Winding machine for a rotating electric machine and method for manufacturing a rotating electric machine

Abstract

To provide a winding machine of a rotary electric machine which enables high-speed winding and easy change of a nozzle position in the winding machine of a nozzle drive type driving a nozzle, and a manufacturing method of the rotary electric machine.SOLUTION: A winding machine of a rotary electric machine winds a wire 4 via a nozzle 3 on a core 2 of a stator 1 constituting the rotary electric machine. The winding machine comprises a vertical direction movement mechanism 12 which moves the nozzle 3 in the axial direction of the core 2 of the stator 1 and a rotating-shaking mechanism 13 which rotates and shakes the core 2 independently of the vertical direction movement mechanism 12. Using the winding machine of the rotary electric machine, the wire 4 is wound on the core 2 to manufacture the rotary electric machine.SELECTED DRAWING: Figure 2

Description

Technical Field

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[0001] This application relates to a winding machine for a rotating electrical machine and a method for manufacturing a rotating electrical machine.

Background Art

[0002] Conventionally, in a winding machine for a rotating electrical machine, instead of rotating a nozzle for supplying a wire in a circular shape with respect to a stator core (hereinafter simply referred to as a core) and winding it around teeth, there is a so-called nozzle winding method in which the nozzle is moved along the tooth shape of the core for winding (see, for example, Patent Document 1 below).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the above prior art, in order to move the nozzle along the tooth shape of the core, frequent acceleration and deceleration of the motor for moving the nozzle are required. That is, in this nozzle winding method, although the nozzle is moved by a servo motor, there is a limit to performing high-speed acceleration and deceleration of the servo motor, and there is a problem that winding cannot be performed at high speed. In particular, in order to swing the nozzle along the circumferential direction of the core, it is necessary to alternately perform forward and reverse rotations of the servo motor and perform acceleration and deceleration at the time of switching, so high-speed winding is difficult.

[0005] This application discloses a technique for solving the above problems, and an object thereof is to provide a winding machine for a rotating electrical machine and a method for manufacturing a rotating electrical machine that can wind at high speed and can easily change the nozzle position in a winding machine using a nozzle drive method for moving the nozzle.

Means for Solving the Problems

[0006] The winding machine for a rotating electric machine disclosed herein is A winding machine for a rotating electric machine that winds wire onto the core of a stator, which constitutes a rotating electric machine, via a nozzle, A vertical movement mechanism for moving the nozzle along the axial direction of the core, The system comprises a rotational oscillating mechanism that rotates and oscillates the core in the circumferential direction, independently of the vertical movement mechanism. picture, The rotational oscillating mechanism includes a core gripping mechanism for gripping the core, an output gear fixed to a main shaft attached to the core gripping mechanism, an input gear meshed with the output gear, an auxiliary drive motor for driving the input gear via an auxiliary shaft, a link bar loosely fitted to both the main shaft and the auxiliary shaft, a cam for oscillating the link bar around the main shaft, and a cam drive motor for driving the cam. It is. Furthermore, the method for manufacturing a rotating electric machine disclosed in this application involves using a winding machine for the rotating electric machine to wind wire onto the core in order to manufacture the rotating electric machine. [Effects of the Invention]

[0007] According to the rotating electric winding machine disclosed in this application, in a nozzle-driven winding machine that moves a nozzle, high-speed winding is possible and the nozzle position can be easily changed. Furthermore, the manufacturing method for a rotating electric machine disclosed in this application can reduce manufacturing costs. [Brief explanation of the drawing]

[0008] [Figure 1] This is a perspective view of the core that makes up the stator of a rotating electric machine. [Figure 2] This is a perspective view showing the overall configuration of the winding machine for a rotating electric machine according to Embodiment 1. [Figure 3] This is a front view showing the detailed configuration of the rotational oscillating mechanism of the winding machine according to Embodiment 1. [Figure 4] This is an explanatory diagram showing the movement of the nozzle relative to the core of the winding machine according to Embodiment 1. [Figure 5] This is a block diagram showing the schematic configuration of a controller for controlling the operation of a winding machine according to Embodiment 1. [Modes for carrying out the invention]

[0009] Embodiment 1. Figure 1 is a perspective view of the core constituting the stator of a rotating electric machine, Figure 2 is a perspective view showing the overall configuration of the winding machine of the rotating electric machine according to Embodiment 1, Figure 3 is a front view showing a detailed configuration of the drive unit of the winding machine according to Embodiment 1, Figure 4 is an explanatory diagram showing the movement of the nozzle of the winding machine according to Embodiment 1, and Figure 5 is a block diagram showing the schematic configuration of the controller for controlling the operation of the winding machine according to Embodiment 1.

[0010] In this embodiment 1, the nozzle winding type winding machine, as shown in Figure 1, winds are applied to the teeth 2b formed between each slot 2a of the core 2 constituting the stator 1 of the rotating electric machine via a winding supply nozzle 3. Here, the vertical direction in the diagram along the axial direction of the core 2 is referred to as the Z direction, the left and right directions in the diagram perpendicular to the axial direction (Z direction) of the core 2 are referred to as the X direction, and the circumferential direction of the core 2 is referred to as the θ direction.

[0011] As shown in Figure 2, the nozzle winding winding machine of this embodiment 1 includes a mechanism 11 for moving the nozzle 3 in the X direction of the core 2 (hereinafter referred to as the lateral movement mechanism 11), a mechanism 12 for moving the nozzle 3 in the Z direction of the core 2 (hereinafter referred to as the vertical movement mechanism 12), and a mechanism 13 for rotating and oscillating the core 2 in the circumferential direction (hereinafter referred to as the rotational oscillation mechanism 13). The operation of the lateral movement mechanism 11, the vertical movement mechanism 12, and the rotational oscillation mechanism 13 is controlled by a controller 100.

[0012] The tip of the vertical movement mechanism 12 is provided with a nozzle 3 through which a wire 4, such as a copper wire, passes. Specifically, the nozzle 3 has a hole formed therein for the wire 4 to pass through, and the wire 4 passes through this hole and is wound onto the teeth 2b of the core 2.

[0013] The wire 4 is connected to the nozzle 3 via a tensioner unit 6 from a wire supply bobbin 5. In this case, there are various tensioner types, such as a servo tensioner pressurization type, but in this embodiment 1, it is not particularly limited and any type may be used.

[0014] The horizontal movement mechanism 11 can be a combination of a generally used servo motor and a ball screw in order to perform acceleration and deceleration about 1 / 10 that of the vertical movement mechanism 12 which moves the nozzle 3 in the Z direction.

[0015] On the other hand, the vertical movement mechanism 12 moves the nozzle 3 along the Z direction with respect to the core 2. In the case of this Embodiment 1, since high acceleration is required, a linear servo motor is adopted. In a mechanism combining a generally used servo motor and a ball screw, an acceleration of about 5G at maximum can be generated. For this reason, the movement of the nozzle 3 through which the wire 4 passes at high speed cannot be speeded up accordingly.

[0016] In the winding machine of the nozzle winding method in this Embodiment 1, as shown in FIG. 1, a vertical movement mechanism 12 that moves the nozzle 3 in the Z direction is attached to the horizontal movement mechanism 11 that moves the nozzle 3 in the X direction. With such a structure, the inertial force applied to the vertical movement mechanism 12 is reduced, so that high acceleration and deceleration of the nozzle 3 can be realized, which is convenient.

[0017] On the other hand, a configuration in which the horizontal movement mechanism 11 is attached to the vertical movement mechanism 12 and the nozzle 3 is attached to the tip of the horizontal movement mechanism 11 can be considered. Even with this configuration, it is structurally feasible as a winding machine of the nozzle method. However, since the inertial force of the vertical movement mechanism 12 that requires high acceleration and deceleration increases by the weight of the horizontal movement mechanism 11 that moves the nozzle 3 left and right, it is not suitable for moving the nozzle 3 at high speed.

[0018] FIG. 3 is a front view showing a detailed configuration of the rotation and swing mechanism provided in the winding machine in this Embodiment 1.

[0019] The core 2 that constitutes the stator 1 is fixed by a core gripping mechanism 20. This core gripping mechanism 20 is integrally connected to one end of the main shaft 21. A link bar 22 is loosely fitted to the other end of the main shaft 21. That is, the link bar 22 is not fixed in the rotational direction of the main shaft 21, but is provided to be rotatable so that it can be aligned with the main shaft 21.

[0020] An output gear 23, acting as a sun gear, is integrally fixed to the main shaft 21 at a point between the core gripping mechanism 20 and the link bar 22. An input gear 24, acting as a planetary gear, is meshed with the output gear 23. As a result, when the input gear 24 rotates, the output gear 23 rotates, which in turn causes the main shaft 21 to rotate, and the core 2, gripped by the core gripping mechanism 20, to rotate.

[0021] The drive sources that drive the core 2 in the θ direction include a cam drive motor 25 and an auxiliary drive motor 26.

[0022] Here, a cam 27 is connected to the cam drive motor 25. The outer surface of this cam 27 has a cam curve formed on it that causes the core 2, which is gripped by the core gripping mechanism 20, to oscillate in the θ direction. The cam 27 is in contact with the link bar 22. As a result, the link bar 22 moves along the phase of the cam 27, and the input gear 24 revolves around the output gear 23 with the center 22a of the link bar 22 as the pivot point. This defines the range Lθ (see Figure 4) in which the core 2 oscillates in the θ direction.

[0023] In conventional nozzle-winding winding machines, the servo motor for driving the nozzle 3 is directly connected to the main shaft 21, and the servo motor needs to be used to oscillate in the θ direction. Therefore, after the nozzle 3 stops at the end of its movement in the θ direction, it needs to be rotated in the reverse direction, requiring rapid acceleration and deceleration. Since there are limits to the acceleration and deceleration of the servo motor, if winding is performed at a speed above a certain level, the servo motor may not be able to keep up, and in the worst case, the nozzle 3 may come into contact with the core 2.

[0024] In contrast, in this embodiment 1, since the cam 27 moves in an oscillating motion, the cam drive motor 25 only needs to rotate in one direction, and there is no stopping or rotation in the reverse direction, so acceleration and deceleration are not required. Therefore, the core 2 can be oscillated in the θ direction at high speed, enabling high-speed winding.

[0025] An auxiliary drive motor 26 is integrally connected to an auxiliary input gear 28, and an auxiliary output gear 29 is meshed with this auxiliary input gear 28. The auxiliary output gear 29 is fixed to one end of the auxiliary shaft 30, and the aforementioned input gear 24 is fixed to the other end of the auxiliary shaft 30. Furthermore, the aforementioned link bar 22 is loosely fitted to the auxiliary shaft 30 at an intermediate position between the auxiliary output gear 29 and the input gear 24. In other words, the link bar 22 and the auxiliary shaft 30 are not fixed to each other, and the auxiliary shaft 30 is allowed to rotate freely.

[0026] As a result, when the cam drive motor 25 is stopped, even if the auxiliary drive motor 26 is driven, the link bar 22 will not rotate as a result, and only the input gear 24 will rotate, causing the core 2 to rotate in the θ direction.

[0027] Furthermore, when the auxiliary drive motor 26 is stopped, driving the cam drive motor 25 causes the link bar 22 to swing only around its core 22a, and the input gear 24 itself does not rotate. Instead, the input gear 24 swings within a certain range Lθ in the θ direction along the outer circumference of the output gear 23, centered on the core 22a through which the main shaft 21 of the link bar 22 passes.

[0028] When both the cam drive motor 25 and the auxiliary drive motor 26 are driven, the input gear 24 rotates on its own axis due to the auxiliary drive motor 26, the auxiliary input gear 28, and the auxiliary output gear 29, and also revolves along the outer circumference of the output gear 23 within a certain range Lθ due to the action of the cam drive motor 25, the cam 27, and the link bar 22. Therefore, by synchronously driving and controlling the cam drive motor 25 and the auxiliary drive motor 26 with the controller 100, the core 16 can be rotated and oscillated within a certain range Lθ in the θ direction by their combined value.

[0029] Figure 4 is an explanatory diagram showing the movement of the nozzle relative to the core in this embodiment 1. The vertical movement mechanism 12 is responsible for moving the nozzle 3 in the Z direction within a certain range Lz. The cam drive motor 25, cam 27, and link bar 22 that constitute the rotational oscillation mechanism 13 define the range Lθ in which the core 2 oscillates in the θ direction within the same winding, as shown in Figure 4. Furthermore, the auxiliary drive motor 26, auxiliary input gear 28, and auxiliary output gear 29, which constitute the rotational oscillating mechanism 13, are responsible in Figure 4 for adjusting the position of the moving end P1, which is the winding start position for one tooth 2b by the nozzle 3, and for moving the winding to the next tooth. This results in a core 2 winding machine that can wind at high speed and allows for fine adjustment of the winding position.

[0030] Next, a winding method using the nozzle-type winding machine in this embodiment 1 will be described.

[0031] First, the wire 4 is passed through the tensioner unit 6 to the nozzle 3. Next, the core 2 is set in the core gripping mechanism 20. The gripping force of the core 2 by the core gripping mechanism 20 must be set to be greater than or equal to the force applied to the wire 4 during winding.

[0032] Next, the starting position of the winding of the wire 4 is adjusted. To do this, the nozzle 3 is moved in the Z direction by the vertical movement mechanism 12, and the cam drive motor 25 and auxiliary drive motor 26 are driven to move the core 2 in the θ direction, adjusting the position so that the nozzle 3 reaches the moving end P1 in Figure 4.

[0033] Here, the Z-direction position adjustment of the movable end P1 of the nozzle 3 can be adjusted by controlling the linear servo motor that constitutes the vertical movement mechanism 12. Furthermore, the θ-direction position adjustment of the movable end P1 of the nozzle 3 is performed by driving the auxiliary drive motor 26 to rotate the core 2 via the auxiliary output gear 29, input gear 24, and output gear 23, thereby adjusting the position of the nozzle 3 in the θ-direction to be at the movable end P1. Note that even if the cam drive motor 25 is driven alone, the input gear 24 will only revolve around the output gear 23 due to the movement of the cam 27, and the θ-direction position of the nozzle 3 cannot be adjusted. In this way, the position of the movable end P1, which is the starting position for winding the wire 4 for this one tooth 2b, is stored in the controller 100.

[0034] Next, the vertical movement mechanism 12 drives the nozzle 3 in the Z direction to move it to the next movement end P2. The Z-direction position of the movement end P2 of the nozzle 3 can be adjusted by controlling the linear servo motor that constitutes the vertical movement mechanism 12. The position of this movement end P2 is then stored in the controller 100.

[0035] If, for example, it is desired to change the direction of movement of the nozzle 3 during its movement in the Z direction, the auxiliary drive motor 26 can be driven at the desired position for the change in direction, and this position can be stored in the controller 100, thereby changing the position of the nozzle 3's moving end P2 in the θ direction.

[0036] Next, the cam drive motor 25 is driven, and the auxiliary drive motor 26 is driven in synchronization with it to move the nozzle 3 in the θ direction to the next moving end P3. The position of the moving end P3 of the nozzle 3 in the θ direction can be adjusted by controlling the amount of rotational drive of the auxiliary drive motor 26. The position of this moving end P3 is then stored in the controller 100.

[0037] If, for example, it is desired to change the direction of movement of the nozzle 3 during its movement in the θ direction, the vertical movement mechanism 12 can be driven at the position where the direction of movement needs to be changed, and this changed position can be stored in the controller 100, thereby changing the position of the nozzle 3's moving end P3 in the Z direction.

[0038] Next, the nozzle 3 is driven in the Z direction by the vertical movement mechanism 12 in a similar manner to move the nozzle 3 to the next moving end P4. The Z-direction position of the moving end P4 of the nozzle 3 can be adjusted by controlling the linear servo motor that constitutes the vertical movement mechanism 12. The position of this moving end P4 is then stored in the controller 100.

[0039] If, for example, you want to change the direction of movement of the nozzle 3 midway through its movement in the Z direction, you can change the position of the nozzle 3's moving end P4 in the θ direction by driving the auxiliary drive motor 26 at the position where you want to change the direction of movement and storing that changed position in the controller 100.

[0040] This makes it possible to arbitrarily adjust the position of the moving end where the important nozzle 3 changes direction within one turn when winding the wire 4 (hereinafter referred to as the direction change position), that is, the positions of each of the four moving ends P1, P2, P3, and P4 of the nozzle 3, without changing the shape of the cam 27.

[0041] Once the adjustment of the turning position for one turn relative to core 2 is complete, the vertical movement mechanism 12 is driven to move nozzle 3 in the up and down direction (Z direction), thereby moving it to the next turn and storing that turning position in controller 100.

[0042] Next, in the same manner as described above, the controller 100 stores the direction change positions P1 to P4 of the nozzle 3 required when winding one turn of wire onto the core 2. By repeating this process for the number of turns required to wind a single tooth 2b, the controller 100 stores the direction change positions for all turns during winding necessary for motor control.

[0043] In this way, once the controller 100 has stored the direction change positions P1 to P4 for the number of turns required to wind a single tooth 2b, the auxiliary drive motor 26 is driven to rotate the core 2 by one pitch of tooth 2b, moving the nozzle 3 in the θ direction. This process is then repeated for the next tooth 2b for the number of turns required to wind it.

[0044] In this way, the controller 100 stores the direction change positions P1 to P4 for all teeth 2b that make up the core 2. Once the controller 100 has stored the information on the direction change positions P1 to P4 for all teeth 2b that make up the core 2, it is not necessary to store it again for the same shape.

[0045] Once the above steps are completed, the wire 4 is wound onto the core 2 based on that information to complete the stator 1. After that, the core gripping mechanism 20 is removed and the stator 1 is taken out.

[0046] As described above, the winding machine of this embodiment 1 of the rotating electric machine is configured to include a vertical movement mechanism 12 that moves the core 2 along the axial direction, and a rotational oscillation mechanism 13 that rotates and oscillates the core 2 in the circumferential direction independently of the vertical movement mechanism 12. The rotational oscillation mechanism 13 uses a cam mechanism with a cam 27 and a link bar 22 to oscillate the core 2 along the circumferential direction relative to the nozzle 3, thus eliminating acceleration and deceleration of the cam drive motor 25. Furthermore, while it is difficult to position the nozzle 3 relative to the core 2 with the cam mechanism alone, the position of the nozzle 3 can be adjusted by rotating the input gear 24 with the auxiliary drive motor 26. As a result, high-speed winding is possible, and the manufacturing cost of the rotating electric machine can also be reduced.

[0047] In the above embodiment 1, the controller 100 is composed of hardware consisting of a processor 101 and a storage device 102, as shown in Figure 5, for example. Although not shown, the storage device 102 includes a volatile storage device such as random access memory and a non-volatile auxiliary storage device such as flash memory. Alternatively, an auxiliary storage device such as a hard disk drive may be provided instead of flash memory. The processor 101 executes the program input from the storage device 102. In this case, the program is input from the auxiliary storage device to the processor 101 via the volatile storage device. The processor 101 may also output data such as calculation results to the volatile storage device of the storage device 12, or it may store the data in the auxiliary storage device via the volatile storage device.

[0048] Furthermore, although this application describes an exemplary embodiment 1, the various features, aspects, and functions described in this embodiment 1 are not limited to the application of a specific embodiment, but can be applied to embodiment 1 individually or in various combinations.

[0049] Accordingly, countless variations not illustrated are conceivable within the scope of the art disclosed herein. These include, for example, modifications, additions, or omissions of at least one component.

[0050] The various aspects of this disclosure are described below as supplementary information. (Note 1) A winding machine for a rotating electric machine that winds wire onto the core of a stator, which constitutes a rotating electric machine, via a nozzle, A vertical movement mechanism for moving the nozzle along the axial direction of the core, A winding machine for a rotating electric machine, comprising a rotational oscillating mechanism that rotates and oscillates the core in the circumferential direction independently of the vertical movement mechanism. (Note 2) The vertical movement mechanism is a winding machine for a rotating electric machine as described in Appendix 1, comprising a linear servo motor. (Note 3) The rotational oscillating mechanism comprises a core gripping mechanism for gripping the core, an output gear fixed to a main shaft attached to the core gripping mechanism, an input gear meshed with the output gear, an auxiliary drive motor for driving the input gear via an auxiliary shaft, a link bar loosely fitted to both the main shaft and the auxiliary shaft, a cam for oscillating the link bar about the main shaft, and a cam drive motor for driving the cam, as described in Appendix 1 or Appendix 2. (Note 4) A method for manufacturing a rotating electric machine, comprising winding a wire onto the core using a rotating electric machine winding machine described in any one of the items from Appendix 1 to Appendix 3. [Explanation of symbols]

[0051] 1 stator, 2 cores, 3 nozzles, 4 wires, 11 lateral movement mechanism, 12 Vertical movement mechanism, 13 Rotational oscillating mechanism, 20 Core gripping mechanism, 21 Main shaft, 22 Link bar, 23 Output gear, 24 Input gear, 25 Cam drive motor, 26 Auxiliary drive motor, 27 Cam, 30 Auxiliary shaft.

Claims

1. A winding machine for a rotating electric machine that winds wire onto the core of a stator, which constitutes a rotating electric machine, via a nozzle, A vertical movement mechanism for moving the nozzle along the axial direction of the core, The system includes a rotational oscillating mechanism that rotates and oscillates the core in the circumferential direction, independently of the vertical movement mechanism. The rotational oscillating mechanism is a winding machine for a rotating electric machine, comprising a core gripping mechanism for gripping the core, an output gear fixed to a main shaft attached to the core gripping mechanism, an input gear meshed with the output gear, an auxiliary drive motor for driving the input gear via an auxiliary shaft, a link bar loosely fitted to both the main shaft and the auxiliary shaft, a cam for oscillating the link bar about the main shaft, and a cam drive motor for driving the cam.

2. The winding machine for a rotating electric machine according to claim 1, wherein the vertical movement mechanism is provided with a linear servo motor.

3. A method for manufacturing a rotating electric machine, comprising winding a wire onto a core using a winding machine for a rotating electric machine according to claim 1 or claim 2.

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