Coil Insertion Device

Abstract

To provide a coil insertion device that reduces the load generated on a coil.SOLUTION: The coil insertion device includes a plurality of blades 110 arranged on the inside of a stator core in a radial direction in line in the circumferential direction of the stator core, extending in the axial direction and holding coils. At least one of the blades 110 includes, in the axial direction view, a first end point 111 located on one side of the circumferential direction among outer radial end edges E, a second end point 112 located on the other side of the circumferential direction among the outer radial end edges E, a first line 113 extending from the first end point 111 toward the inner side in the radial direction, and a second line 114 extending from the second end point 112 toward the inner side in the radial direction and including the radially inner end edge 115 of the blade 110. The radially inner end edge 115 is located in an area that includes the second end point 112 in the area of two areas divided by a straight line L that passes through the midpoint of the first end point 111 and the second end point 112 and extends in the radial direction.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a coil insertion device. [Background technology]

[0002] Conventionally, there is known a coil insertion device for inserting coils into slots of a stator core. For example, Japanese Patent Laid-Open Publication No. 2000-125521 (Patent Document 1) discloses a device in which coils are held by first and second movable blades 37 and 39 that are alternately arranged corresponding to the internal teeth of a cylindrical stator core and are movable relative to each other in the axial direction. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2000-125521 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the above-mentioned Patent Document 1 has a problem in that a large load is generated on the coil due to friction with the blade.

[0005] An object of the present invention is to provide a coil insertion device that reduces the load on the coil. [Means for solving the problem]

[0006] A coil insertion device from a first aspect of the present invention is a coil insertion device that inserts coils into a plurality of slots that penetrate a stator core in the axial direction by relatively moving the coils from one axial side to the other, and includes a plurality of blades that are arranged side by side in the circumferential direction of the stator core on the radially inner side of the stator core, extend in the axial direction, and hold the coils, and at least one of the blades includes, when viewed in the axial direction, a first end point located on one circumferential side of the radially outer edge, a second end point located on the other circumferential side of the radially outer edge, a first line extending radially inward from the first end point, and a second line extending radially inward from the second end point and including the radially inner edge of the blade, and the radially inner edge is located within the region that includes the second end point of two regions separated by a straight line that passes through the midpoint between the first end point and the second end point and extends radially. [Effects of the Invention]

[0007] The present invention can provide a coil insertion device that reduces the load on the coil. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a schematic diagram of a cross section perpendicular to the axial direction of the stator. [Figure 2] FIG. 2 is a perspective schematic view of the stator of the embodiment. [Figure 3] FIG. 3 is a schematic diagram showing a coil insertion device. [Figure 4] FIG. 4 is a schematic diagram showing a coil insertion device. [Figure 5] FIG. 5 is a schematic diagram showing a coil insertion device. [Figure 6] FIG. 6 is a schematic diagram showing the blades as viewed in the axial direction. [Figure 7] FIG. 7 is a schematic view showing a step of the method for manufacturing the stator as viewed in the axial direction. [Figure 8] FIG. 8 is a schematic diagram showing a stripper. [Figure 9]9 is a flow chart showing a coil insertion method, and is a schematic diagram showing one step of the method. [Figure 10] FIG. 10 is a schematic diagram showing a blade of a comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following drawings, the same or corresponding parts are designated by the same reference characters, and the description thereof will not be repeated.

[0010] In the following description, the direction in which the central axis of the stator 1 extends, i.e., the direction in which the slots penetrate, is referred to as the "axial direction." One side along the axial direction is referred to as the lower side, and the other side as the upper side. The up-down direction is used to identify the positional relationship and does not limit the actual direction. In other words, the down direction does not necessarily mean the direction of gravity. The axial direction is not particularly limited and includes the vertical direction, the horizontal direction, and directions intersecting these directions.

[0011] The direction perpendicular to the central axis of the stator 1 is referred to as the "radial direction." One side along the radial direction is referred to as the inner side, and the other side is referred to as the outer side. Furthermore, the direction along the arc centered on the central axis of the stator 1 is referred to as the "circumferential direction."

[0012] In addition, the drawings used in the following description may show characteristic parts enlarged for the purpose of emphasizing the characteristic parts. Therefore, the dimensions and proportions of each component are not necessarily the same as those in reality. For the same purpose, non-characteristic parts may be omitted from the drawings.

[0013] (stator) As shown in Fig. 1, the stator 1 is a component of the motor, and generates rotational torque by interacting with a rotor (not shown). The stator 1 of this embodiment has distributed winding in which coils are wound across several slots 21. The stator 1 includes a coil 10 and a stator core 20.

[0014] <Stator core> The stator core 20 is formed in a hollow cylindrical shape. The stator core 20 is formed by stacking thin silicon steel plates. A plurality of teeth 23 are formed radially in the stator core 20. Slots 21 are formed between the teeth 23. The teeth 23 extend in the radial direction via the slots 21. Slot openings 22, which are radial openings, are formed in the slots 21. The stator core 20 of this embodiment is an integrated stator core.

[0015] <Coil> The coil 10 is formed by winding a coil wire in a circular shape. The coil wire in this embodiment is a round wire, but is not particularly limited thereto and may be a rectangular wire or the like.

[0016] The coil 10 has two coil side portions and a coil transition portion. The two coil side portions are housed in slots 21. Specifically, the slot 21 housing one coil side portion is different from the slot 21 housing the other coil side portion. The slot 21 housing one coil side portion and the slot 21 housing the other coil side portion may be arranged in the circumferential direction via another slot as shown in FIG. 1, or may be adjacent to each other (not shown).

[0017] (coil insertion device) The coil insertion device 100 will be described with reference to Figures 1 to 8. As shown in Figure 1, the coil insertion device 100 inserts the coil 10 into a plurality of slots 21 that penetrate the stator core 20 in the axial direction by relatively moving the coil 10 from one axial side to the other (from right to left in Figures 3 to 5). In detail, the coil insertion device 100 inserts the coil 10, in which the coil wire is wound in a circular shape, from each slot opening 22 so as to straddle two slots 21 of the stator core 20.

[0018] As shown in FIG. 2, the coil 10 to be inserted into the coil insertion device 100 of this embodiment includes a first coil 11 and a second coil 12. The first coil 11 is formed by winding a coil wire around a first bobbin. The second coil 12 is formed by winding a coil wire around a second bobbin. The shapes of the first and second bobbins may be the same or different. Here, the first bobbin is smaller than the second bobbin. Therefore, the coil 10 includes an annular small coil as the first coil 11 and an annular large coil as the second coil 12 that encompasses the small coil.

[0019] As shown in FIGS. 3 to 5, the coil insertion device 100 includes a plurality of blades 110 and a stripper 120 serving as a coil moving mechanism.

[0020] <Blade> 2, a plurality of blades 110 hold the coil 10. The blades 110 are arranged side by side in the circumferential direction of the stator core 20 on the radially inner side of the stator core 20 and extend in the axial direction. The plurality of blades 110 makes it easy to insert the coil 10 into the slot 21.

[0021] The blade 110 is arranged via a plurality of teeth 23. The blade 110 guides the coil 10 hooked on a stripper 120 (described later) along the axial and radial directions to the slot 21. The blade 110 has a shape that allows it to be placed in the slot opening 22. The blade 110 is a rod-shaped member that extends in the axial direction. The blade 110 is a movable blade that moves in the axial direction.

[0022] In this embodiment, the radially outer edge of the blade 110 is located radially inward of the radially inner edge of the stator core 20 , but may be located radially outward of the radially inner edge of the stator core 20 .

[0023] The blade 110 is moved in the axial direction by a blade drive unit (not shown). Specifically, the blade 110 can move axially to one side and the other side. The blade drive unit is attached to the blade 110 and includes a member that pushes the blade 110 in the axial direction, and a drive source that moves the member in the axial direction.

[0024] At least one of the multiple blades 110 has an asymmetric shape when viewed in the axial direction, as shown in Figure 6. At least one of the multiple blades 110 does not have to have the shape shown in Figure 6, but here, all of the multiple blades 110 have the shape shown in Figure 6 when viewed in the axial direction. Furthermore, the multiple blades 110 extend in the axial direction in the shape shown in Figure 6.

[0025] The blade 110 includes a first end point 111, a second end point 112, a first line 113, and a second line 114 in the axial direction.

[0026] The first end point 111 is located on one circumferential side of the radially outer edge E. In FIG. 6, the first end point 111 is located on the one circumferential side and the outermost radial side. That is, the first end point 111 is the radially outer edge E and is also the edge on one circumferential side. The first end point 111 is in contact with the stator core 20.

[0027] The second end point 112 is located on the other circumferential side of the radially outer edge E. In FIG. 6, the second end point 112 is located on the other circumferential side and the outermost side in the radial direction. That is, the second end point 112 is the radially outer edge E and the other circumferential side edge. The second end point 112 is in contact with the stator core 20.

[0028] The first wire 113 extends radially inward from the first end point 111. The side surface including the first wire 113 is in contact with the coil 10.

[0029] The second line 114 extends radially inward from the second end point 112 and includes the radially inner edge 115 of the blade 110. The side including the second line 114 does not contact the coil 10.

[0030] The radially inner edge 115 is located within the region that includes the second end point 112, of two regions divided by a line L that passes through the midpoint between the first end point 111 and the second end point 112 and extends radially. In other words, the radially inner edge 115 is not located within the region that includes the first end point 111, of the two regions divided by the line L. As a result, when the coil 10 is inserted into the slot 21, the side of the blade 110 that includes the first line 113 is positioned to be in contact with the coil 10. This increases the contact area between the blade 110 and the coil 10 compared to the blade having an axisymmetric shape as in Patent Document 1. This reduces the pressure generated by friction between the coil 10 and the blade 110. This reduces the load on the coil 10 due to friction between the coil 10 and the blade 110.

[0031] The radially inner edge 115 is the intersection of the first line 113 and the second line 114. In other words, the intersection is located at the innermost position in the radial direction.

[0032] In this embodiment, the first line 113 is composed of a curved line or a curved line and a straight line. Thus, the first line 113 of this embodiment includes at least a curved line. Here, more than half of the first line 113 is curved. In FIG. 6, the first line 113 is straight near the first endpoint and the remainder is curved. Furthermore, the central portion of the first line 113 is curved.

[0033] The second line 114 is composed of straight lines or curved and straight lines. Thus, the second line 114 of this embodiment includes at least straight lines. Here, the straight lines of the second line 114 are located in the center. Moreover, straight lines account for more than half of the second line 114. In FIG. 6, the second line 114 is curved near the radially inner edge 115, and the remaining part is straight.

[0034] The straight lines of the second wires 114 are longer than the straight lines of the first wires 113. Because the coil 10 does not contact the side of the blade 110 that includes the second wires 114, even if the second wires 114 include many straight lines, this has little effect on reducing the load on the coil 10. Sides that include straight lines when viewed in the axial direction can be manufactured more easily than side surfaces that include curved lines. Therefore, since the side surfaces that include the second wires 114 can be manufactured easily, the blade 110 can be manufactured more easily.

[0035] The straight line constituting the second line 114 includes the second end point 112. That is, the second line 114 includes a straight line extending radially inward from the second end point 112. This makes it easier to manufacture the blade.

[0036] As shown in FIG. 7 , a pair of blades 110 spaced apart in the circumferential direction include a first end point 111, a second end point 112, a first wire 113, and a second wire 114 in an axial view. In an axial view, the first wires 113 of the pair of blades 110 are positioned circumferentially outward from each other. Furthermore, in an axial view, the second wires 114 of the pair of blades 110 are positioned circumferentially inward from each other. When inserting an annular coil 10 into two slots 21, the side surface including the first wire 113 of one blade 110 is positioned so as to contact one coil side of the coil 10, and the side surface including the first wire 113 of the other blade 110 is positioned so as to contact the other coil side of the coil 10, thereby increasing the contact area with the coil side. Therefore, the present invention is suitable for use in a coil insertion device 100 that inserts an annular coil 10 into a slot 21.

[0037] 7 shows a state in which the first coil 11 and the second coil 12 are not being pressed by the stripper 120. Therefore, FIG. 7 roughly illustrates the positional relationship between the first coil 11 and the second coil 12 and the blade 110. The pair of blades 110 shown in FIG. 7 holds the first coil 11. The other pair of blades (not shown) holds the second coil 12.

[0038] <Stripper> The stripper 120 serving as a coil moving mechanism is disposed radially inside the stator core 20. The stripper 120 moves axially relative to the stator core 20, moving the coil 10 relatively from one axial side to the other. The stripper 120 and the blades 110 allow the coil 10 to be easily inserted into the slot 21.

[0039] The stripper 120 moves the coil 10 axially along the radially inner side of the stator core 20, while inserting a portion of the coil 10 into the slot 21 through the slot opening 22. Specifically, the stripper 120 hooks the radially inner side of the coil 10 and pulls the coil 10 up along the blade 110.

[0040] The stripper 120 is moved in the axial direction by a stripper drive unit (not shown). Specifically, the stripper 120 can move to one axial side and the other axial side. The stripper drive unit is attached to the stripper 120 and includes a member that pushes the stripper 120 in the axial direction and a drive source that moves the member in the axial direction.

[0041] The stripper 120 has a shape that allows it to be placed in the slot opening 22. Specifically, as shown in FIG. 3 , the stripper 120 includes a shaft 121 and a large diameter portion 122. The shaft 121 extends in the axial direction. The large diameter portion 122 is provided at the other axial end of the shaft 121. The radially inner side of the annular coil 10 is hooked onto the large diameter portion 122. The large diameter portion 122 has a diameter larger than that of the shaft 121. The shaft 121 and the large diameter portion 122 have the same central axis. The diameter of the large diameter portion 122 is the distance between the blades 110.

[0042] As shown in FIG. 8, the large diameter portion 122 of the stripper 120 has a shape that fits along the blade 110.

[0043] Specifically, the stripper 120 has a side surface 123 that is aligned with the first line 113 (see FIGS. 6 and 7) of the blade 110 when viewed in the axial direction. This allows the coil 10 to be more easily inserted into the slot 21 by the stripper 120 and the blade 110. Here, the side surface 123 is configured as a curved surface or a curved surface and a flat surface.

[0044] Moreover, the stripper 120 has a side surface 124 that is aligned with the second line 114 of the blade 110 (see FIGS. 6 and 7) when viewed in the axial direction. Here, the side surface 124 is configured as a flat surface or a flat surface and a curved surface. In this way, the stripper 120 has a side surface 124 that is aligned with the straight line that constitutes the second line 114 of the blade 110 when viewed in the axial direction. As a result, the side surface 124 includes a straight line when viewed in the axial direction, which makes it easy to fabricate the stripper 120 as well as the blade 110.

[0045] In this embodiment, the radially outer edge of the stripper 120 is located radially inward of the radially inner edge of the stator core 20 , but may be located radially outward of the radially inner edge of the stator core 20 .

[0046] (Coil insertion method) Next, the coil insertion method of this embodiment will be described with reference to Figures 1 to 9. The coil insertion method of this embodiment is a method for inserting the coil 10 using the coil insertion device 100 described above.

[0047] First, as shown in Fig. 9, a coil 10 is formed (step S1). This step S1 includes a step of winding a coil wire around a first bobbin to form a first coil 11, and a step of winding a coil wire around a second bobbin to form a second coil 12. This allows the formation of a coil 10 that includes the first coil 11 and the second coil 12 that encompasses the first coil 11, as shown in Fig. 2.

[0048] Next, the coil insertion device 100 is installed on the stator core 20 (step S2). In this step S2, as shown in Fig. 3, the coil 10 and the coil insertion device 100 are arranged on one axial side of the stator core 20. More specifically, the coil 10 is arranged so as to be held between the plurality of blades 110. Next, a stripper 120 is arranged in the radial center of the plurality of blades 110 on one axial side.

[0049] Next, as shown in Fig. 4, the blades 110 and the stripper 120 are moved from one axial side to the other axial side (step S3). In this step S3, the stripper 120 moves to the other axial side together with the blades 110. During this movement, the blades 110 are positioned radially inside the stator core 20. Since the inside of the coil 10 moves while being hooked on the stripper 120, the coil 10 moves to the other axial side.

[0050] By moving the blades 110 and the stripper 120 in this manner, the coils 10 can be inserted into the slots 21 of the stator core 20 (step S4), as shown in Fig. 5. Note that in step S3, a step of moving at least one of the blades 110 and the stripper 120 from the other axial side to one side may be performed depending on the insertion resistance of the coils 10, etc.

[0051] Next, the coil insertion device 100 is removed from the stator core 20 (step S5). Specifically, the blades 110 are removed from the stator core 20. Also, the stripper 120 is moved downward.

[0052] By carrying out the above steps (steps S1 to S5), coils 10 can be inserted into a plurality of slots 21 that penetrate stator core 20 in the axial direction. As a result, stator 1 shown in FIG. 1 can be manufactured.

[0053] (Action and effect) The effects of the coil insertion device 100 of this embodiment will be described below in comparison with a coil insertion device equipped with a blade of a comparative example shown in Fig. 10. Note that arrows A1 and A2 in Fig. 10 indicate tension applied when the coil 10 is inserted into the slot 21 by the coil insertion device. Similar tension is also applied in Fig. 6, but is not shown in the figure.

[0054] 10 is symmetrical with respect to the line L when viewed in the axial direction. Therefore, in the blade 210 of the comparative example, the radially inner edge 215 is located on the line L.

[0055] In the blade 210 of the comparative example, of the two regions divided by the straight line L, within the region including the first end point 111, the surface pressure due to the tension applied to the coil 10 when inserting the coil 10 is concentrated in the region R1 near the radially inner edge 215. For this reason, when the blade 210 of the comparative example is used, there is a high possibility that the coil 10 will be damaged.

[0056] On the other hand, in the blade 110 of this embodiment, tension is applied to the coil 10 in region R2 near the radially inner edge 215 in both of the two regions separated by the straight line L, the region including the first end point 111 and the region including the second end point 112, when the coil 10 is inserted. However, in the blade 110 of this embodiment, the region in contact with the coil 10 is larger than in the comparative example, so the surface pressure can be dispersed. Therefore, the coil insertion device 100 of this embodiment can reduce the possibility of damaging the coil 10.

[0057] Furthermore, in this embodiment, the length of the straight lines of the second wire 114 is longer than the length of the straight lines of the first wire 113. Because the coil 10 does not contact the side surface including the second wire 114, even if the second wire includes many straight lines, the impact on reducing the load acting on the coil 10 is small. Side surfaces including straight lines when viewed in the axial direction can be processed into flat surfaces, and are therefore easier to manufacture than side surfaces including curved lines. Therefore, since the second wire 114 includes many straight lines, it becomes easier to manufacture the side surface including the second wire 114. This reduces processing costs. Furthermore, the rigidity of the blade 110 can be improved.

[0058] (Variation) In the above-described embodiment, as shown in Fig. 2, a method in which two coils 10, the first coil 11 and the second coil 12, are simultaneously inserted into four slots 21 has been described as an example, but the present invention is not limited to this. One annular coil 10 may be inserted into two slots 21, or three or more annular coils 10 may be inserted into six or more slots 21 simultaneously.

[0059] The embodiments disclosed herein should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is defined not by the above-described embodiments but by the claims, and it is intended to include all modifications within the meaning and scope of the claims. [Explanation of symbols]

[0060] 1: Stator 10: Coil 20: Stator core 21: Slot 100: Coil insertion device 110: Blade 111 :1st end point 112: Second end point 113: First Line 114: Second Line 115: Radial inner edge 120: Stripper 123,124: Side

Claims

1. A coil insertion device that inserts coils into a plurality of slots that penetrate a stator core in the axial direction by relatively moving the coils from one axial side to the other, a plurality of blades arranged side by side in a circumferential direction of the stator core on a radially inner side of the stator core, extending in an axial direction, and holding the coil; At least one of the blades has, in an axial view, a first end point located on one side in the circumferential direction of the radially outer edge; a second end point located on the other side in the circumferential direction of the radially outer edge; a first line extending radially inward from the first end point; a second line extending radially inward from the second end point and including the radially inner edge of the blade; Including, the radially inner edge is located only within a region that includes the second end point, of two regions that are separated by a straight line that passes through a midpoint between the first end point and the second end point and extends radially.

2. The coil insertion device according to claim 1 , wherein the radially inner edge is an intersection of the first line and the second line.

3. 3. The coil insertion device according to claim 1, further comprising a coil moving mechanism arranged radially inside the stator core, moving axially relative to the stator core, and moving the coil relatively from one axial side to the other axial side.

4. The coil insertion device according to claim 3 , wherein the coil moving mechanism has a side surface that is aligned with the first line when viewed in the axial direction.

5. the first line is a curved line or a curved line and a straight line; the second line is a straight line or a curved line and a straight line; The coil insertion device according to any one of claims 1 to 4, wherein the straight line of the second wire is longer than the straight line of the first wire.

6. a coil moving mechanism disposed radially inside the stator core, moving axially relative to the stator core, and moving the coil relatively from one axial side to the other axial side; The coil insertion device according to claim 5 , wherein the coil moving mechanism has a side surface that is aligned with a straight line that constitutes the second line when viewed in the axial direction.

7. The coil insertion device according to claim 5 or 6, wherein the second end point is included in a straight line that constitutes the second line.

8. a pair of the blades arranged at an interval in the circumferential direction includes, when viewed in the axial direction, the first end point, the second end point, the first line, and the second line; The coil insertion device according to any one of claims 1 to 7, wherein the first wires of the pair of blades are positioned circumferentially outward of each other when viewed in the axial direction.

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