 43 arranged at one axial end side (the lower end side in FIG. 6) of the jig body 41. The free end 45b is not fixed to the jig body 41. FIGS. 6 and 7 show a steady state in which no compressive force is acting on the pressing member 45. In this state, the free end 45b extends obliquely from the fixed end 45a toward the comb-tooth grooves 43 arranged at the other axial end side of the jig body 41, and radially outward from the coil winding jig 4. The free end 45b is close to the comb-tooth grooves 43 arranged on the other axial end side (upper end side in FIG. 6) of the jig body 41. Specifically, the free end 45b is arranged slightly outward of the comb-tooth grooves 43 in the radial direction of the jig body 41.

[0035] The pressing members 45 are provided so as to correspond to at least some of the plurality of comb-tooth grooves 43 arranged radially in the circumferential direction of the coil winding jig 4. The coil winding jig 4 shown in FIG. 7 has 48 comb-tooth grooves 43 per circumference. In contrast, 12 pressing members 45 are provided. The fixed ends 45a of the 12 pressing members 45 are attached to the circumferential direction of the jig body 41 so as to match the arrangement pitch of the comb-tooth grooves 43. The 12 pressing members 45 correspond to 12 adjacent comb-tooth grooves 43. Therefore, when the pressing members 45 elastically deform radially inward of the coil winding jig 4 with the fixed ends 45a as fulcrums, the free ends 45b fit into the corresponding comb-tooth grooves 43 (see FIGS. 12 to 16).

[0036] A strip-shaped coil 100 to be mounted on a stator core 2 (not shown) is wound in an annular shape in the comb-tooth grooves 43 of the coil winding jig 4. As shown in FIG. 8 , the strip-shaped coil 100 has a plurality of straight portions 101 and a plurality of coil end portions 102. The straight portions 101 are inserted into the slots 22 of the stator core 2 and are arranged parallel to each other at regular intervals. The coil end portions 102 alternately connect one end and the other end of adjacent straight portions 101 in a mountain shape. When the strip-shaped coil 100 is mounted in the slots 22 of the stator core 2, the coil end portions 102 are arranged so as to protrude from the slots 22 in the axial direction of the stator core 2. The strip-shaped coil 100 of this embodiment is formed into a long sheet shape by bending and forming a plurality of straight portions 101 and a plurality of coil end portions 102 using six conductor wires 110.

[0037] As shown in Fig. 9, each of the conductor wires 110 constituting the strip coil 100 is composed of a plurality of flat wires 111 made of metal wires such as copper wires having a substantially rectangular cross section. The surface of the flat wires 111 is covered with a resin insulating coating (not shown). In this embodiment, the conductor wires 110 are arranged in parallel in the width direction X of the conductor wire 110 so that two flat wires 111, 111 are in close contact with each other. In other words, each conductor wire 110 is a divided line in which two flat wires 111, 111 are arranged in parallel.

[0038] Here, the directions of the strip-shaped coil 100 shown in the figure are defined as follows: The X direction is the width direction of the conductor wire 110 that constitutes the strip-shaped coil 100. This X direction corresponds to the circumferential direction of the stator core 2 and the coil winding jig 4. The Y direction is the length direction of the conductor wire 110 that constitutes the strip-shaped coil 100. This Y direction corresponds to the circumferential direction of the stator core 2 and the coil winding jig 4. The Z direction is the thickness direction of the strip-shaped coil 100 and the conductor wire 110. This Z direction corresponds to the radial direction of the stator core 2 and the coil winding jig 4.

[0039] As shown in FIG. 10 , the strip coil 100 is formed by folding six conductor wires 110, each bent into a U-shape, multiple times in the thickness direction of the conductor wires 110. Specifically, three pairs of conductor wires 110, each pair of which has a double U-shaped portion 110a arranged inside and outside, are stacked in parallel at a regular interval in the width direction X. A total of six U-shaped conductor wires 110 are folded in the width direction X, leaving only straight portions 101 to be accommodated in the slots 22 of the stator core 2. This forms the diagonal portions 103. The diagonal portions 103 are formed into a mountain shape by folding back in the thickness direction Z of the conductor wires 110. Similarly, the process of bending the diagonal portions 103, leaving only the straight portions 101, and the process of folding back the diagonal portions 103 are repeated multiple times to form the long, sheet-like strip coil 100 shown in FIG. 8 .

[0040] The strip coil 100 has a two-layer structure in which pairs of straight portions 101, 101 overlap each other by folding back the conductor wire 110. However, since the strip coil 100 is formed by sequentially folding back the conductor wire 110 starting from the U-shaped portion 110a, as shown in Figures 8, 10, and 11, the strip coil 100 has six U-shaped portions 110a. Therefore, among the twelve straight portions 101 arranged at the leading end 104 of the strip coil 100, some of the straight portions 101 do not overlap each other, resulting in a single-layer structure. The region 104a at the leading end 104 of the strip coil 100 where the single-layer straight portions 101 are arranged is thinner than the other portions (two-layer portions) of the strip coil 100 in the longitudinal direction.

[0041] Before being inserted into the stator core 2, the coil winding jig 4 rotates along the winding direction D as shown in FIG. 12 , and sequentially inserts the straight portions 101 of the strip coil 100 into the comb-tooth grooves 43, thereby winding the strip coil 100 in multiple layers. The strip coil 100 is wound onto the coil winding jig 4 from the leading end 104 side. Specifically, the straight portion 101 located at the endmost portion of the leading end 104 is inserted into the comb-tooth groove 43 corresponding to the position of the pressing member 45. This comb-tooth groove 43 corresponds to the position of the pressing member 45 located at the leading end of the multiple pressing members 45 in the winding direction D. In other words, the pressing member 45 is provided at a position where it can press the straight portion 101 located at the leading end 104, where the thickness of the strip coil 100 is small, among the multiple straight portions 101 of the strip coil 100 accommodated in the comb-tooth grooves 43 of the coil winding jig 4. Thereafter, the straight portions 101 of the strip-shaped coil 100 are inserted into the comb-tooth grooves 43 of the coil winding jig 4 in order.

[0042] 13 to 16, the strip coil 100 is wound around the coil winding jig 4. The straight portions 101 of the strip coil 100 wound around the coil winding jig 4 are accommodated in the comb-tooth grooves 43, 43 of the same phase at both ends of the jig body 41. The coil end portions 102 of the multiply wound strip coil 100 each protrude cylindrically from the comb-tooth grooves 43 to the outside in the axial direction of the jig body 41. As shown in FIGS. 15 and 16, the strip coil 100 is wound around the coil winding jig 4 so that the U-shaped portions 110a of the conductor wires 110 at the leading end 104 are positioned on the free end 45b side of the pressing member 45.

[0043] When the strip coil 100 is wound around the comb-tooth grooves 43 of the coil winding jig 4 in this manner, the straight portions 101 arranged at the leading end 104 are accommodated in the comb-tooth grooves 43 while elastically compressing the pressing member 45. Therefore, the straight portions 101 at the leading end 104 are subjected to the pressing force of the pressing member 45 and are accommodated in the comb-tooth grooves 43 while maintaining the parallel state of the two flat wires 111, 111 constituting the conductor wire 110. As a result, as shown in FIG. 15 , the two flat wires 111, 111 of the conductor wire 110 constituting each straight portion 101 are arranged parallel to each other in the circumferential direction of the coil winding jig 4.

[0044] Each pressing member 45 is disposed between the jig body 41 and the wound strip coil 100 and is compressed by the strip coil 100. As a result, each pressing member 45 elastically deforms along the outer peripheral surface 41a of the jig body 41, and continues to elastically press the two parallel flat wires 111, 111 of the straight portion 101 in the comb-tooth groove 43 from the inside of the strip coil 100 toward the outside in the radial direction. Therefore, the two flat wires 111, 111 of the conductor wire 110 do not become distorted, and the wound strip coil 100 maintains a stable shape.

[0045] The free ends 45b of the compressed pressing members 45 are fitted into the comb-tooth-shaped grooves 43. As a result, each pressing member 45 presses the straight portions 101 in the comb-tooth-shaped grooves 43 while being guided on both sides by the comb-tooth-shaped grooves 43. Therefore, each pressing member 45 can reliably press the straight portions 101 housed in the comb-tooth-shaped grooves 43 radially outward.

[0046] In the strip-shaped coil 100, the straight portions 101 arranged in other parts of the leading end 104 have a two-layer structure, while the straight portion 101 arranged at the leading end 104 has a single-layer structure. Therefore, in the coil winding jig 4 after winding the strip-shaped coil 100, the comb-tooth grooves 43 that accommodate the straight portions 101 arranged at the leading end 104 have a gap on the radially inner side of the coil winding jig 4, compared to the comb-tooth grooves 43 that accommodate only the other two-layered straight portions 101. This gap causes the half-square wires 111, 111 of the conductor wire 110 that constitute the straight portion 101 arranged at the leading end 104 to separate and easily become misaligned toward the radially inner side of the coil winding jig 4. When the flat wire 111 becomes misaligned, the misalignment spreads to the straight portions 101 on the radially outer side, causing a disturbance in the shape of the wound strip-shaped coil 100. However, in the coil winding jig 4 of this embodiment, the pressing member 45 continues to press the single-layered straight portion 101 arranged at least at the leading end 104 of the strip-shaped coil 100 radially outward, so that the two flat wires 111, 111 of the conductor wire 110 constituting the straight portion 101 are maintained in an appropriate parallel state. Therefore, the shape of the wound strip-shaped coil 100 wound on the coil winding jig 4 is stabilized and no disorder occurs.

[0047] The upper limit of the elastic pressing force (pressing load) generated by the pressing member 45 is set to a level at which the straight portion 101 of the wound strip coil 100 does not slip out of the comb-tooth grooves 43. The lower limit of the pressing force (pressing load) is set to a level at which the two rectangular wires 111, 111 constituting the straight portion 101 do not separate in the comb-tooth grooves 43 and can maintain a parallel state along the circumferential direction of the coil winding jig 4.

[0048] The coil winding jig 4 on which the strip-shaped coil 100 has been wound in this manner into a circular shape is inserted into the inside of the stator core 2 fixed to the stator core fixing jig 3 by, for example, the operation of a robot (not shown), as shown in Figures 1, 2 and 3. Note that the strip-shaped coil 100 of the coil winding jig 4 is not shown in Figure 1.

[0049] The coil winding jig 4 inserted inside the stator core 2 is held in a predetermined position and posture by a pair of coil expansion mechanisms 5 arranged on either side of the stator core fixing jig 3. The coil expansion mechanism 5 in this embodiment has a substantially cylindrical external shape and faces the coil winding jig 4 inserted inside the stator core 2 in the axial direction.

[0050] 1, a pair of support substrates 12 corresponding to a pair of coil expansion mechanisms 5 are erected on a base 11 that fixes the stator core fixing jig 3, so as to face each other with the stator core fixing jig 3 in between. The coil expansion mechanisms 5 protrude horizontally from the support substrates 12 toward the coil winding jig 4 that is inserted inside the stator core 2. The coil expansion mechanisms 5 are provided so as to be movable in directions toward and away from the coil winding jig 4 as the support substrates 12 move linearly on the base 11 by being driven by a motor or the like (not shown).

[0051] 17 , the coil expansion mechanism 5 has at its center a main shaft portion 51 extending from the support substrate 12 toward the coil winding jig 4 inserted inside the stator core 2. A holding portion 52 is provided at the tip of the main shaft portion 51, which holds the coil winding jig 4 at a predetermined position and posture inside the stator core 2. The holding portion 52 has an axial protrusion 522 protruding from the center of a circular end plate portion 521 disposed at the tip of the main shaft portion 51. The holding portion 52 fits into the axial hole 44 of the coil winding jig 4, and holds the phase of the slots 22 of the stator core 2 fixed to the stator core fixing jig 3 so that it matches the phase of the comb-tooth grooves 43 of the coil winding jig 4 inserted inside the stator core 2.

[0052] Coil expansion mechanism 5 has coil expansion section 53 on the outer periphery of main shaft section 51. Coil expansion section 53 has movable cylindrical section 531 that fits onto the outer periphery of main shaft section 51, a plurality of movable arms 532 that are arranged further outward from movable cylindrical section 531, and a plurality of bridge members 533 that are respectively provided at the tips of movable arms 532.

[0053] Movable cylinder portion 531 has a length shorter than that of main shaft portion 51, and is provided so as to be slidable along the axial direction of main shaft portion 51 by driving an actuator 54 such as a cylinder arranged behind support substrate 12.

[0054] The movable arms 532 extend along the axial direction of the main shaft 51 and are arranged at regular intervals in the circumferential direction on the outer periphery of the movable cylindrical portion 531. The coil extension portion 53 of this embodiment has twelve movable arms 532 arranged along the circumferential direction of the main shaft 51. Twelve guide rails 121 are provided on the surface of the support substrate 12 and arranged radially outward from the main shaft 51 as the center. Rear ends 532b of the movable arms 532 are attached so as to be movable along the guide rails 121. The movable arms 532 bend from the guide rails along the axial direction of the movable cylindrical portion 531 and extend to near the outer periphery of the holding portion 52. The tips 532a of the movable arms 532 are connected to the outer periphery of the movable cylindrical portion 531 on the tip side via two link portions 534 attached so as to be rotatable.

[0055] The bridge members 533 have a generally fan-like shape and are provided one at each end of the movable arm portion 532. Therefore, the coil extension portion 53 of this embodiment has twelve bridge members 533. As shown in FIGS. 19 and 22, each bridge member 533 has a pair of engaging protrusions 533a at one circumferential end and a pair of engaging grooves 533b at the other circumferential end, which engage with the engaging protrusions 533a. The pair of engaging protrusions 533a are arranged parallel to the axial direction of the coil extension portion 53 and protrude parallel to each other in the circumferential direction of the coil extension portion 53. The twelve bridge members 533 are arranged in an annular shape on the outer circumferential side of the holding portion 52 by the pair of engaging protrusions 533a and the pair of engaging grooves 533b of circumferentially adjacent bridge members 533, 533 engaging with each other.

[0056] The coil expansion mechanism 5 shown in FIG. 18 shows a state in which the movable cylindrical portion 531 of the coil expansion mechanism 53 is retracted to the rear end side (toward the support substrate 12) of the main shaft portion 51. At this time, the movable arms 532 move toward the inner ends of the radial guide rails 121 and are positioned closest to the outer peripheral surface of the movable cylindrical portion 531. As a result, the coil expansion mechanism 53 is reduced in diameter to the maximum extent so that the twelve bridge members 533 are brought into close contact with each other, as shown in FIGS. 18 to 20. When the coil expansion mechanism 53 is reduced in diameter to the maximum extent, the outer diameter of the coil expansion mechanism 53 is slightly smaller than the inner diameter of the coil end portion 102 that protrudes cylindrically in the axial direction from the coil winding jig 4 around which the strip-shaped coil 100 has been wound. With the coil expansion mechanism 5 with the coil expansion mechanism 53 in a reduced diameter state, the coil expansion mechanism 5 is inserted into the coil end portion 102 that protrudes cylindrically in the axial direction of the coil winding jig 4, and the coil winding jig 4 is held by the holding portion 52.

[0057] Next, when the actuator 54 is driven to move the movable cylindrical portion 531 forward along the main shaft portion 51 toward the coil winding jig 4, the link portions 534 connected to the movable cylindrical portion 531 rotate so as to protrude radially outward from the movable cylindrical portion 531. As a result, the twelve movable arms 532 each move parallel to the outside along the guide rails and move away radially outward from the movable cylindrical portion 531. At this time, the coil extension portion 53 moves so as to increase the distance between adjacent bridge members 533, thereby expanding, as shown in FIGS. 21 to 23 . The outer diameter of the fully expanded coil extension portion 53 is slightly larger than the outer diameter of the coil winding jig 4.

[0058] 22 and 23, when the coil extension portion 53 is fully expanded, the adjacent bridge members 533, 533 are spaced apart. However, a pair of engagement protrusions 533a, spaced apart from the engagement grooves 533b, protrude in the circumferential direction between the bridge members 533, 533. Therefore, when the coil extension portion 53 is viewed in the circumferential direction, the adjacent bridge members 533, 533 are continuous with each other through the pair of engagement protrusions 533a. Therefore, when the coil extension portion 53 expands, the expanded coil extension portion 53 is continuous in the circumferential direction, and no groove is formed into which the straight portion 101 of the strip coil 100 may get stuck during expansion.

[0059] Next, a method for inserting the strip coil 100 wound around the coil winding jig 4 into the slot 22 from inside the stator core 2 fixed to the stator core fixing jig 3 in the stator manufacturing apparatus 1 will be described.

[0060] After the coil winding jig 4 around which the strip-shaped coil 100 has been wound in an annular shape is inserted into the stator core 2 fixed to the stator-core fixing jig 3, the cuff guides 33 are moved radially inward by the drive of an actuator (not shown). As a result, as shown in FIG. 24 , the guide grooves 331 of the cuff guides 33 sandwich and support the cuff portions 24a of the insulating paper 24 in the slots 22. At this time, the inner ends 33a of circumferentially adjacent cuff guides 33 also sandwich and support the cuff portions 24a of the insulating paper 24 disposed between the cuff guides 33, in the same manner as the guide grooves 331. The support operation of the cuff guides 33 for the cuff portions 24a is performed at an appropriate timing after the stator core 2 is fixed to the stator-core fixing jig 3 and before the strip-shaped coil 100 is inserted into the slots 22 of the stator core 2 by the operation of the coil extension unit 53 (described later).

[0061] As shown in Figure 17, the coil winding jig 4 inserted inside the stator core 2 is held by the holding portions 52 of the coil expansion mechanism portions 5 as a pair of coil expansion mechanism portions 5, with the coil expansion portions 53 in a reduced diameter state, move from both sides in the axial direction toward the coil winding jig 4.

[0062] Furthermore, after the insulating paper 24 in the slot 22 is positioned by the cuff guide 33, the coil expansion portions 53 of the coil expansion mechanism 5 are expanded by driving the actuators 54, as shown in FIGS. 21 to 23 . As a result, the coil expansion portions 53 press the coil end portions 102 of the wound strip-shaped coil 100 so as to expand them from the inside of the strip-shaped coil 100 toward the outside in the radial direction, as shown in FIG. 25 . The strip-shaped coil 100 pressed by the coil expansion portions 53 gradually expands. Accordingly, the straight portions 101 move toward the slots 22 of the stator core 2 that communicate with the comb-tooth grooves 43 while being guided by the comb-tooth grooves 43.

[0063] As a result, the straight portions 101 of the strip-shaped coil 100 are inserted into the slots 22 from the openings 22a of the slots 22 without interfering with the slots 22 of the stator core 2. At this time, the insulating papers 24 in the slots 22 are positioned at predetermined positions by the cuff guides 33, so that the straight portions 101 of the strip-shaped coil 100 are prevented from getting caught in the insulating papers 24.

[0064] When the coil expansion portions 53 of the two coil expansion mechanisms 5 are each fully expanded, the straight portions 101 of the strip-shaped coil 100 of the coil winding jig 4 are each completely inserted into the slots 22 of the stator core 2, as shown in FIG. 25 . This causes the strip-shaped coil 100 to be mounted in the slots 22 of the stator core 2. The coil expansion portions 53 of the pair of coil expansion mechanisms 5 may operate to expand simultaneously, or may operate to expand sequentially with a time lag so that the straight portions 101 are inserted obliquely in the radial direction relative to the openings 22a of the slots 22.

[0065] Thereafter, the cuff guides 33 move radially outward. Furthermore, after the coil expansion sections 53 each contract in diameter, the coil expansion mechanisms 5 each move away from the coil winding jig 4. As a result, a stator 200 is obtained in which the strip coils 100 are fitted in the slots 22 of the stator core 2, as shown in FIG. 26 .

[0066] The strip coil 100 wound around the coil winding jig 4 continues to be pressed radially outward from the inside of the strip coil 100 by the pressing member 45 of the coil winding jig 4 until just before it is expanded and inserted into the slots 22 of the stator core 2. Therefore, the two flat wires 111, 111 of the conductor wire 110 constituting the straight portion 101 are maintained in a proper parallel state, and no disturbance occurs in the shape of the wound strip coil 100. As shown in FIG. 27 , each straight portion 101 of the strip coil 100 expanded and inserted into the slots 22 of the stator core 2 is regularly arranged in each slot 22 and stably accommodated, with the two flat wires 111, 111 constituting the conductor wire 110 maintaining a proper parallel state in the circumferential direction of the stator core 2.

[0067] FIG. 28 shows a comparison of the amount of misalignment of the rectangular wires 111, 111 that occurs in the straight portion 101 in the slot 22 expanded and inserted as described above when using the coil winding jig 4 of this embodiment equipped with the pressing member 45 and when using a coil winding jig 4 without the pressing member 45. In FIG. 28, the numbers on the horizontal axis indicate the position of the slot 22 into which the straight portion 101 is accommodated, starting from the leading end 104 of the strip-shaped coil 100 shown in FIG. 29. The numbers in FIG. 29 correspond to the numbers on the horizontal axis in FIG. 28. The vertical axis indicates the amount of misalignment of the two rectangular wires 111, 111 of the conductor wire 110 that constitute the straight portion 101. As shown in FIG. 30, the amount of misalignment indicates the relative positional misalignment L of the two rectangular wires 111, 111 in the radial direction of the stator core 2 (thickness direction Z of the conductor wire 110). The dimension of each of the rectangular wires 111, 111 along the thickness direction Z of the conductor wire 110 is 2.45 mm.

[0068] As shown in Fig. 28, when a coil winding jig 4 equipped with a pressing member 45 is used, the amount of deviation of the straight portions 101 of the strip coil 100 in the slot 22 is extremely small. In contrast, when a coil winding jig 4 without a pressing member 45 is used, it is found that the amount of deviation is extremely large compared to when a coil winding jig 4 equipped with a pressing member 45 is used. When a coil winding jig 4 without a pressing member 45 is used, as shown in Fig. 31, the flat wires 111, 111 constituting the conductor wire 110 are separated and dispersed, causing disorder in the straight portions 101 in the comb-tooth grooves 43. As a result, as shown in Fig. 32, after expanded insertion, the straight portions 101 in the slot 22 are accommodated so that some of the flat wires 111 protrude from the slot 22, resulting in a state in which each straight portion 101 is not positioned in the appropriate position in the slot 22.

[0069] The coil winding jig 4 shown in the above embodiment has pressing members 45 made up of 12 leaf springs corresponding to the 12 straight portions 101 arranged at the leading end 104 of the strip-shaped coil 100. However, the number of pressing members 45 is not limited to this. It is sufficient that the coil winding jig 4 is provided with pressing members 45 in a number that corresponds at least to the number of straight portions 101 with a single-layer structure at the leading end 104.

[0070] The pressing member 45 provided in the coil winding jig 4 is not limited to a leaf spring, and various other elastic structures can be used as long as it is configured to be able to press the straight portion 101 housed in the comb-tooth groove 43 from the inside of the strip coil 100 radially outward. [Explanation of symbols]

[0071] 1 Stator manufacturing equipment 2 stator core 20 shaft hole 22 slots 200 Stator 4 Coil winding jig 43 Pectinate groove 45 Push member 45a fixed end 45b free end 100 Strip coil 101 Straight section 104 Leading end (part thinner than other parts)

Claims

1. A stator manufacturing apparatus for inserting a plurality of straight portions of a strip-shaped coil into a plurality of slots that open toward a central axial hole by expanding a strip-shaped coil that is wound around the axial hole, the strip-shaped coil comprising: a coil winding jig configured to be insertable into the axial hole of the stator core and winding the strip-shaped coil around an outer periphery thereof; The coil winding jig is a plurality of comb-tooth grooves that can accommodate the plurality of linear portions and allow the strip-shaped coil to be wound therearound; a pressing member that is compressed by the wound strip-shaped coil and elastically presses at least some of the straight portions of the plurality of straight portions accommodated in the plurality of comb-tooth grooves from the inside of the wound strip-shaped coil toward the outside in the radial direction.

2. the strip-shaped coil has a portion at at least one end in a longitudinal direction that is thinner than other portions in the longitudinal direction of the strip-shaped coil, 2. The stator manufacturing apparatus according to claim 1, wherein the pressing member is provided in a position in the coil winding jig where it can press at least the straight portions of the strip coil that are arranged in the thinnest portions of the strip coil, among the straight portions accommodated in the comb-tooth grooves.

3. The stator manufacturing device according to claim 1 or 2, wherein the pressing member is provided so as to press the linear portion inside the comb-tooth-shaped groove.

4. 4. The stator manufacturing apparatus according to claim 3, wherein the pressing member is configured by a leaf spring having one end fixed to the coil winding jig and the other end free to be placed inside the comb-tooth groove.

5. A method for manufacturing a stator, in which a strip-shaped coil in a wound state and disposed in a stator core having a plurality of slots opening toward a central axial hole is expanded to insert a plurality of straight portions of the strip-shaped coil into the slots, After winding the strip-shaped coil around an outer periphery of a coil winding jig configured to be insertable into the axial hole of the stator core and having a plurality of comb-tooth grooves capable of accommodating the plurality of straight portions of the strip-shaped coil, A method for manufacturing a stator, comprising: pressing at least some of the straight portions of the plurality of straight portions housed in the plurality of comb-tooth grooves from the inside of the wound strip-shaped coil toward the outside in the radial direction using a pressing member until the wound strip-shaped coil is expanded.

6. the strip-shaped coil has a portion at at least one end in a longitudinal direction that is thinner than other portions in the longitudinal direction of the strip-shaped coil, 6. The method for manufacturing a stator according to claim 5, wherein the pressing member presses at least the straight portions of the strip coil that are arranged in the thinnest portions of the strip coil, among the straight portions accommodated in the comb-tooth grooves.

7. The method for manufacturing a stator according to claim 5 or 6, wherein the pressing member presses the linear portion inside the comb-tooth groove.

8. 8. The method for manufacturing a stator according to claim 7, wherein the pressing member is configured by a leaf spring having one end fixed to the coil winding jig and the other end free to be placed inside the comb-tooth groove.

Images