Winding device and winding method for split core

Abstract

To set a crossover wire length to an appropriate length to improve productivity.SOLUTION: A winding device 20 for a split core according to the present disclosure comprises: a core supporting member 26 having a first core supporting part 29 and a second core supporting part 30, is rotatable around a rotary axis, and is slidable in a slide direction S; a wire nozzle 22; and a side guide 27 arranged on one side in the slide direction S of the core supporting member 26 to define a core accommodation space. The core supporting member 26 arranges the second core supporting part 30 at a winding position by a sliding movement from a first state in which the first core supporting part 29 is arranged at the winding position toward the above one side, and can change to a second state in which a first split core 10a is accommodated in the core accommodation space. The side guide 27 covers the first split core 10a in the second state, and restricts interference of a winding 14 toward the first split core 10a during a winding around a second split core 10b to guide the winding 14 toward the second split core 10b side.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates to a split core winding device and a winding method for winding coils around a plurality of split cores arranged side by side in the circumferential direction of a rotating electric machine. [Background technology]

[0002] Conventional techniques exist for continuously winding coils around multiple split cores. For example, Patent Document 1 describes a winding machine equipped with a spindle machine that rotates teeth in the axial direction and winds wire around the teeth by supplying wire from a nozzle installed on the side. This winding machine axially connects the teeth with a winding jig when winding the wire around the teeth. The winding jig is supported axially movably by guide rails installed on both sides. These guide rails are rotated by the spindle machine, thereby rotating the winding jig and teeth. As the wire is wound around the teeth, the winding machine feeds the winding jig and teeth along the guide rails. In this way, the winding machine described in Patent Document 1 winds the wire while displacing the winding jig and teeth relative to the nozzle. The outer surface of the winding jig has a spiral guide groove for guiding a jumper wire, which connects the coils as it is wound around the winding jig. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-42446 Summary of the Invention [Problem to be solved by the invention]

[0004] In the winding machine (winding device) described in Patent Document 1, a spiral guide groove for guiding a jumper wire is formed on the outer surface of a winding jig. The jumper wire connects coils while being wound around the winding jig. However, the length of the spiral guide groove for guiding the jumper wire is uniquely determined by the distance between the divided cores of the winding jig and the diameter of the winding jig, making it difficult to set the jumper wire length arbitrarily. For example, even if it is desired to shorten the jumper wire between divided cores, such as when continuously winding wires around two adjacent divided cores, it is difficult to shorten the jumper wire length, which may require post-processing of the excess jumper wire after winding. This may complicate the process and reduce productivity.

[0005] Therefore, an object of the present disclosure is to provide a winding device and a winding method for a split core that can set the length of the jumper wire to an appropriate length and improve productivity. [Means for solving the problem]

[0006] In order to solve the above-mentioned problems, a first aspect of the present invention is a split core winding device that continuously winds a winding around at least two split cores having teeth around which the winding is wound, the device comprising: a core support member having a first core support portion and a second core support portion that can support the split cores, that is rotatable about a rotation axis and that is slidable in a sliding direction that intersects with the axial direction of the rotation axis; a winding supply member that supplies the winding to the core support member; and a side guide that is arranged on one side of the core support member in the sliding direction and that defines a core accommodating space that is open toward the other side in the sliding direction, wherein the core support member can slide from a first state in which the first core support portion is arranged at a winding position that includes the rotation axis to the one side, to a second state in which the second core support portion is arranged at the winding position and a first split core supported by the first core support portion is accommodated in the core accommodating space, a guide disposed on both sides of the teeth of the split core positioned at the winding position and guiding the winding to a predetermined position of the teeth, the guide being rotatable together with the core support member and movable in the axial direction relative to the core support member; The side guide is In the first state, the first divided core is not covered, and when a winding is performed on the first divided core supported by the first core support portion, interference of the winding with the first divided core is restricted, and the winding is guided toward the first divided core together with the guide, In the second state teethThe first divided core is covered, and when winding is performed on the second divided core supported by the second core support portion, interference of the winding with the first divided core is restricted, Together with the guide, The winding is guided toward the second divided core.

[0007] A second aspect of the present invention is a winding device for a split core of the first aspect, wherein the edge portion of the side guide on the opening side that opens the core storage space to the other side is curved toward the inside of the opening.

[0009] The present invention 3 This aspect is the same as the above-mentioned 1 In a winding device for a split core of this type, the guide moves in the axial direction relative to the core support member depending on the winding state of the winding so as to leave a gap at the specified position of the tooth portion that is at least large enough to insert the winding.

[0010] The present invention 4 The aspect of the present invention is a split core winding method for continuously winding a winding around at least two split cores having teeth on which the winding is wound, the method comprising a first setting step of setting a first split core on a first core support part of a core support member; a first guide moving step of moving guides that guide the winding to predetermined positions of the teeth portions to both sides of the teeth portions of the first split cores set on the first core support portions; a first winding step of rotating the core support member about the rotation axis relative to the winding supply member while holding an end of the winding supplied from the winding supply member toward the core support member, thereby winding the winding around the teeth of the first split core; a sliding step of sliding the first split core with the winding wound thereon in a direction intersecting the axial direction of the rotation axis to a position covered by a side guide; and a second setting step of setting a second split core on the second core support portion of the core support member. a second guide moving step of moving the guide to both sides of the teeth portion of the second split core set on the second core support portion; a second winding step of rotating the core support member about the rotation axis relative to the winding supply member to wind the winding around the teeth of the second split core. In the first winding step, the first core support portion, the guide, and the side guide are rotated about the rotation axis relative to the winding supply member, and the guide is moved in the axial direction of the rotation axis relative to the first core support portion, and the winding is slid onto the guide and the side guide using the guide and the side guide to wind the winding around the teeth of the first split core; in the second winding step, with the first split core covered by the side guide, the second core support portion, the guide, and the side guide are rotated about the rotation axis relative to the winding supply member, and the guide is moved in the axial direction relative to the second core support portion, and the winding is slid onto the guide and the side guide to wind the winding around the teeth of the second split core; and after the second winding step, the first split core and the second split core around which the winding has been continuously wound are removed from the first core support portion and the second core support portion, respectively. .

[0012] The present invention 5 This aspect is the same as the above-mentioned 4In the winding method for a split core of the above aspect, in the first winding process and the second winding process, the guide is moved in the axial direction relative to the core support member according to the winding state of the winding so as to leave a gap at the predetermined position of the tooth portion that is at least large enough to insert the winding. [Effects of the Invention]

[0013] According to the present disclosure, the length of the crossover wire can be set to an appropriate length, thereby improving productivity. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. [Figure 2] 2 is a perspective view of adjacent split cores of the motor of FIG. 1. [Figure 3] FIG. 2 is a perspective view of two split cores. [Figure 4] FIG. 4 is a cross-sectional view taken along the line IV-IV in FIG. 3. [Figure 5] 1 is a schematic diagram of a winding device according to an embodiment of the present invention; [Figure 6] FIG. [Figure 7] FIG. [Figure 8] FIG. 4 is a plan view of the core support member and the side guide. [Figure 9] FIG. 9 is a perspective view of FIG. 8. [Figure 10] 5A and 5B are explanatory views of the sliding movement of the core support member, in which FIG. 5A shows a first state and FIG. 5B shows a second state. [Figure 11] FIG. 10 is a cross-sectional view taken along the line XI-XI in FIG. 7. DETAILED DESCRIPTION OF THE INVENTION

[0015] An embodiment of the present invention will be described below with reference to the drawings. In each drawing, the dashed line CL indicates the rotation axis (axial center) of the split core at the winding position of the winding device. In this embodiment, the rotation axis CL of the split core at the winding position will be described as extending in the vertical direction.

[0016] Fig. 1 is a perspective view of a motor 1. Fig. 2 is a perspective view of adjacent split cores 10a and 10b of the motor 1 of Fig. 1. Fig. 3 is a perspective view of the two split cores 10a and 10b. Fig. 4 is a cross-sectional view taken along the line IV-IV in Fig. 3.

[0017] As shown in Fig. 1, a winding device and winding method for a split core according to one embodiment of the present invention is applied to, for example, a winding device and winding method for a stator 2 of a brushless motor (rotating electric machine) 1. Brushless motor 1 (hereinafter referred to as "motor 1") has a stator 2 press-fitted into a housing (not shown), and a rotor 3 disposed radially inside stator 2 and rotatable relative to stator 2. Motor 1 is a permanent magnet synchronous motor, and is used, for example, as a drive source for a power steering device (not shown) mounted on a vehicle such as an automobile.

[0018] 1 to 4, the stator 2 includes a stator core 4, an insulating insulator 5 attached to the stator core 4, and a coil 6. The stator core 4 of this embodiment is a split-core type stator core 4 that is split in the circumferential direction of the motor, and is formed by connecting a plurality of split cores 10 in an annular shape in the circumferential direction of the motor.

[0019] The split core 10 includes a yoke portion 11 having a generally arc-shaped cross section that extends circumferentially of the motor on the radially outer side of the motor, teeth portions 12 that extend radially inward from a central portion (approximately the center in this embodiment) of the inner circumferential surface of the yoke portion 11 in the motor circumferential direction, and flange portions 13 that extend radially inward from inner ends of the teeth portions 12 on both sides in the motor circumferential direction. The split core 10 is formed, for example, by stacking a plurality of metal plates in the axial direction of the motor, and extends linearly along the axial direction of the motor.

[0020] Connecting portions 11a, 11b are formed at both ends of the yoke portion 11 in the motor circumferential direction to connect adjacent split cores 10a, 10b. One connecting portion 11a extends in the motor axial direction and protrudes outward in the motor circumferential direction. The other connecting portion 11b is formed as a groove extending in the motor axial direction and recessed inward in the motor circumferential direction, and is engageable with the one connecting portion 11a (see FIG. 2). The connecting portions 11a, 11b at both ends of the yoke portion 11 in the motor circumferential direction are engaged with the connecting portions 11b, 11a of the yoke portions 11 of other split cores 10 adjacent on both sides in the motor circumferential direction, thereby connecting multiple split cores 10 to form the stator core 4. When the stator core 4 is formed by connecting multiple split cores 10 in an annular shape in the motor circumferential direction, the yoke portion 11 forms a substantially cylindrical back yoke that forms a ring-shaped magnetic path.

[0021] A pair of slots 15 for winding wire 14 that forms coil 6 are defined on both sides of tooth portion 12 in the circumferential direction of the motor by yoke portion 11, tooth portion 12, and flange portion 13. In other words, slot 15 is located inside an imaginary line (two-dot chain line L in FIG. 4) that connects the end of yoke portion 11 in the circumferential direction of the motor and the end of flange portion 13 in the circumferential direction of the motor.

[0022] The insulators 5 are attached to the split cores 10 so as to cover the peripheries of the teeth 12. The insulators 5 cover the portions of the split cores 10 facing the slots 15 (the inner surfaces of the yoke portions 11 in the motor radial direction, the circumferential surfaces of the teeth 12, and the outer surfaces of the flange portions 13 in the motor radial direction), and also cover both ends of the teeth 12 in the motor axial direction. Walls 7 and 8 protruding in the motor axial direction from both sides in the motor radial direction are provided on the insulators 5 at the locations covering the ends of the teeth 12 in the motor axial direction. A winding 14 forming the coil 6 is wound between the walls 7 and 8 on both sides in the motor radial direction of the insulator 5. A slit 9 (see FIG. 2 ) is formed in the wall 7 on one side of the insulator 5 in the motor axial direction and on the outer side in the motor radial direction, for engaging a winding start end 14a or a winding end end 14b of the winding 14.

[0023] The winding 14 is wound around the teeth 12 in multiple layers using concentrated winding. The winding 14 wound around the teeth 12 forms the coil 6. The winding 14 is wound around the teeth 12 of the split core 10 by a winding device 20. In this embodiment, the winding device 20 continuously winds the winding 14 around two adjacent split cores 10a, 10b. A crossover wire 14c of the winding 14 extends between the two split cores 10a, 10b around which the winding 14 is wound. The winding method for the winding 14 will be described later.

[0024] FIG. 5 is a schematic diagram of a winding device 20 according to one embodiment of the present invention. FIG. 6 is a side view of the winding device 20. FIG. 7 is a perspective view of the winding machine 21. FIG. 8 is a plan view of the core support member 26 and the side guide 27. FIG. 9 is a perspective view of FIG. 8. FIG. 10 is an explanatory diagram of the sliding movement of the core support member 26, with (a) showing a first state and (b) showing a second state. FIG. 11 is a cross-sectional view taken along the line XI-XI in FIG. 7. In FIGS. 6 to 10, S indicates the sliding direction S of the core support member 26, and W indicates a direction perpendicular to both the axial direction of the rotation axis CL and the sliding direction S.

[0025] As shown in Figures 5 to 11, the winding device 20 is a split core winding device 20 that continuously winds the winding 14 around at least two split cores 10 having tooth portions 12 around which the winding 14 is wound, and is equipped with a winding machine 21 that supports and rotates the split cores 10, and a wire nozzle (winding supply member) 22 that supplies the winding 14 to the winding machine 21 side.

[0026] The winding machine 21 has two drive units 23, 24 that face each other in the axial direction of the rotation axis CL when rotating the split core 10. The winding machine 21 of this embodiment has a lower drive unit 23 and an upper drive unit 24 located above the lower drive unit 23.

[0027] The lower drive unit 23 includes a rotatable and vertically movable base 25, a core support member 26 supported on the base 25 so as to be slidable, and a side guide 27 disposed on the side of the core support member 26.

[0028] The pedestal 25 is supported by a rotary lifting mechanism 28 below, and is rotatable about a rotation axis CL and is movable up and down along the axial direction of the rotation axis CL. For example, the rotary lifting mechanism 28 may rotatably support the pedestal 25 using the driving force of a motor (not shown). Alternatively, the rotary lifting mechanism 28 may support the pedestal 25 so that it can be lifted up and down using a rack and pinion, a hydraulic cylinder, or the like.

[0029] The core support member 26 is a member for supporting at least two (two in this embodiment) split cores 10, and is supported by the base portion 25 so as to be rotatable and movable up and down together with the base portion 25. The core support member 26 is slidable relative to the base portion 25 and a side guide 27 (described later) in a direction intersecting the axial direction of the rotation axis CL (in this embodiment, a direction S perpendicular to the axial direction (hereinafter referred to as the "sliding direction S").) In other words, the core support member 26 is rotatable about the rotation axis CL and slidable in a direction intersecting the axial direction of the rotation axis CL. The core support member 26 is provided with a gripping portion 26a that grips the end 14a (hereinafter referred to as the "tip portion 14a") of the winding 14 supplied from the wire nozzle 22 at the winding start side and fixes it to the core support member 26. The gripping portion 26a is actuated by hydraulic pressure from a hydraulic pressure supply source (not shown).

[0030] The core support member 26 has a first core support portion 29 and a second core support portion 30 capable of supporting the split core 10. The first core support portion 29 and the second core support portion 30 are provided at positions spaced apart from each other in the sliding direction S. The split core 10 can be placed and set on each of the first core support portion 29 and the second core support portion 30. In this embodiment, the split core 10 can be set on the first core support portion 29 and the second core support portion 30 with the longitudinal direction (motor axial direction) of the split core 10 aligned along a direction W (hereinafter referred to as the "width direction W") perpendicular to both the axial direction of the rotation shaft CL and the sliding direction S. In the following description, the side on which the first core support portion 29 is located will be referred to as the rear side (one side) in the sliding direction S, and the side on which the second core support portion 30 is located will be referred to as the front side (other side) in the sliding direction S. The split core 10 set on the first core support portion 29 is referred to as a first split core 10a, and the split core 10 set on the second core support portion 30 is referred to as a second split core 10b.

[0031] The core support member 26 can be switched between a first state (the state shown in FIGS. 7 to 9 and FIG. 10(a)) in which it is moved toward the front side in the sliding direction S, and a second state (the state shown in FIG. 10(b)) in which it is moved toward the rear side in the sliding direction S. The portion of the core support member 26 that is located at the winding position including the rotation axis CL in the first state becomes the first core support part 29, and the portion that is located at the winding position in the second state becomes the second core support part 30. That is, the second core support part 30 is located in a different position depending on the sliding distance (hereinafter simply referred to as the "sliding distance") of the core support member 26 between the first state and the second state. In the first state, the second core support part 30 is located toward the front side of the winding position in the sliding direction S. On the other hand, in the second state, the first core support part 29 is located inside a side guide 27 (described later) that is located further rearward in the sliding direction S than the winding position. When winding the first divided core 10a, the core support member 26 is set to the first position, and when winding the second divided core 10b, the core support member 26 is set to the second position. The sliding distance of the core support member 26 can be changed depending on the desired length of the crossover wire 14c.

[0032] In this embodiment, the sliding distance of the core support member 26 is kept to a minimum while ensuring a distance that allows winding around the second split core 10b in the second state, so as to minimize the crossover wire 14c. Note that in this embodiment, the second core support portion 30 is located at a position determined based on the sliding distance of the core support member 26, but this is not limited to this. For example, two predetermined locations on the core support member 26 may be the first core support portion 29 and the second core support portion 30. In this case, multiple core support members 26 with different separation distances between the first core support portion 29 and the second core support portion 30 in the sliding direction S may be prepared, and the core support member 26 may be replaced depending on the desired length of the crossover wire 14c.

[0033] The mechanism for moving the core support member 26 in the sliding direction S is not particularly limited, and various mechanisms capable of moving the core support member 26 in the sliding direction S can be used. For example, in this embodiment, the core support member 26 is moved in the sliding direction S by the restoring force (biasing force) of the coil spring 31, a pressing mechanism (not shown), and a stopper (not shown). The core support member 26 is biased toward the front side in the sliding direction S by the coil spring 31 so that the core support member 26 is in the first state. Note that movement of the core support member 26 toward the front side in the sliding direction S from the first state is restricted. When the core support member 26 is changed from the first state to the second state, the pressing mechanism (not shown) slides the core support member 26 toward the rear side in the sliding direction S against the restoring force (biasing force) of the coil spring 31. When the core support member 26 is in the second state, movement toward the front side in the sliding direction S is restricted by the stopper (not shown). When the restriction on movement of the core support member 26 by the stopper is released, the core support member 26 slides forward in the sliding direction S due to the restoring force of the coil spring 31, and returns from the second state to the first state.

[0034] In this embodiment, one core support member 26 has the first core support portion 29 and the second core support portion 30, but the core support member is not limited to this and may be, for example, two core support members each having one core support portion (first core support portion 29 or second core support portion 30). These two core support members may be slidable relative to base portion 25 independently of each other.

[0035] The side guide 27 is disposed on the rear side of the core support member 26 in the sliding direction S and is fixed to the base portion 25. That is, the side guide 27 is supported by the base portion 25 so as to be rotatable and movable up and down together with the base portion 25 and the core support member 26. Furthermore, the side guide 27 does not move relative to the core support member 26 when the core support member 26 slides. The side guide 27 has an upper plate portion 27a that extends obliquely from the rear side in the sliding direction S (outside in the radial direction centered on the rotation axis CL) toward one side (upper side) in the axial direction of the rotation axis CL, and a pair of side plate portions 27b, 27b that extend obliquely downward and outward in the width direction W from both sides of the upper plate portion 27a. A core storage space 32 that can store the first split core 10a of the first core support member 29 in the second state is defined inside the side guide 27.

[0036] The upper plate portion 27a of the side guide 27 is disposed above the divided core 10 at the winding position, and defines the upper side and the inner side in the sliding direction S of the core accommodating space 32. The front edge of the upper plate portion 27a in the sliding direction S extends linearly in the width direction W in top view.

[0037] The pair of side plate portions 27b, 27b of the side guide 27 are arranged outside in the width direction W of the split core 10 at the winding position, and define both sides in the width direction W of the core storage space 32. The front end edges in the sliding direction S of the pair of side plate portions 27b, 27b extend downward on the front side in the sliding direction S continuously from both ends in the width direction W of the front end edge of the upper plate portion 27a in the sliding direction S in a side view (as viewed from the width direction W).

[0038] The side guide 27 has an opening 33 that opens the core storage space 32 toward the front side in the sliding direction S. The opening 33 is located at a position away from the split core 10 at the winding position toward the rear side in the sliding direction S. The opening 33 is formed with a size that allows movement of the first split core 10a supported by the core support member 26 in the sliding direction S. The upper surface of the edge portion 34 of the side guide 27 on the opening 33 side (the front side in the sliding direction S) is curved toward the inside of the opening 33 so that the diameter decreases toward the opening 33 (see FIG. 11).

[0039] The side guides 27 cover the first split core 10a supported by the core support member 26 in the second state from above, both sides in the width direction W, and the rear side in the sliding direction S (see FIG. 10(b)). The upper surfaces 35 of the side guides 27 (upper surfaces of the upper plate portion 27a and the pair of side plate portions 27b, 27b) guide the wire 14 supplied from the wire nozzle 22 toward the front side in the sliding direction S when winding the wire around the first split core 10a in the first state. Furthermore, the upper surfaces 35 of the side guides 27 prevent the wire 14 supplied from the wire nozzle 22 from interfering with the first split core 10a when winding the wire around the second split core 10b in the second state, and guide the wire 14 toward the second core support member 30.

[0040] 9 and 10, the upper drive unit 24 has a core holding member 36 and a pair of traverse guides (guides) 37a, 37a. The upper drive unit 24 is supported by an upper rotary lifting mechanism (not shown), and is rotatable about a rotation axis CL in synchronization with the lower drive unit 23, and is also movable up and down along the axial direction of the rotation axis CL. The rotary lifting mechanism may be a rotatable mechanism using the driving force of a motor (not shown), similar to the lower drive unit 23, or may be a lifting mechanism using a rack and pinion, a hydraulic cylinder, or the like.

[0041] The core holding member 36 is a member that holds the split core 10 toward the core support member 26 during winding, is disposed above the winding position, and can be rotated up and down by the rotation and elevation mechanism of the upper drive unit 24. By moving downward during winding, the core holding member 36 presses the split core 10 at the winding position downward toward the core support member 26, and sandwiches the split core 10 between itself and the core support member 26. In this way, the core holding member 36 fixedly holds the split core 10 toward the core support member 26.

[0042] The pair of traverse guides 37a, 37a are members for guiding the windings 14 to predetermined positions on the teeth 12 of the split core 10 at the winding position, and are rotatable and movable up and down by the rotation and elevation mechanism of the upper drive unit 24. The traverse guides 37a, 37a can be raised and lowered relative to the core holding member 36 and moved toward or away from each other, as shown by the two-dot chain lines in FIG. 10(b), by a mechanism different from the rotation and elevation mechanism of the upper drive unit 24. The traverse guides 37a, 37a are disposed on both sides of the teeth 12 of the split core 10 in the circumferential direction of the motor when the core holding member 36 holds the split core 10 at the winding position. The traverse guides 37a, 37a have inclined surfaces 38 for guiding the windings 14 to predetermined positions on the teeth 12 of the split core 10 at the winding position. The inclined surfaces 38 of the traverse guides 37a extend in the width direction W while being inclined from above to below so as to approach each other. The winding 14 slides downward along the inclined surfaces 38 of the traverse guides 37a and is guided to a predetermined position on the tooth portion 12.

[0043] The traverse guides 37a, 37a are controlled by a controller (not shown) to move up and down (in the axial direction of the rotation axis CL) relative to the core support member 26 and the core holding member 36 depending on the state of winding of the winding 14 around the teeth 12. This changes the guide position of the winding 14 relative to the teeth 12. In this embodiment, the traverse guides 37a, 37a move in the axial direction of the rotation axis CL relative to the core support member 26 and the core holding member 36 depending on the state of winding of the winding 14 so as to provide a space (e.g., a space slightly larger in width than the diameter of the winding 14) at the guide position (the predetermined position) of the winding 14 around the teeth 12 that allows at least the winding 14 to be inserted. The state of winding of the winding 14 around the teeth 12 can be controlled by the rotation angle (number of rotations) of the split core 10 from the start of winding. The rotation angle (number of rotations) of the split core 10 from the start of winding can be recognized from the operating state of the rotary lift mechanism 28 of the lower drive unit 23 and the rotary lift mechanism of the upper drive unit 24. In this way, since the rotation angle (number of rotations) of the split core 10 is determined by the operation of the rotary lift mechanism 28, etc., a controller (not shown) can grasp the winding state of the winding 14 in real time.

[0044] The wire nozzle 22 is a member that supplies the wire 14 to the winding machine 21 and is disposed on one side of the winding position of the winding machine 21 in a direction intersecting the axial direction of the rotation axis CL. For example, the wire nozzle 22 supplies the wire 14 from the reel R to the winding machine 21. The wire nozzle 22 is disposed at a height position between the upper and lower ends of the side guide 27. Before the split core 10 is rotated, the wire nozzle 22 is disposed on one side of the split core 10 in the width direction W at the winding position. The wire nozzle 22 is provided in the winding device 20 so as not to rotate relative to the rotation of the split core 10. The wire 14 supplied from the wire nozzle 22 is wound around the teeth 12 as the split core 10 rotates and moves up and down at the winding position.

[0045] Next, a split core winding method according to one embodiment of the present invention will be described. The split core winding method according to this embodiment is a method for continuously winding the winding 14 around at least two split cores 10 each having teeth 12 around which the winding 14 is wound, and includes a first setting step, a first guide moving step, a first winding step, a sliding step, a second setting step, a second guide moving step, and a second winding step.

[0046] In the first setting step, the first split core 10a is set on the first core support portion 29 of the core support member 26. Specifically, first, the core support member 26 is set in the first state, and the first split core 10a is placed on the first core support portion 29 at the winding position (see FIG. 8 ). The first split core 10a is placed on the first core support portion 29 with the yoke portion 11 facing downward (the flange portion 13 facing upward) and the teeth portion 12 standing upright along the axial direction of the rotation axis CL. The first split core 10a is placed on the core support member 26 manually or by the operation of an automatic feeder (not shown). Next, the upper drive unit 24 is lowered, and the first split core 10a at the winding position is sandwiched between the core support member 26 and the core holding member 36, thereby fixedly holding the first split core 10a on the core support member 26. As a result, the first divided core 10a is set on the first core supporting portion 29 of the core supporting member 26 in the first state.

[0047] In the first guide moving step, the pair of traverse guides 37a are moved to both sides in a direction (sliding direction S in this embodiment) intersecting the axial direction of the rotation axis CL of the teeth 12 of the first split core 10a set in the first setting step (see FIG. 9). The tips (lower ends) of the traverse guides 37a are disposed in the slots 15 on both sides of the teeth 12 without contacting the side surfaces of the teeth 12. At this time, a gap is formed between the tips of the traverse guides 37a and the insulator 5 located below them on the yoke 11 side of the first split core 10a, allowing the winding 14 to be inserted. The first guide moving step may be performed simultaneously with the first setting step.

[0048] The first winding process is performed after the first setting process (after the first guide moving process in this embodiment). In the first winding process, with the tip end 14a of the winding 14 held on the core support member 26 side, the core support member 26, the side guide 27, and the traverse guides 37a, 37a are rotated about the rotation axis CL relative to the wire nozzle 22, and the traverse guides 37a, 37a are moved in the axial direction of the rotation axis CL relative to the core support member 26, thereby winding the winding 14 around the teeth 12 of the first split core 10a (see FIG. 10(a)). Specifically, first, the winding 14 supplied from the wire nozzle 22 is pulled out along the longitudinal direction of the first split core 10a, and the tip end 14a of the winding 14 is gripped by the gripping portion 26a on the core support member 26 side and fixed to the core support member 26 side. As a result, the tip end 14a of the winding 14 is held toward the core support member 26. The winding 14 is drawn from the wire nozzle 22 to the gripping portion 26a manually by an operator or by the operation of an automatic feeder (not shown). Next, the lower drive unit 23 and the upper drive unit 24 are rotated and raised and lowered by the rotary lifting mechanism 28 or the like. As the lower drive unit 23 and the upper drive unit 24 rotate and raised, the core support member 26 and the traverse guides 37a, 37a rotate about the rotation axis CL relative to the wire nozzle 22 and also rise and fall (move up and down) relative to the wire nozzle 22. As a result, the first divided core 10a at the winding position rotates and rises and falls relative to the wire nozzle 22. In this embodiment, the first divided core 10a at the winding position is rotated clockwise when viewed from above. As the core support member 26 rotates relative to the wire nozzle 22, the winding 14 is pulled out from the wire nozzle 22 and wound around the slots 15 of the teeth 12 of the first split core 10a. When the winding 14 contacts the upper surfaces 35 of the side guides 27, it slides along the upper surfaces 35 of the side guides 27 and is guided toward the first split core 10a on the near side in the sliding direction S. At this time, the traverse guides 37a, 37a are moved in the axial direction of the rotation axis CL (upward in this embodiment) relative to the core support member 26 in accordance with the winding state of the winding 14 so as to leave a gap at the guide position (predetermined position) of the winding 14 on the teeth 12 that is at least large enough to insert the winding 14.As a result, the winding 14 slides downward along the inclined surfaces 38 of the traverse guides 37a, 37a, and is guided to a predetermined position on the teeth portion 12.

[0049] The pair of traverse guides 37a, 37a may be moved alternately and independently of each other, or may be moved simultaneously. Furthermore, when winding the winding 14 from above to below the teeth 12 of the first split core 10a, the traverse guides 37a, 37a do not have to be used. In this embodiment, the tip 14a of the winding 14 is held by the gripping portion 26a of the core support member 26, but this is not limitative. Holding the tip 14a of the winding 14 on the core support member 26 side means holding the tip 14a of the winding 14 on the side that moves together with the core support member 26 when the core support member 26 is rotated, moved up and down, or slid. Therefore, for example, the tip portion 14a of the winding 14 may be held on the core support member 26 side via the first split core 10a by holding the tip portion 14a of the winding 14 in the slit 9 of the insulator 5 of the first split core 10a, which moves (rotates, moves up and down, and slides) together with the core support member 26.

[0050] The sliding movement process is performed after the winding of the winding 14 around the first split core 10a is completed in the first winding process. In the sliding movement process, the first split core 10a on which the winding 14 has been completed is moved toward the rear in the sliding direction S to a position covered by the side guide 27 (see FIG. 10(b)). Specifically, after the winding of the winding 14 around the first split core 10a is completed in the first winding process, the upper drive unit 24 is raised to release the first split core 10a from the core holding member 36, and the traverse guides 37a, 37a are moved above the first split core 10a. Next, the core support member 26 is moved from the first state toward the rear in the sliding direction S to the second state, and the first split core 10a is stored in the core storage space 32 of the side guide 27.

[0051] The second setting process is performed after the sliding process. In the second setting process, the second split core 10b is set on the second core support portion 30 of the core support member 26 in the second state. Specifically, first, the second split core 10b is placed on the second core support portion 30 at the winding position of the core support member 26 in the second state. The second split core 10b is placed on the second core support portion 30 with the yoke portion 11 facing downward (the flange portion 13 facing upward) and the teeth portion 12 standing up along the axial direction of the rotation axis CL. The second split core 10b is placed on the core support member 26 manually or by the operation of an automatic feeder (not shown). Next, the upper drive unit 24 is lowered, and the second split core 10b at the winding position is sandwiched between the core support member 26 and the core holding member 36, and the second split core 10b is fixedly held on the core support member 26. As a result, the second divided core 10b is set on the second core supporting portion 30 of the core supporting member 26 in the second state.

[0052] In the second guide moving process, the pair of traverse guides 37a, 37a are moved to both sides in a direction intersecting the axial direction of the rotation axis CL of the teeth portion 12 of the second divided core 10b set in the second setting process (in this embodiment, the sliding direction S) (see FIG. 10(b)). The arrangement positions of the pair of traverse guides 37a, 37a are the same as in the first guide moving process, so a description thereof will be omitted. The second guide moving process may be performed simultaneously with the second setting process.

[0053] The second winding process is performed after the second setting process (after the second guide moving process in this embodiment). In the second winding process, the core support member 26, the side guide 27, and the traverse guides 37a, 37a are rotated about the rotation axis CL relative to the wire nozzle 22, and the traverse guides 37a, 37a are moved in the axial direction of the rotation axis CL relative to the core support member 26, thereby winding the wire 14 around the teeth 12 of the second split core 10b. Specifically, the lower drive unit 23 and the upper drive unit 24 are rotated and raised and lowered by the rotary lift mechanism 28 or the like, thereby rotating and raising and lowering the core support member 26, the side guide 27, and the traverse guides 37a, 37a relative to the wire nozzle 22, as in the first winding process. As a result, the second split core 10b at the winding position is rotated and raised and lowered relative to the wire nozzle 22. In this embodiment, the second split core 10b at the winding position is rotated in the opposite direction to that of the first winding process (counterclockwise when viewed from above). This rotation of the core support member 26, side guide 27, and traverse guides 37a, 37a relative to the wire nozzle 22 causes the winding wire 14 to be pulled out from the wire nozzle 22 and wound around the slots 15 in the teeth portions 12 of the second split core 10b. The upper surface 35 of the side guide 27 prevents the winding wire 14 supplied from the wire nozzle 22 from interfering with the first split core 10a, and guides the winding wire 14 toward the second core support member 30. The positioning and movement of the traverse guides 37a, 37a are the same as those in the first winding process, and therefore will not be described here.

[0054] After the winding of the winding wire 14 around the second split core 10b is completed (after the second winding step), the upper drive unit 24 is raised to release the second split core 10b from the core holding member 36, and the traverse guides 37a, 37a are moved above the second split core 10b. Next, the core support member 26 is moved forward in the sliding direction S from the second state to return to the first state. This allows the two split cores 10a, 10b, on which the winding wire 14 has been continuously wound, to be removed after the winding is complete. The two split cores 10a, 10b can be removed from the winding device 20 manually or by the operation of an automatic removal device (not shown).

[0055] In the winding device 20 configured as described above, the core support member 26 is slidable in a sliding direction S that intersects the axial direction of the rotation axis CL, and from a first state in which the first core support part 29 is disposed at a winding position including the rotation axis CL, the second core support part 30 is disposed at the winding position by sliding it toward the rear in the sliding direction S. Therefore, after the core support member 26 is placed in the first state and the winding 14 is wound around the first divided core 10a, the core support member 26 can be placed in the second state without removing the first divided core 10a, and the winding 14 can be continuously wound around the second divided core 10b.

[0056] In the second state, the first split core 10a supported by the first core support portion 29 is stored in the core storage space 32 within the side guide 27. The upper surface 35 of the side guide 27 prevents the winding 14 supplied from the wire nozzle 22 from interfering with the first split core 10a, guiding the winding 14 toward the second core support portion 30. Therefore, when winding the winding 14 onto the second split core 10b, the winding 14 can be favorably guided toward the second split core 10b without interfering with the first split core 10a, allowing the winding 14 to be wound continuously around the two split cores 10a, 10b.

[0057] The sliding distance of the core support member 26 can be changed depending on the desired length of the crossover wire 14c. In this embodiment, the sliding distance of the core support member 26 is kept to a minimum while still ensuring the distance that allows winding around the second split core 10b in the second state, so as to minimize the crossover wire 14c. This prevents the generation of excess crossover wire 14c, eliminating the need for post-processing of excess crossover wire 14c after continuously winding the winding 14 around the two split cores 10a, 10b, and improving productivity.

[0058] Furthermore, the sliding distance of the core support member 26 can be changed depending on the desired length of the crossover wire 14c. Therefore, for example, when windings 14 are continuously wound around two split cores 10a, 10b that are spaced apart in the circumferential direction of the motor 1, the length of the crossover wire 14c can be set to the required length by appropriately setting the sliding distance of the core support member 26 from the first state to the second state.

[0059] As described above, according to this embodiment, the length of the crossover wire 14c can be set to an appropriate length, thereby improving productivity.

[0060] Furthermore, an edge 34 of the side guide 27 on the opening 33 side is curved toward the inside of the opening 33 so as to reduce in diameter toward the opening 33. Therefore, when the winding wire 14 is wound around the split core 10, it is possible to prevent or suppress the winding wire 14 from becoming bent when the winding wire 14 slides along the upper surface 35 of the side guide 27 and passes through the edge 34 on the opening 33 side.

[0061] Furthermore, since traverse guides 37a, 37a are provided that guide the winding 14 to a predetermined position on the teeth 12 of the split core 10 at the winding position, the winding 14 can be guided to a desired position on the teeth 12 during winding, allowing the winding 14 to be wound densely. In this embodiment, the traverse guides 37a, 37a move in the axial direction of the rotation axis CL relative to the core support member 26 and the core holding member 36 in accordance with the winding state of the winding 14 so as to provide a space (e.g., a space slightly larger in width than the diameter of the winding 14) at the guide position (the predetermined position) of the winding 14 onto the teeth 12, allowing at least the winding 14 to be inserted therein. This allows the winding 14 to be wound reliably densely, thereby improving the density (space factor) of the winding 14 wound around the teeth 12.

[0062] In the split core winding method described above, after the winding of the winding wire 14 onto the first split core 10a is completed (after the first winding step), a sliding movement step is performed in which the first split core 10a is moved to the rear in the sliding direction S until it is positioned so as to be covered by the side guide 27. After that, the second split core 10b is set at the winding position (second setting step), and the winding wire 14 is wound onto the teeth 12 of the second split core 10b (second winding step). Therefore, after the winding wire 14 has been wound onto the first split core 10a, the winding wire 14 can be continuously wound onto the second split core 10b without removing the first split core 10a.

[0063] Furthermore, in the sliding movement step, the first split core 10a is moved to the rear side in the sliding direction S and positioned so as to be covered by the side guide 27. Therefore, when winding the winding 14 onto the second split core 10b, the side guide 27 prevents the winding 14 from interfering with the first split core 10a, and the winding 14 can be suitably guided towards the second split core 10b. This allows the winding 14 to be wound continuously onto the two split cores 10a, 10b.

[0064] Furthermore, in the sliding movement step, the first divided core 10a is moved toward the rear side in the sliding direction S, so the length of the crossover wire 14c can be determined by the amount of sliding movement of the first divided core 10a. Therefore, the length of the crossover wire 14c can be appropriately set, and post-processing related to the length of the crossover wire 14c (for example, post-processing of excess crossover wire 14c) is not required, thereby improving productivity.

[0065] In the first and second winding processes, the traverse guides 37a are moved in the axial direction of the rotation axis CL relative to the core support member 26 to wind the winding 14 around the teeth 12 of the split core 10 at the winding position. Since the winding is performed using the traverse guides 37a that guide the winding 14 to a predetermined position on the teeth 12, the winding 14 can be densely wound as described above. In the first and second winding processes, the traverse guides 37a are moved in the axial direction of the rotation axis CL according to the winding state of the winding 14 so as to provide a space (e.g., a space slightly larger in width than the diameter of the winding 14) at the guide position (the predetermined position) for the winding 14 onto the teeth 12, allowing at least the winding 14 to be inserted. This ensures dense winding of the winding 14, thereby improving the space factor of the winding 14 wound around the teeth 12.

[0066] In this embodiment, the rotation axis CL of the split core 10 at the winding position is set to extend in the vertical direction, but this is not limited to this and can be set to any direction.

[0067] In addition, in this embodiment, the winding device 20 continuously winds the winding 14 around the adjacent split cores 10a, 10b, but this is not limiting. For example, the winding device 20 may continuously wind the winding 14 around split cores 10a, 10b that are spaced apart from each other in the circumferential direction of the motor.

[0068] In addition, in this embodiment, the winding 14 is continuously wound around the two split cores 10a and 10b by the winding device 20, but this is not limited to this, and for example, the winding 14 may be continuously wound around three or more split cores 10.

[0069] In addition, in this embodiment, the split core 10 is set in the first core support part 29 and the second core support part 30 with the longitudinal direction of the split core 10 aligned with the width direction W, but this is not limited to this. For example, the split core 10 may be set in the first core support part 29 and the second core support part 30 with the longitudinal direction of the split core 10 aligned with the sliding direction S. In this case, the side guide 27 may have a shape that is elongated in the sliding direction S.

[0070] In addition, in this embodiment, the split core winding device and winding method according to the present disclosure are applied to a split core winding device and winding method for a motor (rotating electric machine) 1 used as a drive source for a power steering device or the like mounted on a vehicle such as an automobile, but the present disclosure is not limited to this and can be applied to split core winding devices and winding methods for various rotating electric machines. For example, the split core winding device and winding method according to the present disclosure can also be applied to motors (rotating electric machines) for other purposes, or alternators (rotating electric machines), etc.

[0071] Although the present invention has been described above based on the above embodiment, the present invention is not limited to the content of the above embodiment, and can be modified as appropriate without departing from the scope of the present invention. In other words, all other embodiments, examples, operational techniques, etc. made by those skilled in the art based on this embodiment are naturally included in the scope of the present invention. [Explanation of symbols]

[0072] 10: Split core 10a: First divided core 10b: Second split core 12: Teeth 14: Winding 20: Winding device 22: Wire nozzle (winding wire supply member) 26: Core support member 27: Side guide 29: First core support 30: Second core support part 32: Core storage space 33: Side guide opening 34: Edge of side guide 37a: Traverse Guide (Guide)

Claims

1. A split core winding device for continuously winding a winding around at least two split cores having teeth on which the winding is wound, comprising: a core support member having a first core support portion and a second core support portion capable of supporting the split cores, the core support member being rotatable about a rotation axis and slidable in a sliding direction intersecting an axial direction of the rotation axis; a winding supply member that supplies the winding to the core support member; a side guide disposed on one side of the core support member in the sliding direction and defining a core accommodating space that is open toward the other side in the sliding direction, the core support member can be slid to one side from a first state in which the first core support portion is disposed at a winding position including the rotation shaft to a second state in which the second core support portion is disposed at the winding position and the first divided core supported by the first core support portion is accommodated in the core accommodating space, guides arranged on both sides of the teeth of the split core positioned at the winding position to guide the winding to a predetermined position on the teeth, the guide is rotatable with the core support member and movable in the axial direction relative to the core support member; The side guide is In the first state, the first divided core is not covered, and when winding a wire onto the first divided core supported by the first core support portion, the winding is guided toward the first divided core together with the guide, In the second state, the first divided core is covered, and when a winding is wound onto the second divided core supported by the second core support portion, the winding is prevented from interfering with the first divided core, and the guide guides the winding toward the second divided core. A split core winding device characterized by the above.

2. The edge of the side guide on the opening side that opens the core storage space to the other side is curved toward the inside of the opening.

2. The split core winding device according to claim 1.

3. The guide moves in the axial direction relative to the core support member in accordance with a winding state of the winding so as to provide a gap at the predetermined position of the tooth portion that allows at least the winding to be inserted.

2. The split core winding device according to claim 1.

4. A winding method for a split core, in which a winding is continuously wound around at least two split cores having teeth on which the winding is wound, comprising: a first setting step of setting the first divided core on the first core support portion of the core support member; a first guide moving step of moving a guide that guides the winding to a predetermined position of the tooth portion to both sides of the tooth portion of the first split core set on the first core support portion; a first winding step of rotating the core support member about a rotation axis relative to the winding supply member while holding an end of the winding supplied from the winding supply member on the core support member side, thereby winding the winding around the teeth of the first split core; a sliding movement step of sliding the first divided core around which the winding is wound in a direction intersecting the axial direction of the rotary shaft to place the first divided core in a position covered by a side guide; a second setting step of setting a second divided core on a second core support portion of the core support member; a second guide moving step of moving the guide to both sides of the teeth portion of the second split core set on the second core support portion; a second winding step of rotating the core support member about the rotation axis relative to the winding supply member to wind the winding around the teeth of the second split core; Including, In the first winding step, the first core support portion, the guide, and the side guide are rotated about the rotation axis relative to the winding supply member, and the guide is moved in the axial direction of the rotation axis relative to the first core support portion, and the winding is slid along the guide and the side guide using the guide and the side guide, and wound around the teeth portion of the first split core; In the second winding step, with the first divided core covered by the side guide, the second core support portion, the guide, and the side guide are rotated about the rotation axis relative to the winding supply member, and the guide is moved in the axial direction relative to the second core support portion, so that the winding is slid on the guide and the side guide to be wound around the teeth portion of the second divided core, After the second winding step, the first divided core and the second divided core around which the winding is continuously wound are removed from the first core support portion and the second core support portion, respectively. A method for winding a split core.

5. In the first winding step and the second winding step, the guide is moved in the axial direction relative to the core support member in accordance with a winding state of the winding so as to provide a gap at the predetermined position of the tooth portion that allows at least the winding to be inserted.

5. The method for winding a split core according to claim 4.

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