Method for manufacturing a segment coil unit and apparatus for manufacturing the same.

Abstract

The present invention provides a method and apparatus for manufacturing a segment coil unit that can stably and efficiently stack multiple segment coils so that they overlap in a substantially spiral shape. [Solution] This manufacturing method uses a temporary assembly jig 20 provided with a support column 21, a plurality of hooking parts 23 and an inclined part 28, and involves picking up segment coils 3 and 4 one by one and dropping them in so that the legs 5 and 6 are inserted into predetermined gaps in the temporary assembly jig 20, rotating the jig to change the position of the gap into which the legs 5 and 6 of the segment coils 3 and 4 are dropped, and repeatedly performing a coil pressing operation to press already dropped segment coils 3 and 4 radially inward to restrict the position of the segment coils 3 and 4 when dropping them in.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a segment coil unit in which a plurality of segment coils are laminated and an apparatus for manufacturing the same.

Background Art

[0002] For example, in an electric vehicle or the like, there is a method of manufacturing a stator coil by preliminarily temporarily assembling a segment coil unit in which a plurality of segment coils having a substantially U shape are laminated, and inserting the temporarily assembled segment coil unit into a slot of a stator core.

[0003] Regarding the temporary assembly of the segment coil unit as described above, Patent Document 1 below describes a method for annular alignment of coil segments in which a plurality of coil segments are aligned annularly over a plurality of layers.

[0004] This method includes an insertion step of inserting one straight portion of each coil segment into an insertion recess of an inner annular alignment jig having an outer peripheral surface and an insertion recess for one turn, and after the insertion step, rotating each coil segment about this one straight portion so that the other straight portion abuts or approaches the outer peripheral surface of the inner annular alignment jig, and annularly aligning the coil segments so as to form two layers of the segment type coil; and a clamping step of covering the inner annular alignment jig and the outside of the coil segments with an outer annular alignment jig having a plurality of insertion recesses, restricting the movement of the other straight portion of the coil segments toward the centrifugal side at its inner peripheral surface, and clamping the other straight portion of the coil segments between the inner annular alignment jig and the outer annular alignment jig.

[0005] Then, using the outer annular alignment jig as the next inner annular alignment jig, after sequentially performing the insertion step and the rotation step using new next two layers of coil segments, the clamping step is performed using a new next outer annular alignment jig, so that the annular alignment step is repeated a plurality of times.

Prior Art Documents

[0006] [Patent Document 1] Japanese Patent Publication No. 2004-72839 [Overview of the project] [Problems that the invention aims to solve]

[0007] In the method described in Patent Document 1 above, after the rotation process, the outer annular alignment jig is placed over the inner annular alignment jig and the outside of the coil segment.

[0008] However, when placing the outer annular alignment jig, the coil segment with one perpendicular portion inserted into the insertion recess of the inner annular alignment jig may rotate in a direction away from the outer circumferential surface of the inner annular alignment jig. As a result, the coil segment may get caught on the inner circumferential surface of the outer annular alignment jig, making it difficult to stably align (preliminarily assemble) the coil segment.

[0009] Furthermore, if the coil segment rotates away from the outer surface of the inner annular alignment jig, it is necessary to bring the coil segment back into contact with or close to the outer surface of the inner annular alignment jig, which also takes time.

[0010] Therefore, the object of the present invention is to provide a method for manufacturing a segment coil unit and an apparatus for manufacturing the same, which enables the stable and efficient stacking of multiple segment coils so that they overlap in a substantially spiral shape. [Means for solving the problem]

[0011] To achieve the above objective, the present invention provides a method for pre-assembling a plurality of segment coils, each having a pair of legs and a connecting portion that connects the pair of legs, to fit into the slots of the stator core to be applied. CircularA method for manufacturing a segment coil unit, comprising a rotatably supported column and a plurality of hooks projecting radially from the outer circumference of the column at predetermined intervals in the circumferential direction, wherein gaps are formed in the circumferential direction between adjacent hooks so as to correspond to the slots of the stator core, and above the hooks are inclined to gradually descend in the outward diameter direction. The connecting portion of the segment coil is then slid in the outer diameter direction. The method is characterized by using a temporary assembly jig equipped with an inclined section to pick up the segment coils one by one and dropping them in so that the legs are inserted into a predetermined gap; rotating the support column by a predetermined angle to change the position of the gap into which the legs of the picked-up segment coils are dropped; and appropriately repeating a coil pressing operation in which, when dropping in the segment coils, the segment coils that have already been dropped are pressed radially inward to restrict the position of those segment coils.

[0012] Another aspect of the present invention involves pre-assembling a plurality of segment coils, each having a pair of legs and a connecting portion that connects the pair of legs, to fit into the slots of the stator core to be applied. Circular A segment coil unit manufacturing apparatus comprising a rotatably supported column and a plurality of hooks projecting radially from the outer circumference of the column at predetermined intervals in the circumferential direction, wherein gaps are formed in the circumferential direction between adjacent hooks so as to correspond to the slots of the stator core, and above the hooks are inclined to gradually descend in the outward diameter direction. The connecting portion of the segment coil is then slid in the outer diameter direction.The device comprises a temporary assembly jig with an inclined section, a coil insertion section that picks up the segment coils one by one and drops them in so that their legs are inserted into a predetermined gap, a jig rotation section that rotates the support section by a predetermined angle to change the position of the gap into which the legs of the picked-up segment coils are dropped, and a coil pressing section that, when dropping in the segment coils, presses the segment coils that have already been dropped radially inward to regulate the position of the segment coils, and is configured to repeat the segment insertion operation by the segment insertion device, the jig rotation operation by the jig rotation device, and the coil pressing operation by the coil pressing device as appropriate.

[0013] According to the above invention, by using a temporary assembly jig and appropriately repeating the segment insertion operation, jig rotation operation, and coil pressing operation, multiple segment coils can be temporarily assembled to fit the slots of the stator core to be applied, thereby manufacturing a single segment coil unit.

[0014] Furthermore, since a sloping section is provided above the hook portion of the temporary assembly jig, which gradually slopes downward in the outward direction, the dropped segment coil can be slightly shifted in the outward direction. Also, when dropping a segment coil, a coil pressing operation is performed to press the already dropped segment coil radially inward to regulate the position of the segment coil. This allows the segment coil to be dropped to be correctly stacked on top of the already dropped and regulated segment coils so that it is in the predetermined position, and multiple segment coils can be stacked in a substantially spiral shape.

[0015] Therefore, a single segment coil unit can be manufactured stably and efficiently by stacking multiple segment coils in a roughly spiral shape.

[0016] Furthermore, by aligning the legs of the segment coil units manufactured as described above with the slots of the stator core and inserting them, all the legs of the segment coils can be inserted simultaneously into the corresponding slots of the stator core.

[0017] In the method for manufacturing segment coils according to the present invention, when stacking the segment coils by appropriately repeating the coil insertion operation, the jig rotation operation, and the coil pressing operation, a gap forming operation may be performed by inserting a gap forming tool into the inner diameter side of a segment coil adjacent to the opposite side in the circumferential direction, so that one side of the connecting portion of the segment coil overlaps the outer diameter side of an adjacent segment coil in the circumferential direction, and the other side of the connecting portion of the segment coil enters the inner diameter side of an adjacent segment coil on the opposite side in the circumferential direction, thereby forming a gap into which the other side of the connecting portion of the segment coil enters.

[0018] In the segment coil manufacturing apparatus according to the present invention, when stacking the segment coils by appropriately repeating the segment insertion operation, the jig rotation operation, and the coil pressing operation, the apparatus may further include a gap forming device that inserts a gap forming tool into the inner diameter side of a segment coil adjacent to the opposite side in the circumferential direction, so that one side of the bent portion of the segment coil overlaps the outer diameter side of an adjacent segment in the circumferential direction, and the other side of the bent portion of the segment coil enters the inner diameter side of a segment coil adjacent to the opposite side in the circumferential direction, thereby forming a gap into which the other side of the bent portion of the segment coil enters.

[0019] According to the above embodiment, by performing a gap-forming operation using a gap-forming tool, the other side of the connecting portion of the segment coil can be reliably inserted into the inner diameter side of the adjacent segment coil on the opposite side in the circumferential direction, thereby enabling more reliable stacking of multiple segment coils so that they overlap in a substantially spiral shape.

[0020] In the method for manufacturing a segment coil according to the present invention, after the insertion operation of the leg portions of the segment coil into all the gaps of the temporary assembly jig is completed, the annular support plate disposed below the temporary assembly jig is raised to lift the leg portions of the segment coil, and then a lift-up operation may be performed in which the annular support plate is lowered and supported again by the temporary assembly jig.

[0021] The manufacturing apparatus for a segment coil according to the present invention includes an annular support plate disposed below the temporary assembly jig and a lifting / lowering unit that moves the annular support plate up and down. After the insertion operation of the leg portions of the segment coil into all the gaps of the temporary assembly jig is completed, the lifting / lowering unit raises the annular support plate to lift the leg portions of the segment coil, and then the lifting / lowering unit lowers the annular support plate and is configured to perform a lift-up operation in which it is supported again by the temporary assembly jig.

[0022] According to the above aspect, due to the lift-up operation of the annular support plate by the lifting / lowering unit, the segment coil hooked on the temporary assembly jig is once lifted and then hooked again on the temporary assembly jig, so that a plurality of segment coils can be realigned and stacked more correctly so as to overlap in a substantially spiral shape.

[0023] In the method for manufacturing a segment coil according to the present invention, as the segment coil, a first segment coil having a pair of leg portions inserted into slots separated by a predetermined number and a second segment coil in which leg portions are inserted into outer slots one by one with respect to the slots into which the leg portions of the first segment coil are inserted are used, and an operation of sequentially picking up the first segment coil and the second segment coil and inserting them concentrically is performed. Then, the support column portion may be rotated by a predetermined angle, and an insertion operation of the next first segment coil and second segment coil arranged concentrically may be performed.

[0024] In the manufacturing apparatus for a segment coil according to the present invention, as the segment coil, a first segment coil having a pair of legs inserted into slots separated by a predetermined number, and with respect to the slots into which the legs of the first segment coil are inserted, a second segment coil having legs inserted into the outer slots one by one may be used, and the coil insertion unit may be configured to perform an operation of sequentially picking up the first segment coil and the second segment coil and inserting them concentrically.

[0025] According to the above aspect, it is possible to reliably manufacture one segment coil unit that is concentrically wound and distributed wound by the first segment coil and the second segment coil.

Effect of the Invention

[0026] According to the present invention, above the hooking portion of the temporary assembly jig, with an inclined portion that is inclined so as to gradually descend in the outer diameter direction, the segment coil can be slightly shifted in the outer diameter direction, and the already dropped segment coil can be pressed inward in the radial direction to perform a coil pressing operation for restricting the position of the segment coil. By doing so, the segment coil to be dropped can be correctly overlapped so as to be in a predetermined position with respect to the segment coil whose position is restricted, and a plurality of segment coils can be laminated so as to overlap in a substantially spiral shape. Therefore, one segment coil unit can be stably and efficiently laminated and manufactured so that a plurality of segment coils overlap in a substantially spiral shape.

Brief Description of the Drawings

[0027] [Figure 1] It is a perspective view showing an embodiment of a manufacturing apparatus for a segment coil unit according to the present invention, an insertion apparatus for a segment coil unit, and further a manufacturing apparatus for a stator core composed of both apparatuses. [Figure 2] It is a plan view of each apparatus shown in FIG. 1. [Figure 3] It is a front view of each apparatus shown in FIG. 1. [Figure 4]This is a perspective view of a segment coil unit manufactured using the segment coil unit manufacturing apparatus according to the present invention. [Figure 5] This is a perspective view of the narrow first segment coil that makes up the segment coil unit. [Figure 6] This is a perspective view of the wide second segment coil that makes up the segment coil unit. [Figure 7] This is a perspective view of the stator core into which the segment coil unit is inserted in a segment coil unit insertion device. [Figure 8] This is a perspective view of a component in which a segment coil unit has been inserted into a slot in a stator core, in the segment coil unit insertion device. [Figure 9] This is an enlarged perspective view of the main part of the manufacturing apparatus for a segment coil unit according to the present invention. [Figure 10] This is an enlarged plan view of the main components of the manufacturing equipment for the segment coil unit. [Figure 11] This is a flowchart of the method for manufacturing a segment coil unit according to the present invention. [Figure 12] This is a perspective view showing the segment coil insertion process in the same manufacturing method. [Figure 13] This is a perspective view showing a later step in the manufacturing method (the rotation step of the temporary assembly jig) than shown in Figure 12. [Figure 14] This is a perspective view showing a later step (gap formation) in the same manufacturing method, as shown in Figure 13. [Figure 15] This is a perspective view showing a later step in the manufacturing method (insertion of the legs into the gap) than shown in Figure 14. [Figure 16] This is a perspective view showing a later step (lift-up) in the same manufacturing method, as shown in Figure 15. [Figure 17] This is an enlarged perspective view of the main part of the segment coil unit insertion device. [Figure 18] This is an enlarged plan view of the main part of the insertion guide that constitutes the insertion device for the segment unit. [Figure 19]This is an enlarged bottom view of the main part of the unit supply section that constitutes the insertion device for the segment unit. [Figure 20] This is an enlarged perspective view of the main part of the core supply section that constitutes the insertion device for the segment unit. [Figure 21] This is an enlarged perspective view of the key parts of the core supply section, showing how the stator core is received and supported by the core receiving section. [Figure 22] This is a flowchart illustrating a method for inserting segment coil units using a segment coil unit insertion device. [Figure 23] This is a perspective view showing the unit transport process in the same insertion method. [Figure 24] This is a perspective view showing a later step (chucking the coil unit) in the same insertion method, as shown in Figure 23. [Figure 25] This is a perspective view showing the third step (transporting the coil unit upwards to the insertion section) of the same insertion method, which is a later step than that shown in Figure 24. [Figure 26] This is a perspective view showing a later step (lowering of the coil unit) in the same insertion method, as shown in Figure 25. [Figure 27] This is a plan view showing a step later than Figure 26 (protrusion of the guide piece from the inner circumference of the opening) in the same insertion method. [Figure 28] This is a perspective view showing a later step (the upward movement of the push-up member) in the same insertion method, as shown in Figure 27. [Figure 29] This is a perspective view showing the steps after Figure 28 in the same insertion method (lowering of the push-up member and core transport by the core supply unit). [Figure 30] This is a perspective view showing a step later than that in Figure 29 (temporary insertion of the coil unit's legs into the stator core's slots) in the same insertion method. [Figure 31] This is a perspective view showing a later step (retraction of the unit supply unit) in the same insertion method, as shown in Figure 30. [Figure 32] This is a perspective view showing a step (pusher movement) later than that shown in Figure 31 in the same insertion method. [Figure 33]This is a perspective view showing a step (first pressing operation) later than that shown in Figure 32 in the same insertion method. [Figure 34] This is a perspective view showing a later step (pusher raising) in the same insertion method, compared to Figure 33. [Figure 35] This is a plan view showing a step later than that in the same insertion method (retracting the guide piece from the inner circumference of the opening) as shown in Figure 34. [Figure 36] This is a perspective view showing a step (second pressing operation) after the one shown in Figure 35 in the same insertion method. [Figure 37] This is a perspective view showing a later step (stator core retraction) in the same insertion method, as shown in Figure 36. [Modes for carrying out the invention]

[0028] (One embodiment of a manufacturing apparatus for segment coil units) First, one embodiment of the manufacturing apparatus for segment coil units according to the present invention will be described.

[0029] As shown in Figures 1 to 3, the segment coil unit manufacturing apparatus 10 (hereinafter also simply referred to as "unit manufacturing apparatus 10") manufactures a segment coil unit 8 as shown in Figure 4 by temporarily assembling a plurality of segment coils 3, 4 (see Figures 5 and 6), each having a pair of legs 5, 6 and a connecting portion 7 that connects the pair of legs 5, 6, so that they fit into the slots 210 of the applicable stator core 200 (see Figure 7).

[0030] Furthermore, as shown in Figures 5 and 6, the segment coils 3 and 4 consist of a pair of legs 5 and 6 extending parallel to each other, and a connecting portion 7 that is bent perpendicular to the pair of legs 5 and 6 and connects the pair of legs 5 and 6 to each other, and in a front view, the overall shape is approximately U-shaped. However, the segment coil may be not limited to the above shape, but may also be approximately V-shaped, approximately U-shaped, etc. Note that the outer circumferential surface of the segment coils 3 and 4 is coated with an insulating film, except for the tips (lower ends) of the legs 5 and 6.

[0031] Furthermore, the connecting portion 7 has a roughly mountain-like shape, with its longitudinal central portion 7a being bent in a stepped manner, and the bent central portion 7a being the highest protruding portion (farthest from the tips of the leg portions 5 and 6), and the side portions 7b and 7c sloping downward from this central portion 7a toward both ends in the longitudinal direction. Of the two sides 7b and 7c of the connecting portion 7, the side facing the rotation direction R1 of the jig rotating portion 50 (see Figure 12) is referred to as "one side portion 7b," and the side facing the opposite direction of rotation of the jig rotating portion 50 is referred to as "the other side portion 7c."

[0032] Furthermore, the segment coil in this embodiment consists of a first segment coil 3 having a pair of legs 5, 6 inserted into slots 210, 210 of the stator core 200 that are a predetermined number of spaces apart, and a second segment coil 4 in which the legs 5, 6 are inserted into slots 210, 210 that are one space outward (outward in the direction along the circumferential direction of the stator core 200) from the slots 210, 210 into which the legs 5, 6 of the first segment coil 3 are inserted.

[0033] In other words, the second segment coil 4 in this embodiment is a wide segment coil in which the width of the pair of legs 5, 6 is wider than the width of the pair of legs 5, 6 of the first segment coil 3.

[0034] Furthermore, as shown in Figure 7, the stator core 200 in this embodiment has 48 slots 210. Six legs 5 or legs 6 of multiple segment coils 3, 4 are inserted into each slot 210.

[0035] Furthermore, the segment coils 3 and 4 are stacked in a substantially spiral shape when viewed from the axial direction of the jig rotating part 50.

[0036] Referring to Figure 4, (1) the wide second segment coil 4's connecting portion 7 is placed on both sides 7b, 7c of the narrow first segment coil 3's connecting portion 7, forming a pair of upper and lower segment coils 3 and 4. (2) One side 7b of the connecting portion 7 of the second segment coil 4 constituting the above pair is placed on one side 7b of the connecting portion 7 of the other circumferentially adjacent first segment coil 3. The connecting portions 7b, 7c of the paired second segment coil 4 are placed on both sides 7b, 7c of the connecting portion 7 of this first segment coil 3's connecting portion 7, forming another pair of upper and lower segment coils 3 and 4 constituting a pair.

[0037] Subsequently, as described in (2) above, the pair of upper and lower segment coils 3 and 4 are repeatedly placed over the entire circumference while shifting their position in the circumferential direction, thereby forming a roughly annular single layer (one circumference) of segment coils.

[0038] Then, as described above, multiple segments of a single-layer segment coil, which is constructed to extend around the entire circumference, are stacked radially (in this embodiment, three layers are stacked radially), so that the multiple segment coils 3 and 4 are stacked in a substantially spiral shape as a whole (or, when viewed from the axial direction of the support column 21 of the temporary assembly jig 20, the multiple segment coils 3 and 4 are stacked in a substantially spiral shape), thus forming one segment coil unit 8.

[0039] As shown in Figures 1 to 3, the unit manufacturing apparatus 10 mainly consists of a temporary assembly jig 20 having a support column 21, a hook 23, an inclined section 28, etc., coil temporary placement sections 30, 31, a coil insertion section 40, a jig rotation section 50, a coil pressing section 60, an annular support plate 70 and a lifting section 71, and a gap forming section 80.

[0040] Furthermore, in this embodiment, in addition to the unit manufacturing apparatus 10 according to the present invention, a segment coil unit insertion apparatus 100 (hereinafter also simply referred to as "unit insertion apparatus 100") is provided. That is, in this embodiment, the stator manufacturing apparatus 1 consists of the unit manufacturing apparatus 10 and the unit insertion apparatus 100 as a whole, and is configured to produce a stator in which segment coil units 8 are inserted into slots 210 of the stator core 200.

[0041] Figure 8 shows a component in which the legs 5 and 6 of a segment coil unit 8 are inserted into the slots 210 of a stator core 200. In this component, the stator is manufactured by welding the multiple legs 5 and 6 that are inserted from the lower opening of the slots 210 of the stator core 200 as appropriate.

[0042] Furthermore, an insulating sheet 220 is inserted into each slot 210 of the stator core 200, and the legs 5 and 6 of the segment coils 3 and 4 are inserted into this insulating sheet 220. In other words, the legs 5 and 6 of the segment coils 3 and 4 are inserted into the corresponding slots 210 of the stator core 200 via the insulating sheet 220.

[0043] Furthermore, as shown in Figures 1 to 3, the stator manufacturing apparatus 1 has a frame (not shown) and a long plate-shaped base portion 11 extending for a predetermined length, which is installed above the frame.

[0044] In the following explanation, the direction in which the base portion 11 extends (also known as the extension direction) will be referred to as the "X direction," the direction perpendicular to the extension direction of the base portion 11 (also known as the width direction) will be referred to as the "Y direction," and the vertical direction perpendicular to the X and Y directions (also known as the height direction) will be referred to as the "Z direction."

[0045] Furthermore, as shown in Figure 1, the stator manufacturing apparatus 1 is generally arranged such that the unit manufacturing apparatus 10 is located in one area of ​​the base section 11 in the Y direction (the area towards the back of the page in Figure 1), and the unit insertion apparatus 100 is located in the other area of ​​the base section 11 in the Y direction (the area towards the front of the page in Figure 1).

[0046] (Configuration of the temporary assembly jig 20) First, the temporary assembly jig 20 will be described. As shown in Figures 9 and 16, the temporary assembly jig 20 has a rotatably supported support column 21 and a plurality of hooks 23 that protrude radially from the outer circumference of the support column 21 at predetermined intervals in the circumferential direction. As shown in Figure 1, the temporary assembly jig 20 is installed on the other side in the X direction (the back side of the page in Figure 1) of one region in the Y direction of the base portion 11.

[0047] Furthermore, a gap G1 is formed in the circumferential direction between adjacent hook portions 23, 23 so as to correspond to the slots 210 of the stator core 200, and above each hook portion 23, an inclined portion 28 is provided that slopes downward in the outer diameter direction.

[0048] In this embodiment, the support column 21 is substantially cylindrical and is rotatably supported by a rotational drive unit (motor, etc.) not shown. The hook portion 23 consists of a long plate-shaped projection 24 that protrudes from the outer circumference of the support column 21 and extends in the axial direction of the support column 21, and an inclined forming portion 25 made by bending a linear member, which is installed above the projection 24 in the Z direction. The connecting portions 7 of the segment coils 3 and 4 are hooked onto the hook portion 23.

[0049] Furthermore, as shown in Figure 9, the inclined forming portion 25 consists of a base portion 27 and an inclined portion 28 that is bent at a predetermined angle relative to the base portion 27 and inclined to gradually descend radially outward (outer diameter direction) of the temporary assembly jig 20.

[0050] In this embodiment, the hook portion 23 consists of a projection 24 and a separate inclined forming portion 25, with an inclined portion 28 provided on the separate inclined forming portion 25. However, the hook portion may also be made into a long plate shape that extends continuously from bottom to top, with an inclined portion inclined in the outer diameter direction at its upper end, and is not particularly limited.

[0051] (Configuration of coil temporary placement sections 30, 31) The coil temporary storage sections 30 and 31 are used to temporarily store multiple segment coils 3 and 4, and after the segment coils 3 and 4 are picked up in the coil insertion section 40, the next segment coil 3 or 4 is transferred.

[0052] The coil temporary storage sections 30 and 31 of this embodiment include a support frame 33 installed on the base section 11, a rotating shaft 34 positioned horizontally above the support frame 33 and along the X direction of the base section 11, which is rotatably supported and rotatable by a rotating means (not shown), a spiral projection 35 that protrudes spirally along the outer circumference of the rotating shaft 34 and presses the legs 5 of the segment coils 3 and 4 as the rotating shaft 34 rotates, and a coil stopper 36 positioned above the support frame 33 and in front of the rotating shaft 34 (on one end of the base section 11 in the X direction (the front side of the page in Figure 1)) which restricts the movement of the segment coils 3 and 4.

[0053] Furthermore, as shown in Figures 1 and 2, the coil temporary storage sections 30 and 31 are installed in one region of the base section 11 in the Y direction, on one side in the X direction relative to the temporary assembly jig 20 (the side closer to the viewer in Figure 1). In addition, coil temporary storage section 30 is installed on the other side in the Y direction, and coil temporary storage section 31 is installed adjacent to coil temporary storage section 30 on one side in the Y direction.

[0054] Furthermore, multiple narrow first-segment coils 3 are temporarily placed in the coil temporary placement section 30, and multiple wide second-segment coils 4 are temporarily placed in the coil temporary placement section 31.

[0055] As each rotating shaft 34 rotates, the helical projection 35 pushes the connecting portion 7 of the segment coils 3 and 4, causing the segment coils 3 and 4 to be moved to the other end of the base portion 11 in the X direction. The segment coils 3 and 4 are moved until the central portion 7a of their connecting portion 7 abuts against the coil stopper 36, and are then positioned and held in that position.

[0056] (Configuration of the coil insertion section 40) The coil insertion section 40 picks up the segment coils 3 and 4 one by one and drops them in so that their legs 5 and 6 are inserted into a predetermined gap G1.

[0057] As shown in Figures 1-3, the coil insertion section 40 in this embodiment includes a support base 41 installed on the base section 11, a first movable section 42 that is reciprocally movable in the X direction of the base section 11 by a drive unit (not shown) relative to the support base 41, a second movable section 43 that is reciprocally movable in the Z direction of the base section 11 by a drive unit (not shown) relative to the first movable section 42, a third movable section 44 that is reciprocally movable in the Y direction of the base section 11 by a drive unit (not shown) relative to the second movable section 43, and a pickup section 45 provided on the third movable section 44 for picking up segment coils 3 and 4.

[0058] As shown in Figures 1-3, the coil insertion section 40 is installed on one side in the Y direction of the base section 11 relative to the pair of temporary coil placement sections 30 and 31.

[0059] Furthermore, the above-mentioned drive unit can employ, for example, a linear actuator, an electric cylinder, a hydraulic cylinder, etc., but is not particularly limited. The same applies to the "drive unit" in the following explanation.

[0060] As shown in Figures 9, 13, and 15, the pickup unit 45 has a pair of pins arranged in the Y direction (a total of four pins) that are positioned in the X direction and can move closer to and further apart from each other. When the pair of pins moves closer to each other, it grips the connecting unit 7, making it possible to pick up the segment coils 3 and 4. When the pair of pins moves further apart from each other, the gripping state of the connecting unit 7 is released, making it possible to release the segment coils 3 and 4.

[0061] The pickup unit 45 then moves as appropriate via the first moving unit 42, the second moving unit 43, and the third moving unit 44 to pick up the segment coils 3 and 4, one by one, which are temporarily held in the pickup position positioned by the coil stopper 36 of the coil temporary storage units 30 and 31. After that, the coils are dropped into the predetermined gap G1 of the temporary assembly jig 20.

[0062] Furthermore, the coil insertion section 40 is configured to sequentially pick up the first segment coil 3 and the second segment coil 4 and insert them concentrically.

[0063] Specifically, the coil insertion section 40 first picks up the narrow first segment coil 3 that has been temporarily placed in the coil temporary placement section 30 and drops it in so that its legs 5 and 6 are inserted into predetermined gaps G1 and G1 of the temporary assembly jig 20. Then, it picks up the wide second segment coil 4 that has been temporarily placed in the coil temporary placement section 31 and drops it in so that it is inserted into predetermined gaps G1 and G1 that are shifted one notch outward in the circumferential direction from the gaps G1 and G1 in which the legs 5 and 6 of the first segment coil 3 have been inserted.

[0064] Then, the connecting portion 7 of the second segment coil 4 is placed on the connecting portion 7 of the first segment coil 3, and the second segment coil 4 is positioned on a concentric circle common to the axis of the temporary assembly jig 20 with respect to the axis of the temporary assembly jig 20, overlapping in the axial direction (direction along the Z direction) of the temporary assembly jig 20, thereby forming a pair of upper and lower segment coils 3 and 4.

[0065] Subsequently, the rotational movement of the jig's rotating part 50 causes the next pair of upper and lower segment coils 3 and 4 to be positioned around the entire circumference, shifting circumferentially, thereby forming a roughly annular single-layer segment coil structure. The segment coils 3 and 4 that constitute the same segment coil layer are arranged on concentric circles common to the axis of the temporary assembly jig 20.

[0066] (Configuration of the jig rotating part 50) The jig rotating part 50 rotates the support column 21 of the temporary assembly jig 20 by predetermined angles to change the position of the gaps G1, G1 into which the legs 5, 6 of the picked-up segment coils 3, 4 are dropped.

[0067] As shown in Figure 9, the jig rotating part 50 of this embodiment has a support part 51 installed on the base part 11 and a rotational drive part 53 such as a motor located below the support part 51. A temporary assembly jig 20 is positioned above the support part 51, and a drive shaft (not shown) of the rotational drive part 53 is connected to its support column 21.

[0068] Then, when the rotary drive unit 53 is driven and the drive shaft (not shown) rotates in a predetermined direction by a predetermined angle, the support column 21 follows suit and rotates in a predetermined direction (the rotation direction shown by arrow R1 in Figure 12) by a predetermined angle, thereby changing the position of the gap G1 in the temporary assembly jig 20.

[0069] (Configuration of the coil pressing section 60) The coil pressing section 60, when dropping in the segment coils 3 and 4, presses the segment coils 3 and 4 that have already been dropped in radially inward, thereby regulating the position of the segment coils 3 and 4.

[0070] As shown in Figure 9, the coil pressing section 60 of this embodiment includes a support bracket 61 connected to one side of the support section 51 of the jig rotating section 50 and rising upward, positioned radially outward from the temporary assembly jig 20; a shaft section 63 supported horizontally at the upper end of the support bracket 61 and along the X direction of the base section 11; a rod 65 coaxially arranged within the shaft section 63 and capable of reciprocating motion by air, hydraulics, etc.; and a pressing section 67 provided at the axial end of the rod 65 (the end facing the temporary assembly jig 20).

[0071] Then, as shown in Figure 12, when the segment coils 3 and 4 are dropped into place, the coil pressing section 60 has a rod 65 protruding from the tip of the shaft section 63, and the pressing section 67 at the tip of the rod presses the already dropped segment coils 3 and 4 radially inward.

[0072] This mechanism restricts the position of the segment coils 3 and 4 that have already been installed, so that the segment coils 3 and 4 that are about to be installed will correctly overlap with the segment coils 3 and 4 that have already been installed at predetermined positions in the axial direction (along the Z-direction) and circumferential direction of the temporary assembly jig 20.

[0073] (Basic operation of the unit manufacturing device 10) As described above, the unit manufacturing apparatus 10, which has a temporary assembly jig 20, a coil insertion section 40, a jig rotation section 50, and a coil pressing section 60, performs the following operations. That is, the unit manufacturing apparatus 10 is configured to repeat the coil insertion operation by the coil insertion section 40, the jig rotation operation by the jig rotation section 50, and the coil pressing operation by the coil pressing section 60 as appropriate.

[0074] (Configuration of the annular support plate 70 and the lifting / lowering section 71) The annular support plate 70 is positioned below the temporary assembly jig 20, and the lifting mechanism 71 moves the annular support plate 70 up and down.

[0075] As shown in Figure 9, the annular support plate 70 is located radially outside the support column 21 of the temporary assembly jig 20, between the support portion 51 of the jig rotation portion 50 and the axial lower end of the temporary assembly jig 20, and is configured to move up and down along the axial direction of the support column 21, as shown by arrow H in Figure 9.

[0076] Furthermore, a plurality of lifting and lowering parts 71, consisting of air cylinders or the like, are installed at the lower part of the support part 51 of the jig rotating part 50, and the tips of rods (not shown) that reciprocate and slide in the direction of these lifting and lowering parts 71 are connected to the annular support plate 70.

[0077] Furthermore, an annular projection 73 is provided on the upper surface of the annular support plate 70, specifically on the outer peripheral edge of the annular portion. The outer peripheral surface of this annular projection 73 is an inclined surface that gradually decreases in height towards the radially outward direction.

[0078] Then, after the insertion operation of the legs 5 and 6 of the segment coils 3 and 4 into all the gaps G1 of the temporary assembly jig 20 is completed, the annular support plate 70 is raised by the lifting unit 71 to lift the legs 5 and 6 of the segment coils 3 and 4, and then the annular support plate 70 is lowered by the lifting unit 71 to perform a lift-up operation to support it again on the temporary assembly jig 20.

[0079] (Configuration of the gap-forming section 80) As shown in Figures 14 and 15, the gap forming section 80 is designed so that when the coil insertion operation by the coil insertion section 40, the jig rotation operation by the jig rotation section 50, and the coil pressing operation by the coil pressing section 60 are repeated as appropriate, one side 7b of the connecting section 7 of the segment coils 3 and 4 overlaps the outer diameter side of the adjacent segment coils 3 and 4 in the circumferential direction, and the other side 7c of the connecting section 7 of the segment coils 3 and 4 enters the inner diameter side of the adjacent segment coils 3 and 4 on the opposite side in the circumferential direction. The gap forming section 80 is designed to form a gap G2 into which the other side 7c of the connecting section 7 of the segment coils 3 and 4 enters.

[0080] As shown in Figures 2, 10, 12, 14, etc., the gap forming section 80 of this embodiment includes a support section 81 installed on the base section 11, a first movable section 82 that is reciprocally movable in the X direction of the base section 11 relative to the support section 81 by a drive unit (not shown), a second movable section 83 that is reciprocally movable in the Z direction of the base section 11 relative to the first movable section 82 by a drive unit (not shown), a third movable section 84 that is reciprocally movable in the Y direction of the base section 11 relative to the second movable section 83 by a drive unit (not shown), and a gap forming tool 85 provided on the third movable section 84.

[0081] As shown in Figure 2, the gap forming portion 80 is installed in one region of the base portion 11 in the Y direction, on one side of the base portion 11 in the Y direction relative to the coil insertion portion 40, and on the side of the temporary assembly jig 20.

[0082] Furthermore, the gap-forming tool 85 is substantially cylindrical in shape and extends from the lower surface of the tip of the third movable part 84, and a cut surface 86 is formed at its lower end, which is cut obliquely at a predetermined angle with respect to the axis of the gap-forming tool 85. The shape of the lower end of the gap-forming tool 85 may be, for example, a tapered inclined surface that gradually narrows towards the lowest end of the gap-forming tool 85, as long as it can be inserted between the segment coils that have already been installed.

[0083] Then, as shown in Figure 14, the gap-forming tool 85 moves appropriately via the first moving part 82, the second moving part 83, and the third moving part 84 to fit between one side 7b of the connecting part 7 of a predetermined segment coil 3, 4 located radially outward of the temporary assembly jig 20 and one side 7b of the connecting part 7 of a predetermined segment coil 3, 4 located radially inward adjacent to the said segment coil 3, 4.

[0084] As a result, as shown in Figure 15, a gap G2 is formed between one side 7b of the connecting portion 7 of the radially outer segment coils 3 and 4 and one side 7b of the connecting portion 7 of the radially inner segment coils 3 and 4, allowing the other side 7c of the connecting portion 7 of the segment coil 3 and 4 that is about to be inserted to fit in.

[0085] Furthermore, while the gap-forming section 80 forms the gap G2 as described above, at predetermined timings other than the gap-forming operation, it also performs an operation similar to that of the coil-pressing section 60, that is, as shown in Figure 13, an operation to press the segment coils 3 and 4 radially inward and restrict their position.

[0086] Furthermore, the operation of each part described above, such as the rotational operation of the jig's rotating part for temporary assembly, the segment coil transfer operation of the coil temporary placement part, the coil pickup and release operation of the coil insertion part, and the segment coil pressing operation of the coil pressing part, is controlled by a control unit (not shown) or the like.

[0087] (One embodiment of a method for manufacturing a segment coil unit) Next, one embodiment of the method for manufacturing a segment coil unit according to the present invention will be described.

[0088] As shown in Figure 11, the manufacturing method of the segment coil unit in this embodiment (hereinafter also simply referred to as the "unit manufacturing method") includes a coil insertion step S1, a jig rotation step S2, a coil pressing step S3, a gap formation step S5, and a lift-up step S7. These will be described in detail below.

[0089] (Coil insertion process S1, jig rotation process S2, and coil pressing process S3) This insertion process S1 is a process in which the segment coils 3 and 4 are picked up one by one and dropped into place so that the legs 5 and 6 are inserted into predetermined gaps G1 and G1, in which case a coil insertion operation is performed.

[0090] Specifically, the pickup unit 45 moves appropriately via the movable units 42, 43, and 44 so that the legs 5 and 6 are positioned directly above the predetermined gaps G1, G1 of the temporary assembly jig 20. In this state, the pickup unit 45 releases the segment coils 3 and 4, causing the legs 5 and 6 to be dropped into the predetermined gaps G1, G1 (see Figure 12).

[0091] In the coil insertion process S1 described above, the first segment coil 3 and the second segment coil 4 are sequentially picked up and inserted concentrically. Then, the support column 21 is rotated by a predetermined angle to insert the next first segment coil 3 and second segment coil 4, which are then arranged concentrically.

[0092] Furthermore, the jig rotation process S2 is a process of rotating the jig by rotating the support column 21 by predetermined angles to change the position of the gaps G1, G1 into which the legs 5, 6 of the picked-up segment coils 3, 4 are dropped.

[0093] Specifically, the jig rotation unit 50 is rotated via the rotation drive unit 53, causing the support column 21 of the temporary assembly jig 20 to rotate by a predetermined angle in the R1 direction in Figure 12, thereby changing the position of the gaps G1, G1 into which the legs 5, 6 of the next picked-up segment coils 3, 4 are dropped.

[0094] Furthermore, the coil pressing process S3 involves performing a coil pressing operation to control the position of the segment coils 3 and 4 by pressing the segment coils 3 and 4 that have already been placed radially inward when dropping them into place.

[0095] Specifically, as shown in Figures 12, 13, 15, etc., when dropping in the next segment coils 3, 4 while segment coils 3, 4 are already in place, the coil pressing part 60 operates, and its pressing part 67 presses the already dropped segment coils 3, 4 radially inward.

[0096] As a result, the position of the segment coils 3 and 4 that are about to be installed is regulated so that they overlap correctly with the segment coils 3 and 4 that have already been installed at predetermined positions in the axial and circumferential directions of the temporary assembly jig 20.

[0097] The specific operation of each step will be described in detail below. First, the pickup unit 45 picks up one of the first segment coils 3 that has been temporarily placed in the coil temporary placement unit 30.

[0098] Subsequently, the pickup unit 45 moves so that the legs 5 and 6 of the first segment coil 3 are positioned directly above the predetermined gaps G1, G1 of the temporary assembly jig 20. In this state, the first segment coil 3 is released, causing it to drop into the predetermined gaps G1, G1 so that the legs 5 and 6 are inserted into them.

[0099] At this time, the connecting portion 7 of the first segment coil 3 is placed on the inclined portion 28 of the temporary assembly jig 20, so the connecting portion 7 slides on the inclined portion 28, causing the first segment coil 3 to move slightly outward in the radial direction.

[0100] Subsequently, the pickup unit 45 moves and picks up one of the second segment coils 4 that has been temporarily placed in the coil temporary placement unit 31.

[0101] Then, the pickup unit 45 moves so that the legs 5 and 6 of the second segment coil 4 are positioned directly above the predetermined gaps G1, G1 of the temporary assembly jig 20. At the same time, the coil pressing unit 60 operates, and its pressing unit 67 presses the already dropped first segment coil 3 radially inward, thereby regulating the position of the first segment coil 3.

[0102] In this state, the pickup unit 45 releases the second segment coil 4, causing the legs 5 and 6 to be inserted into the predetermined gaps G1 and G1 (see Figure 12).

[0103] Then, the legs 5 and 6 of the second segment coil 4 are inserted into the gaps G1 and G1 of the temporary assembly jig 20, which already contain the legs 5 and 6 of the first segment coil 3, and the legs 5 and 6 of the second segment coil 4 are inserted into the gaps G1 and G1 that are one position outside the gaps G1 and G1 in the circumferential direction. At the same time, the sides 7b and 7c of the connecting portion 7 of the second segment coil 4 are placed on the sides 7b and 7c of the connecting portion 7 of the first segment coil 3. In other words, the segment coils 3 and 4 are located on a common concentric circle and overlap in the vertical direction, forming a pair of upper and lower segment coils 3 and 4.

[0104] Subsequently, the coil pressing part 60 operates, causing the pressing part 67 to retract and return to its initial position. At the same time, the temporary assembly jig 20 rotates by a predetermined angle in the R1 direction so that the legs 5 and 6 of the next first segment coil 3 are inserted into the gaps G1 and G1 of the temporary assembly jig 20 that are one gap G1 and G1 outward in the circumferential direction from the gaps G1 and G1 of the temporary assembly jig 20 into which the legs 5 and 6 of the second segment coil 4 have already been inserted.

[0105] Subsequently, the pickup unit 45 moves and picks up one of the first segment coils 3 that has been temporarily placed in the coil temporary placement unit 30.

[0106] Then, the pickup unit 45 moves so that the legs 5 and 6 of the first segment coil 3 are positioned directly above the predetermined gaps G1, G1 of the temporary assembly jig 20 (see Figure 13). At the same time, the coil pressing unit 60 operates, and its pressing unit 67 presses the already dropped second segment coil 4 radially inward, thereby regulating the position of the second segment coil 4.

[0107] In this state, the pickup unit 45 releases the first segment coil 3, causing the legs 5 and 6 to be inserted into the predetermined gaps G1 and G1.

[0108] Then, the legs 5 and 6 of the first segment coil 3 are inserted into the gaps G1 and G1 of the temporary assembly jig 20, which are two gaps G1 and G1 further outward in the circumferential direction. At the same time, one side 7b of the connecting portion 7 of the first segment coil 3 is placed so as to straddle the other side 7c of the connecting portion 7 of the second segment coil 4. As a result, the next first segment coil 3 is dropped in such a way that it is offset in the circumferential direction from the second segment coil 4 that has already been dropped in.

[0109] Thereafter, the above operations (A) and (B) are repeated alternately to form a roughly ring-shaped single layer of segment coils, by (A) the retraction of the pressing part 67 of the coil pressing part 60, the rotation of the temporary assembly jig 20 by a predetermined angle in the R1 direction, the pressing and restricting operation of the first segment coil 3 by the pressing part 67 of the coil pressing part 60, and the dropping of the second segment coil 4 by the pickup and release operation; and (B) the retraction of the pressing part 67 of the coil pressing part 60, the rotation of the temporary assembly jig 20 by a predetermined angle in the R1 direction, the pressing and restricting operation of the second segment coil 4 by the pressing part 67 of the coil pressing part 60, and the dropping of the first segment coil 3 by the pickup and release operation, resulting in coil stacking with the next pair of first segment coils 3 circumferentially misaligned relative to a predetermined pair of second segment coils 4.

[0110] Furthermore, when constructing a single-layer segment coil, the end portion of the segment coil (located within a predetermined range centered on the point where the stacking of segment coils 3 and 4 ends) is positioned on the inner diameter side of the starting portion of the segment coil (located within a predetermined range centered on the point where the stacking of segment coils 3 and 4 begins).

[0111] Furthermore, in this unit manufacturing method, one segment coil unit 8 is manufactured by stacking multiple annular segment coil layers radially (in this embodiment, three layers are stacked). In this embodiment, the next segment coil layer is sequentially stacked on the outer diameter side of a predetermined segment coil layer.

[0112] (Gap formation process S5) This gap-forming process S5 is a process in which, when stacking segment coils 3 and 4 by appropriately repeating the coil insertion operation (coil insertion process S1), the jig rotation operation (jig rotation process S2), and the coil pressing operation (coil pressing process S3), a gap-forming tool 85 is inserted into the inner diameter side of the segment coil adjacent to the opposite side in the circumferential direction, so that one side 7b of the connecting portion 7 of the segment coils 3 and 4 overlaps the outer diameter side of the adjacent segment coils 3 and 4 in the circumferential direction, and the other side 7c of the connecting portion 7 of the segment coils 3 and 4 enters the inner diameter side of the adjacent segment coils 3 and 4 on the opposite side in the circumferential direction, thereby forming a gap G2 into which the other side 7c of the connecting portion 7 of the segment coils 3 and 4 enters.

[0113] In this embodiment, when the next segment coil layer is superimposed on the outer diameter side of a predetermined segment coil layer, the end portion of the next segment coil layer (the end portion of the segment coil superposition in the predetermined layer) is positioned on the inner diameter side of the starting portion of the next segment coil layer (the beginning portion of the segment coil superposition in the predetermined layer). However, since the previous segment coil layer already exists on the inner diameter side of the starting portion of the next segment coil layer, it is not possible to position the end portion of the next segment coil layer on the inner diameter side of the starting portion of the next segment coil layer in this manner.

[0114] Therefore, this gap-forming step S5 forms a gap G2 between the previously existing segment coil layer and the starting end portion of the next segment coil layer that overlaps on the outer diameter side.

[0115] For example, when positioning the end portion of the second segment coil layer on the inner diameter side of the starting end portion of the second segment coil layer, a gap G2 is formed between the first segment coil layer and the starting end portion of the second segment coil layer. Similarly, when positioning the end portion of the third segment coil layer on the inner diameter side of the starting end portion of the third segment coil layer, a gap G2 is formed between the second segment coil layer and the starting end portion of the third segment coil layer.

[0116] Specifically, the coil insertion process S1, the jig rotation process S2, and the coil pressing process S3 are repeated as appropriate to determine whether or not a gap G2 needs to be formed when stacking the segment coils 3 and 4 (see S4 in Figure 11). If it is determined that a gap G2 needs to be formed, the gap forming unit 80 moves the gap forming tool 85 as appropriate via the moving parts 82, 83, and 84, and moves it directly above the space between the segment coils where the gap G2 should be formed. If it is determined that gap formation is not necessary, the process proceeds to the next step.

[0117] Subsequently, as the gap-forming tool 85 descends by the second moving part 83, as shown in Figure 15, the gap-forming tool 85 enters between one side 7b of the connecting portion 7 of a predetermined segment coil 3, 4 located radially outward of the temporary assembly jig 20 and one side 7b of the connecting portion 7 of a predetermined segment coil 3, 4 located radially inward and adjacent to the segment coil 3, 4.

[0118] As a result, a gap G2 is formed between one side 7b of the connecting portion 7 of the radially outer segment coils 3 and 4 and one side 7b of the connecting portion 7 of the radially inner segment coils 3 and 4, allowing the other side 7c of the connecting portion 7 of the segment coil 3 and 4 that is about to be inserted to fit in (see Figure 14).

[0119] As a result, one side 7b of the connecting portion 7 of the segment coils 3 and 4 that are to be inserted is positioned to overlap the outer diameter side of the adjacent segment coils 3 and 4 in the circumferential direction (see Figure 15), and the other side 7c of the segment coils 3 and 4 that are to be inserted into the gap G2 (not shown in Figure 15) fits into it.

[0120] More specifically, as shown in Figure 14, the gap-forming tool 85 is inserted between one side 7b of the connecting portion 7 of the segment coils 3 and 4 that constitute the starting end portion of the second segment coil layer and one side 7b of the connecting portion 7 of the segment coils 3 and 4 of the first segment coil layer, which is positioned adjacent to it on its inner diameter side. This creates a gap G2 between the starting end portion of the second segment coil layer and the first segment coil layer, into which the other side 7c of the connecting portion 7 of the segment coils 3 and 4 that constitute the ending end portion of the second segment coil layer can enter.

[0121] Subsequently, the coil pressing unit 60 operates, and the pressing unit 67 presses the segment coils 3 and 4, which have already been dropped in, radially inward, thereby regulating the position of the segment coils 3 and 4. As a result, one side 7b of the connecting portion 7 of the segment coils 3 and 4 that constitute the end portion of the second segment coil layer is positioned to overlap the outer diameter side of the adjacent segment coils 3 and 4 in the circumferential direction (see Figure 15), and the other side 7c of the connecting portion 7 of the segment coils 3 and 4 that constitute the end portion of the second segment coil layer (not shown in Figure 15) fits into the gap G2.

[0122] (Lift-up process S7) This lift-up process S7 is a process in which, after the insertion of the legs 5 and 6 of the segment coils 3 and 4 into all the gaps G1 of the temporary assembly jig 20 is completed, the annular support plate 70 positioned below the temporary assembly jig 20 is raised to lift the legs 5 and 6 of the segment coils 3 and 4, and then the annular support plate 70 is lowered to support them again on the temporary assembly jig 20.

[0123] Specifically, when it is determined that the legs 5 and 6 of the segment coils 3 and 4 have been inserted into all the gaps G1 of the temporary assembly jig 20 by the coil insertion process S1 and the jig rotation process S2 described above, and that one roughly annular segment coil layer has been formed (S6 in Figure 11), the lifting unit 71 is driven to raise the annular support plate 70. Then, the inclined surface of the annular projection 73 of the annular support plate 70 lifts the tips (lower ends) of the legs 5 and 6 of the segment coil layer (see Figure 16). Figure 16 shows the lift-up when three segment coil layers have been stacked.

[0124] Furthermore, if the determination step S6 determines that the legs 5 and 6 of the segment coils 3 and 4 are not inserted into all of the gaps G1 of the temporary assembly jig 20, the process returns to the coil insertion step S1.

[0125] Subsequently, the lifting mechanism 71 is driven to lower the annular support plate 70, and it is supported again by the temporary assembly jig 20.

[0126] The lift-up operation described above is performed each time a roughly annular segment coil layer is formed. In this embodiment, the segment coil unit 8 is composed of three roughly annular segment coil layers stacked radially, so the pickup operation is performed three times.

[0127] (Overlapping of segment coil layers) After the lift-up process S7 described above, it is determined whether the necessary number of segment coil layers to form the desired segment coil unit 8 have been stacked (see S8 in Figure 11). If the required number of segment coil layers have been stacked, the manufacturing process for the segment coil unit 8 is completed. If the required number of segment coil layers have not been stacked, the process returns to the coil insertion process S1 and each step is repeated.

[0128] (Effects and Benefits) Next, the effects of the unit manufacturing method and unit manufacturing apparatus 10 according to the present invention, which have the above configuration, will be described.

[0129] In other words, in the unit manufacturing method and unit manufacturing apparatus, by using a temporary assembly jig 20 and appropriately repeating the segment insertion operation (segment insertion step S1), the jig rotation operation (jig rotation step S2), and the coil pressing operation (coil pressing step S3) (see Figures 12 and 13, etc.), a plurality of segment coils 3, 4 can be temporarily assembled to fit the slots 210 of the stator core 200 to be applied, thereby manufacturing a single segment coil unit 8.

[0130] Furthermore, since an inclined portion 28 is provided above the hook portion 23 that constitutes the temporary assembly jig 20, which is inclined to gradually descend in the outer diameter direction, the dropped segment coil (in this embodiment, the first segment coil 3 in particular) can be slightly shifted in the outer diameter direction.

[0131] Furthermore, when dropping in the segment coils 3 and 4, a coil pressing operation is performed to restrict the position of the segment coils 3 and 4 that have already been dropped in by pressing them radially inward. This allows the segment coils to be dropped to be correctly stacked on top of the segment coils 3 and 4 that have already been dropped and whose positions have been restricted, so that they are in the predetermined position, and so that multiple segment coils 3 and 4 can be stacked in a substantially spiral shape.

[0132] In other words, the inclined portion 28 allows the segment coil to be slightly shifted in the outer diameter direction during the segment coil insertion process, thereby improving the manufacturability of the segment coil unit 8. Furthermore, the position of the segment coil that has been shifted in the outer diameter direction can be controlled by the coil pressing operation, thus maintaining the position of the inserted segment coil and stably preserving the shape of the segment coil unit.

[0133] Therefore, a single segment coil unit 8 can be manufactured stably and efficiently by stacking multiple segment coils 3 and 4 so that they overlap in a roughly spiral shape.

[0134] Furthermore, by aligning the legs 5 and 6 of the segment coil unit 8 manufactured as described above with the slots 210 of the stator core 200 and inserting them, the legs 5 and 6 of all the segment coils 3 and 4 can be inserted simultaneously into the corresponding slots 210 of the stator core 200.

[0135] In the unit manufacturing method and unit manufacturing apparatus 10 according to the present invention, a sloping portion 28 is provided that gradually slopes toward the outer diameter. However, if the sloping portion were to be configured to gradually slope toward the inner diameter, the distance between the outer diameter peripheral portion of the temporary assembly jig and the axis would be fixed, and there is a risk that the desired number of segment coils could not be inserted due to dimensional errors in the segment coils themselves, or due to impacts or misalignment when dropping the segment coils.

[0136] Furthermore, because the segment coil moves in a direction that fixes the distance between the outer diameter peripheral portion of the temporary assembly jig and the axis, it is necessary to ensure high machining accuracy for the segment coil itself. Moreover, it is necessary to ensure high accuracy for the position of the segment coil when it is dropped (inserted), which leads to increased equipment costs.

[0137] In contrast, the unit manufacturing method and unit manufacturing apparatus 10 according to the present invention are provided with an inclined portion 28 that gradually slopes toward the outer diameter, allowing the dropped segment coils 3 and 4 to slide toward the outer diameter while simultaneously restricting their position. Furthermore, a coil pressing portion 60 for simply pressing the coils is partially positioned on the outer circumference of the temporary assembly jig 20, allowing for coil pressing operations as needed. There is no configuration to fix the distance between the axis of the temporary assembly jig 20 and the peripheral portion toward the outer diameter, and the distance between the axis of the temporary assembly jig 20 and the peripheral portion toward the outer diameter is not fixed but free, so the desired number of segment coils 3 and 4 can be reliably and easily dropped and inserted.

[0138] Furthermore, in this embodiment, a gap formation operation (gap formation step S5) is performed as described above (see Figures 14 and 15, etc.).

[0139] According to the above embodiment, by performing a gap-forming operation using the gap-forming tool 85, the other side 7c of the connecting portion 7 of the segment coils 3 and 4 can be reliably inserted into the inner diameter side of the adjacent segment coil 3 and 4 on the opposite side in the circumferential direction. As a result, multiple segment coils 3 and 4 can be stacked more reliably and easily so that they overlap in a substantially spiral shape.

[0140] Furthermore, in this embodiment, a lift-up operation (lift-up process S7) is performed as described above (see Figure 16).

[0141] According to the above embodiment, the lifting operation of the annular support plate 70 by the lifting unit 71 lifts up the segment coils 3 and 4 hooked onto the temporary assembly jig 20, and then hooks them onto the temporary assembly jig 20 again. This allows the multiple segment coils 3 and 4 to be realigned and stacked more correctly so that they overlap in a roughly spiral shape.

[0142] Furthermore, in this embodiment, as described above, the first segment coil 3 and the second segment coil 4 are sequentially picked up and inserted concentrically, and then the support column 21 is rotated by a predetermined angle to insert the next first segment coil 3 and second segment coil 4 which are arranged concentrically.

[0143] According to the above embodiment, a single segment coil unit 8, as shown in Figure 4, can be manufactured by concentrically winding and distributed winding using the first segment coil 3 and the second segment coil 4.

[0144] (An embodiment of a segment coil unit insertion device) Next, one embodiment of a segment coil unit insertion device will be described.

[0145] As shown in Figures 1 to 3, the segment coil unit insertion device 100 (hereinafter also simply referred to as "unit insertion device 100") inserts a segment coil unit 8 (see Figure 4), which is temporarily assembled by stacking a plurality of segment coils 3, 4 (see Figures 5 and 6), each having a pair of legs 5, 6 and a connecting portion 7 that connects the pair of legs 5, 6, into the slot 210 of the stator core 200 (see Figure 7), into the slot 210 of the stator core 200.

[0146] As shown in Figures 1 to 3, the unit insertion device 100 mainly consists of an insertion guide 110 having an opening 123 and a guide piece 124 with a guide groove 127, a push-up member 130, a unit supply unit 140 having a chuck 145, a unit transport unit 143, a unit lifting unit 144, a core supply unit 150 having a core receiving unit 151 and a core transport unit 153, and a coil pusher 170.

[0147] (Structure of insertion guide 110) As shown in Figures 17 and 18, the insertion guide 110 has an opening 123 into which the legs 5 and 6 of the segment coil unit 8 are inserted, and a plurality of guide pieces 124 arranged at predetermined intervals on the inner circumference of the opening 123 and capable of extending and retracting in the radial direction, and each guide piece has a guide groove 127 that guides the legs 5 and 6 to the corresponding slots 210 of the stator core 200.

[0148] As shown in Figure 2, the insertion guide 110 is installed in the other region of the base portion 11 in the Y direction, approximately midway in the Y direction and closer to the other side in the X direction. Furthermore, the insertion guide 110 is installed in a position that aligns with the X direction of the base portion 11 with respect to the temporary assembly jig 20 that constitutes the unit manufacturing method and unit manufacturing apparatus 10 described above.

[0149] As shown in Figure 17, the base portion 11 is fitted with a pair of left and right support portions 111 and 112, which are roughly elongated and plate-shaped, supported by multiple support columns. The longitudinal direction of the support portions 111 and 112 is aligned with the X direction of the base portion 11. Furthermore, sliders 121 and 122 are positioned on the support portions 111 and 112, which are capable of reciprocating movement in the X direction of the base portion 11 by drive units 111a and 112a.

[0150] Furthermore, a guide retractable frame section 113 is installed on the longitudinal inner edges of the pair of support sections 111 and 112 via multiple column sections, allowing the guide piece 124 to extend and retract. Above this guide retractable frame section 113, an annular section 115, which is roughly the shape of a ring plate, is placed. An opening 123, which is roughly the shape of a ring, is provided on the radially inner side of these guide retractable frame sections 113 and annular section 115.

[0151] As shown in Figure 17, the guide retractable frame section 113 is provided with a plurality of frame sections 114 that extend toward the axis (radial center) of the insertion guide 110 and have an open radial end. The tip opening of each frame section 114 is positioned slightly radially outward from the inner circumference of the opening 123.

[0152] Each frame portion 114 houses and arranges a guide piece 124 so as to be able to slide back and forth. As shown in Figure 18, the guide piece 124 has a base portion 125 that is roughly elongated and block-shaped, and a pair of claw portions 126, 126 that protrude from the tip of the base portion 125, with the guide groove 127 provided between the pair of claw portions 126, 126. In addition, a rotatably supported cam follower 128 is arranged at the base end of the base portion 125 of each guide piece 124.

[0153] Furthermore, the guide groove 127 formed between the pair of claw portions 126, 126 has an opening at its tip (the side facing the axis of the insertion guide 110). Also, each slot 210 of the stator core 200 is positioned and supported by the core receiving portion 151 of the core supply portion 150 so as to align with the corresponding guide piece 124 of the insertion guide 110. For this reason, the guide groove 127 of each guide piece 124 has an opening on the side facing the opening of the slot 210 of the stator core 200.

[0154] Furthermore, above the guide retractable frame portion 113 and below the annular portion 115, an annular plate 117, which is roughly annular in shape, is arranged so as to be rotatable by a predetermined angle. As shown in Figure 18, a plurality of roughly arc-shaped cam grooves 118 are formed in this annular plate 117. Each cam groove 118 is arranged in a manner that is obliquely curved so as to be offset in the circumferential direction from the radially inner to the radially outer side of the annular plate 117 (the radially inner position and the radially outer position do not align in the circumferential direction and are misaligned), and these cam grooves 118 are formed around the entire circumference of the annular plate 117.

[0155] Furthermore, projecting end pieces 119 and 120 are provided on the outer peripheral edge of the annular plate 117 at radially opposite locations. End piece 119 is connected to a slider 121 located on the support portion 111, and end piece 120 is connected to a slider 122 located on the support portion 112.

[0156] Then, as shown in Figure 18, when the slider 121 is positioned on one end of the support portion 111 in the X direction (towards the viewer) and the slider 122 is positioned on the other end of the support portion 112 in the X direction (towards the viewer), the cam follower 128 is positioned on the inner end side of the cam groove 118, and the pair of claw portions 126, 126 and guide grooves 127 of each guide piece 124 are positioned to protrude from the inner circumference of the opening 123 (see Figure 27).

[0157] On the other hand, when slider 121 moves to the other end of support portion 111 in the X direction, and slider 122 moves to one end of support portion 112 in the X direction, the annular plate 117 rotates in the direction of arrow R2 in Figure 18, and the cam groove 118 presses against the cam follower 128, causing the cam follower 128 to move to the outer end of the cam groove 118, so that the pair of claw portions 126, 126 and the guide groove 127 move so that each guide piece 124 is pulled in from the inner circumference of the opening 123 (see Figure 35).

[0158] Furthermore, an insulating sheet 220 having a cuff portion 221 is pre-inserted into the slot 210 of the stator core 200, and when the guide piece 124 is viewed from the axial direction of the stator core 200 with the guide piece 124 protruding from the inner circumference of the opening 123, the cuff portion 221 of the insulating sheet 220 is configured to be hidden and covered from the guide groove 127 of the guide piece 124.

[0159] Specifically, the insulating sheet 220 insulates the inner circumference of the slot 210 and has an elongated rectangular frame shape, with a cuff portion 221 protruding like a cuff at one end in its extending direction. Such insulating sheets 220 are pre-inserted into each slot 210 of the stator core 200.

[0160] Furthermore, with the guide piece 124 protruding from the inner circumference of the opening 123 (see Figure 27), when the guide piece 124 is viewed from the axial direction of the stator core 200, the cuff portion 221 of the insulating sheet 220 is hidden and covered from the guide groove 127.

[0161] (Configuration of the push-up member 130) The push-up member 130 is positioned below the insertion guide 110, with the core receiving portion 151 retracted from below the insertion guide 110, and is capable of moving up and down toward the lower surface of the insertion guide 110.

[0162] Specifically, as shown in Figure 17, a retractable opening 131 is formed by cutting out the base portion 11 below the insertion guide 110, and a base portion 133 is positioned to align with this retractable opening 131. A substantially circular plate-shaped pressing plate 135 is provided on the upper part of the base portion 133, and an inclined surface 136 is formed on the radially inner circumference side of this pressing plate 135. Furthermore, a drive unit (not shown) allows the pressing plate 135 to reciprocate (or move up and down) relative to the base portion 133 in the Z direction of the base portion 11.

[0163] The drive unit causes the pressing plate 135 to move up and down, so that it extends and retracts from the retraction opening 131, and during this movement, the pressing plate 135 presses against the tips of the legs 5 and 6 of the segment coil unit 8.

[0164] Furthermore, the push-up member 130 is configured to operate at the following timings: The unit lifting unit 144 lowers the segment coil unit 8, and before the legs 5 and 6 are inserted into the slots 210 of the stator core 200 through the guide grooves 127 of the guide piece 124, the push-up member 130 is raised to push up the tips of the legs 5 and 6 by a predetermined distance, thereby aligning the height of the segment coils 3 and 4 and the alignment of the legs 5 and 6 in the circumferential direction.

[0165] Specifically, at the timing described above (before the segment coil unit 8 is lowered by the unit lifting section 144), as shown in Figure 28, the pressing plate 135 rises through the retractable opening 131, and the pressing plate 135 presses the tips of the legs 5 and 6 of the segment coil unit 8, pushing them up by a predetermined distance to align the height of the segment coils 3 and 4 and the alignment of the legs 5 and 6 in the circumferential direction. After that, as shown in Figure 29, the pressing plate 135 descends and moves below the base section 11 through the retractable opening 131, retracting to a position where it does not interfere with the operation of the core transport section 153, etc.

[0166] (Configuration of the unit supply unit 140) The unit supply unit 140 includes a chuck 145 that grips the inner and outer circumferences of the annularly stacked connecting portion 7 of the segment coil unit 8, a unit transport unit 143 that transports the segment coil unit 8 held by the chuck 145 above the insertion guide 110, and a unit lifting unit 144 that moves the chuck 145 up and down.

[0167] Specifically, as shown in Figure 1, a pair of support columns 141, 141 are erected at the other end of the base portion 11 in the X direction and at both ends in the Y direction, and a long plate portion 142, which is roughly the shape of a long plate, is installed on this pair of support columns 141, 141. The long plate portion 142 is arranged to span one region and the other region of the base portion 11 in the Y direction.

[0168] A pair of rails 142a, 142a, which form protrusions, are provided on the long plate section 142, extending parallel to each other along the longitudinal direction. A unit transport section 143 is provided via these rails 142a, 142a, which is capable of reciprocating in the Y direction of the base section 11 by a drive unit 143a. A unit lifting section 144 is provided on this unit transport section 143, which is capable of reciprocating (lifting and lowering) in the Z direction of the base section 11 by a drive unit 144a.

[0169] Furthermore, a chuck 145 is provided on the unit lifting section 144. As shown in Figure 19, the chuck 145 has a retaining recess 146 that is in the shape of an upwardly recessed circular concave, provided on the lower surface of the unit lifting section 144, a plurality of (four in this case) substantially arc-shaped pressing portions 147 that are evenly arranged in the circumferential direction on the inner circumferential surface of the retaining recess 146, and a plurality of clamping blocks 148 that are arranged radially inward of the retaining recess 146 and reciprocate relative to the radial direction of the retaining recess 146 via a drive unit (not shown).

[0170] Each clamping block 148 has an outer surface that forms a substantially arc-shaped clamping surface 148a that fits the pressing portion 147, and consists of multiple blocks (four in this case) arranged opposite the corresponding pressing portion 147, and is designed to move toward and away from the corresponding pressing portion 147. Furthermore, all of the multiple clamping blocks 148 are designed to move back and forth simultaneously in conjunction with each other.

[0171] Then, as the multiple clamping blocks 148 move closer to the multiple pressing portions 147, the inner and outer circumferences of the annularly stacked connecting portions 7 of the segment coil unit 8 are clamped by the pressing portions 147 and the clamping surfaces 148a of the clamping blocks 148.

[0172] On the other hand, as the multiple clamping blocks 148 move apart from the multiple pressing portions 147, the clamping of the connecting portion 7 of the segment coil unit 8 by the pressing portions 147 and the clamping surfaces 148a of the clamping blocks 148 is released, making the segment coil unit 8 available for release.

[0173] Furthermore, when it is not necessary to chuck the segment coil unit 8 with the chuck 145, the unit lifting section 144 is retracted upward in the Z direction so as not to interfere with the temporary assembly jig 20 of the unit manufacturing apparatus 10 (see Figures 1-3).

[0174] The unit supply unit configured as described above is configured to perform the following operation: The unit supply unit 140 positions the segment coil unit 8 above the insertion guide 110 (see Figure 23).

[0175] Specifically, after the segment coil unit 8 is manufactured by the unit manufacturing device 10, as shown in Figure 23, the unit transport unit 143 moves to one area in the Y direction of the base unit 11 (the area where the unit manufacturing device 10 is located), and the chuck 145 moves until it is directly above the segment coil unit 8.

[0176] Subsequently, the unit lifting section 144 descends (moves downward in the Z direction), and the upper part of the segment coil unit 8 (the part where multiple connecting sections 7 of multiple segment coils 3 and 4 are arranged) is inserted into the holding recess 146 of the chuck 145 (see Figure 24).

[0177] In this state, multiple clamping blocks 148 move closer to multiple pressing portions 147, and the upper part of the segment coil unit 8 is clamped by the clamping surface 148a and the pressing portions 147. While maintaining this clamping state, the unit lifting portion 144 rises (moves upward in the Z direction), and then the unit transport portion 143 moves until it is directly above the insertion guide 110, positioning the segment coil unit 8 above the insertion guide 110 (see Figure 25).

[0178] Furthermore, after the stator core 200 is positioned below the insertion guide 110 by the core supply unit 150 (see Figure 29), the segment coil unit 8 is lowered by the unit lifting unit 144 with the guide piece 124 of the insertion guide 110 protruding from the inner circumference of the opening 123, and the legs 5 and 6 are partially inserted into the corresponding slots 210 of the stator core 200 through the guide grooves 127 of the guide piece 124 (see Figure 30).

[0179] Specifically, in the state described above (where the guide piece 124 of the insertion guide 110 protrudes from the inner circumference of the opening 123), the unit lifting section 144 descends, lowering the segment coil unit 8, and guiding its legs 5 and 6 with the guide groove 127 of the guide piece 124, it is inserted partway into the corresponding slot 210 of the stator core 200 (see Figure 30).

[0180] In other words, the legs 5 and 6 are not inserted into the entire length of the slot 210 in the axial direction (height direction), but are inserted only up to a predetermined position in the axial direction of the slot 210. To put it another way, the opposing legs 5 and 6 of the segment coil unit 8 are partially inserted into each slot 210 of the stator core 200.

[0181] Furthermore, in the above state, the chuck 145 is opened, leaving the segment coil unit 8 in place, and the chuck 145 constituting the unit supply section 140 is moved away from above the insertion guide 110 (see Figure 31).

[0182] Specifically, in the state described above (with the legs 5 and 6 of the segment coil unit 8 inserted partway into the corresponding slots 210 of the stator core 200), the multiple clamping blocks 148 move apart from the multiple pressing parts 147, releasing the clamped state of the segment coil unit 8. In this state, the unit lifting unit 144 rises, and the chuck 145 moves to one side in the Y direction in the unit transport unit 143, thereby retracting the chuck 145 from above the insertion guide 110 (see Figure 31), leaving only the segment coil unit 8.

[0183] (Configuration of the core supply unit 150) As shown in Figure 17, the core supply unit 150 includes a core receiving unit 151 that supports the stator core 200 so that it can move up and down, and a core transport unit 153 that moves the core receiving unit 151 below the insertion guide 110.

[0184] Specifically, the core transport section 153 is arranged on both sides of the retractable opening 131 cut out in the base section 11 and includes a pair of guide rails 154, 154 that extend parallel to each other along the X direction of the base section 11, a base section 155 that is roughly elongated in the Y direction and slightly longer in the X direction, and is guided by the pair of guide rails 154, 154 so as to be able to reciprocate in the X direction, a guide section 156 that is arranged adjacent to one longitudinal side of the base section 155 and extends along the X direction of the base section 11, and a slider 157 that is attached to one longitudinal side of the base section 155 and is able to reciprocate in the X direction of the base section 11.

[0185] Furthermore, as shown in Figure 20, the core receiving section 151 includes a plurality of plate-like bodies 158, 159 positioned above the base 155 of the core transport section 153, a support column 160 that is erected from the upper plate-like body 159 and has a substantially cylindrical shape that fits the inner circumference of the stator core 200, an annular plate 161 positioned above the plate-like bodies 159 and on the outer circumference of the support column 160, and an annular frame 162 positioned above the annular plate 161 and on the outer circumference of the support column 160.

[0186] The annular frame 162 described above has a bottom portion 163 and is capable of supporting the bottom portion of the stator core 200. In addition, multiple insertion holes 164 are radially formed in the bottom portion 163 of the annular frame 162 for inserting the legs 5 and 6 of the segment coil unit 8. Furthermore, the core receiving portion 151 is capable of reciprocating (moving up and down) in the Z direction of the base portion 11 by a drive unit (not shown) above the base portion 155 of the core transport portion 153.

[0187] The stator core 200 is received and supported by the core receiving portion 151 configured as described above. Specifically, the support column portion 160 of the core receiving portion 151 is inserted into the stator core 200, and the bottom portion 163 of the annular frame 162 supports the bottom of the stator core 200, thereby supporting the stator core 200 in the core receiving portion 151. At this time, the core receiving portion 151 is positioned and supported so that each slot 210 of the stator core 200 aligns with the corresponding guide piece 124 of the insertion guide 110.

[0188] Furthermore, as the core supply unit 150's core transport unit 153 reciprocates along the guide unit 156 in the X direction, the base unit 155 also reciprocates in the X direction, and the core receiving unit 151 is capable of reciprocating in the Z direction of the base unit 11 by a drive unit (not shown).

[0189] Furthermore, multiple guide ribs 165 are provided protruding from the upper outer circumference of the support column 160 that constitutes the core receiving portion 151, corresponding to the slots 210 of the stator core 200. The outer circumference of the upper end of each guide rib 165 forms an inclined surface 166 that gradually slopes downwards toward the top.

[0190] In this embodiment, the guide ribs 165 are elongated plate-like structures that extend along the axial direction of the support column 160 on the upper outer circumference in the vertical direction (direction along the Z direction) of the support column 160, and multiple such ribs are provided at equal intervals in the circumferential direction. Furthermore, the outer circumference of the upper end of each guide rib 165 in the vertical direction forms an inclined surface 166 in which the amount of outward projection from the support column 160 gradually decreases toward the upward direction of the guide rib.

[0191] Furthermore, when the legs 5 and 6 of the segment coil unit 8 are inserted, the upper part of the support column 160 protrudes from the upper end surface of the stator core 200, and the inclined surface 166 of the guide rib 165 forms a guide surface for the legs 5 and 6.

[0192] Specifically, as shown in Figure 21, the support column 160 is inserted into the stator core 200, and the bottom of the stator core 200 is supported by the bottom 163 of the annular frame 162. The upper part of the support column 160 protrudes from the upper end surface of the stator core 200, and the inclined surface 166 of the guide rib 165 is located radially inward of the corresponding slot 210 of the stator core 200, and is located above the cuff portion 221 of the insulating sheet 220 inserted into the corresponding slot 210 in the Z direction.

[0193] Therefore, when inserting the legs 5 and 6 of the segment coil unit 8 into the slots 210 of the stator core 200, the tips (lower ends) of the legs 5 and 6 are guided radially outward by the inclined surface 166 of the guide rib 165, so as to be inserted into the corresponding slots 210, and the inclined surface 166 of the guide rib 165 functions as a guide surface for the legs 5 and 6.

[0194] Then, the core supply unit 150 operates so that, after the unit supply unit 140 positions the segment coil unit 8 above the insertion guide 110, the stator core 200 is positioned below the insertion guide 110 (see Figure 29).

[0195] Specifically, after the unit supply unit 140 moves the segment coil unit 8 above the insertion guide 110, the push-up member 130 rises and pushes up the legs 5 and 6 (see Figure 28). After the push-up member 130 descends and retracts, the core supply unit 150 moves to the other side in the X direction and moves the stator core 200 until it is positioned directly below the insertion guide 110 (see Figure 29). In other words, the core transport unit 153 supplies the stator core 200 to below the insertion guide 110. Subsequently, the core supply unit 150 rises, raising the stator core 200 accordingly (see Figure 30).

[0196] Furthermore, after the coil pusher 170 fully inserts the legs 5 and 6 of the segment coil unit 8 into the slots 210 of the stator core 200, the core supply unit 150 descends, moves further to one side in the X direction, and returns to its initial position, making the stator core 200 removable (see Figure 37).

[0197] (Configuration of coil pusher 170) The coil pusher 170 is movably positioned above the insertion guide 110 and performs a vertical movement to press against the top of the segment coil unit 8, pushing the legs 5 and 6 into the slots 210 of the stator core 200 (see Figures 33, 34, 36, etc.).

[0198] As shown in Figures 1-3 and 32-34, the coil pusher 170 has a first movable part 171 that is reciprocally movable in the Y direction of the base part 11 by a drive unit (not shown) via a pair of rails 142a, 142a of the long plate part 142 that constitute the unit supply part 140, a second movable part 172 provided on the first movable part 171 that is reciprocally movable (up and down) in the Z direction of the base part 11, and a pressing part 173 that has a substantially annular frame shape and is provided on the lower side of the second movable part 172 and presses the upper part of the segment coil unit 8.

[0199] The coil pusher 170 is configured to perform the following operations.

[0200] Specifically, as shown in Figures 34-36, the coil pusher 170 is moved above the insertion guide 110, the guide piece 124 is pulled in from the inner circumference of the opening 123 to a position where the coil pusher 170 does not interfere, and the coil pusher 170 is lowered to fully insert the legs 5 and 6 of the segment coil unit 8 into the slots 210 of the stator core 200. In other words, the final insertion is performed to fully insert the opposing legs 5 and 6 of the segment coil unit 8 into each slot 210 of the stator core 200.

[0201] In this embodiment, as described above, when the guide piece 124 is pulled in from the inner circumference of the opening 123 to a position where it does not interfere with the coil pusher 170, the guide piece 124 is configured to be pulled in from the inner circumference of the opening 123 so as not to interfere with the sides 7b and 7c of the connecting portion 7 of the first and second segment coils 3 and 4 that constitute the segment coil unit 8.

[0202] Furthermore, the insertion of the legs 5 and 6 by the coil pusher 170 is configured to consist of a first pressing operation (see Figure 33) in which the guide piece 124 protrudes from the inner circumference of the opening 123 and the legs 5 and 6 are inserted partway into the corresponding slots 210 of the stator core 200, and a second pressing operation (see Figure 36) in which the guide piece 124 is pulled back from the inner circumference of the opening 123 to a position where the coil pusher 170 does not interfere and the legs 5 and 6 are fully inserted into the corresponding slots 210 of the stator core 200.

[0203] Specifically, after the lifting member 130 moves up and down, and the core supply unit 150 supplies the stator core 200 to below the insertion guide 110, the coil pusher 170 moves above the insertion guide 110 (see Figure 32).

[0204] At this time, the tip of each guide piece 124 protrudes from the inner circumference of the opening 123 of the insertion guide 110, and the guide groove 127 protrudes from the inner circumference of the opening 123 (see Figure 27). From this state, as shown in Figure 33, the coil pusher 170 descends, and its pressing part 173 presses against the upper part of the segment coil unit 8, performing a first pressing operation so that the legs 5 and 6 of the segment coil unit 8 are inserted partway into the corresponding slots 210 of the stator core 200 (the legs 5 and 6 are inserted to a predetermined axial position in the slots 210 of the stator core 200).

[0205] Subsequently, as the sliders 121 and 122 of the insertion guide 110 move, the pair of claw portions 126, 126 and the guide groove 127 are moved so that each guide piece 124 is pulled in from the inner circumference of the opening 123, as shown in Figure 35, so that the tip of each guide piece 124 is pulled in from the inner circumference of the opening 123 to a position where the coil pusher 170 does not interfere.

[0206] In this state, as shown in Figure 36, the coil pusher 170 descends further, and the pressing part 173 presses against the upper part of the segment coil unit 8, performing a second pressing operation so that the legs 5 and 6 of the segment coil unit 8 are fully inserted into the corresponding slots 210 of the stator core 200.

[0207] Furthermore, when the legs 5 and 6 of the segment coil unit 8 are said to be fully inserted into the slot 210 of the stator core 200, it means that the legs 5 and 6 are inserted throughout the entire axial area of ​​the slot 210, and the tips (lower ends) of the legs 5 and 6 are inserted through the lower opening of the slot 210.

[0208] (Method for inserting the segment coil unit) Next, a method for inserting the segment coil unit 8, specifically for inserting the legs 5 and 6 of the temporarily assembled segment coil unit 8 into the corresponding slots 210 of the stator core 200, will be described.

[0209] As shown in Figure 22, the method for inserting the segment coil unit in this embodiment (hereinafter also simply referred to as the "unit insertion method") includes a unit transport step S10, a unit lowering step S11, a guide piece protrusion step S12, a pressing member operation step S13, a core supply step S14, a leg insertion step S15, a pusher movement step S16, a first pressing operation step S17, a guide piece retraction step S18, a second pressing operation step S19, and a core retraction step S20. These will be described in detail below.

[0210] (Unit transport process S10) This unit transport process S10 is a process of positioning the segment coil unit 8 above the insertion guide 110.

[0211] Specifically, the unit transport unit 143 moves the chuck 145 until it is directly above the segment coil unit 8 (see Figure 23), then the unit lifting unit 144 descends to grip the upper part of the segment coil unit 8 (see Figure 24), after which the unit lifting unit 144 rises, and then the unit transport unit 143 moves the segment coil unit 8 so that it is positioned above the insertion guide 110 (see Figure 25).

[0212] (Unit lowering process S11) This unit lowering process S11 is a process in which the unit lifting section 144 is lowered from a state in which the chuck 145 is positioned above the insertion guide 110, so that the tips of the legs 5 and 6 of the segment coil unit 8 are inserted through the lower opening 123 of the opening 110.

[0213] Specifically, from the state described above (where the chuck 145 is positioned above the insertion guide 110) (see Figure 25), the unit lifting section 144 descends, inserting the legs 5 and 6 of the segment coil unit 8 into the opening 123 of the insertion guide 110. In this state, the tip of the guide piece 124 is positioned inside the opening 123 (see Figure 25).

[0214] Then, the unit lifting section 144 descends (see Figure 26) until the bottom surface of the chuck 145 contacts the upper outer edge of the opening 123 of the insertion guide 110, allowing the tips of the legs 5 and 6 of the segment coil unit 8 to be inserted through the lower opening 123 of the insertion guide 110.

[0215] (Guide piece protrusion process S12) This guide piece protrusion process S12 is a process in which, before the leg portions 5,6 of the segment coil unit 8 are inserted into the slots 210 of the stator core 200, the tip of each guide piece 124 protrudes from the inner circumference of the opening 123 of the insertion guide 110, as shown in Figure 27.

[0216] Specifically, first, at the timing described above (before the segment coil unit 8's legs 5 and 6 are inserted into the slots 210 of the stator core 200, i.e., before the segment coil unit 8 is lowered by the unit lifting mechanism 144), as shown in Figure 27, the tip of each guide piece 124 protrudes from the inner circumference of the opening 123 of the insertion guide 110, and the guide groove 127 protrudes from the inner circumference of the opening 123. This causes the tips of the legs 5 and 6 to be inserted into the guide groove 127, aligning the circumferential alignment of the tips of the legs 5 and 6 to a predetermined position.

[0217] (Push-up member operation process S13) This push-up member operation step S13 involves lowering the segment coil unit 8 using the unit lifting section 144, and before inserting the legs 5 and 6 into the slots 210 of the stator core 200 through the guide grooves 127 of the guide piece 124, raising the push-up member 130 to push up the tips of the legs 5 and 6 by a predetermined distance, thereby aligning the height of the segment coils 3 and 4 and the alignment of the legs 5 and 6 in the circumferential direction.

[0218] Specifically, at the timing described above (before the segment coil unit 8 is lowered by the unit lifting section 144), as shown in Figure 27, the tip of each guide piece 124 protrudes from the inner circumference of the opening 123 of the insertion guide 110, and the guide groove 127 protrudes from the inner circumference of the opening 123. From this state, as shown in Figure 26, the push-up member 130, which is located below the retractable opening 131, rises.

[0219] Specifically, the pressing plate 135 rises through the retractable opening 131, pressing against the tips of the legs 5 and 6 of the segment coil unit 8, pushing them up by a predetermined distance to align the heights of the segment coils 3 and 4, and also aligning the circumferential alignment of the legs 5 and 6 (the circumferential alignment of the legs 5 and 6, whose tips have been aligned by the guide piece protrusion process S12, is more reliably achieved). This state when the heights of the segment coils 3 and 4 are aligned is shown in Figure 28. Note that the pressing plate 135 is not visible in Figure 28 due to the viewing angle of the perspective view, but in reality, the pressing plate 135 rises.

[0220] At this time, the legs 5 and 6 of the segment coils 3 and 4 are inserted into the guide grooves 127 of the guide piece 124, and are therefore pushed up by the push-up member 130 while being guided by the guide grooves 127. Also, as shown in Figure 28, as the push-up member 130 moves upward, the unit lifting section 144 moves, causing the chuck 145 to rise (both the push-up member 130 and the chuck 145 rise).

[0221] Subsequently, as shown in Figure 29, the pressing plate 135 descends and moves below the base portion 11 through the retraction opening 131, retracting to a position where it does not interfere with the operation of the core transport portion 153, etc.

[0222] (Core supply process S14) This core supply process S14 involves the unit supply unit 140 positioning the segment coil unit 8 above the insertion guide 110, and then the core supply unit 150 supplying the stator core 200 so that it is positioned below the insertion guide 110.

[0223] Specifically, in the push-up member operation step S13, after the push-up member 130 descends and retracts, the core supply unit 150 moves to the other side in the X direction, moving the stator core 200 until it is positioned directly below the insertion guide 110 (see Figure 29).

[0224] (Step S15: Insertion of the leg into the slot) In this leg insertion step S15, with the guide piece 124 of the insertion guide 110 protruding from the inner circumference of the opening 123, the segment coil unit 8 is lowered by the unit lifting unit 144, and the legs 5 and 6 are partially inserted into the corresponding slots 210 of the stator core 200 through the guide grooves 127 of the guide piece 124.

[0225] Specifically, the core receiving portion 151 of the core supply portion 150 rises, and the stator core 200 rises accordingly. Then, with the guide piece 124 of the insertion guide 110 protruding from the inner circumference of the opening 123 as shown in Figure 27, the unit lifting portion 144 descends, lowering the segment coil unit 8, and guiding its legs 5 and 6 with the guide groove 127 of the guide piece 124, it is inserted partway into the corresponding slot 210 of the stator core 200 (see Figure 30).

[0226] In this case, as described above, since the guide piece 124 of the insertion guide 110 protrudes from the inner circumference of the opening 123, the legs 5 and 6 of the segment coil unit 8 are pushed downward while being guided by the guide groove 127 of the corresponding guide piece 124, and are inserted into the slot 210 and insulating sheet 220 through the cuff portion 221 of the insulating sheet 220 which has been pre-inserted into the slot 210 of the stator core 200, until they reach a predetermined position in the axial direction. That is, the opposing legs 5 and 6 of the segment coil unit 8 are temporarily inserted partway into each slot 210 of the stator core 200.

[0227] Subsequently, the segment coil unit 8 is released from its grip by the chuck 145, the unit lifting section 144 rises, and the chuck 145 moves to one side in the Y direction by the unit transport section 143, thereby retracting the chuck 145 from above the insertion guide 110 (see Figure 31), leaving only the segment coil unit 8.

[0228] (Pusher movement process S16) This pusher movement process S16 is a process of moving the coil pusher 170 above the insertion guide 110. Specifically, after the leg insertion process S14 described above, the coil pusher 170 is moved by the first moving part 171, and as shown in Figure 32, the coil pusher 170 is moved above the insertion guide 110.

[0229] (First pressing operation step S17) This first pressing operation step S17 is a step in which a first pressing operation is performed such that the guide piece 124 protrudes from the inner circumference of the opening 123 and the legs 5 and 6 are inserted partway into the corresponding slots 210 of the stator core 200.

[0230] Specifically, during the pusher movement process S16 described above, the tip of each guide piece 124 protrudes from the inner circumference of the opening 123 of the insertion guide 110, and the guide groove 127 protrudes from the inner circumference of the opening 123 (see Figure 27). From this state, the coil pusher 170 descends, and its pressing portion 173 presses against the upper part of the segment coil unit 8, performing a first pressing operation so that the legs 5 and 6 of the segment coil unit 8 are inserted partway into the corresponding slots 210 of the stator core 200 (see Figure 33).

[0231] During the first pressing operation described above, the legs 5 and 6 of the segment coils 3 and 4 are inserted into the guide groove 127 of the guide piece 124 that protrudes from the inner circumference of the opening 123 of the insertion guide 110, and the first pressing operation is performed while the legs 5 and 6 are guided by the guide groove 127.

[0232] (Guide piece retraction process S18) The guide piece retraction process S18 is a process in which the guide piece 124 is retracted from the inner circumference of the opening 123 to a position where it does not interfere with the coil pusher 170.

[0233] Specifically, after the first pressing operation step S17 described above, the coil pusher 170 is moved above the insertion guide 110, as shown in Figure 34. Then, as shown in Figure 35, each guide piece 124 is moved so that the guide groove 127 of the insertion guide 110 is pulled in from the inner circumference of the opening 123, so that the tip of each guide piece 124 is pulled in from the inner circumference of the opening 123 to a position where the coil pusher 170 does not interfere.

[0234] (Second pressing operation step S19) The second pressing operation step S19 is a step in which, after the guide piece retraction step S18 described above, the guide piece 124 is retracted from the inner circumference of the opening 123 to a position where the coil pusher 170 does not interfere, and the second pressing operation is performed until the legs 5 and 6 are fully inserted into the corresponding slots 210 of the stator core 200.

[0235] Specifically, after the guide piece retraction process S18 described above, when the guide piece 124 has been retracted from the inner circumference of the opening 123 to a position where the coil pusher 170 does not interfere (see Figure 35), as shown in Figure 36, the coil pusher 170 descends further, and the pressing part 173 presses the upper part of the segment coil unit 8, performing a second pressing operation so that the legs 5 and 6 of the segment coil unit 8 are fully inserted into the corresponding slots 210 of the stator core 200 (this is the final insertion in which the opposing legs 5 and 6 of the segment coil unit 8 are fully inserted into each slot 210 of the stator core 200).

[0236] (Core retraction process S20) This core retraction process S20 is a process in which the stator core 200 is retracted to a position where it can be removed after the second pressing operation process S19 has been performed and the legs 5 and 6 of the segment coil unit 8 have been fully inserted into the slots 210 of the stator core 200.

[0237] Specifically, after the legs 5 and 6 of the segment coil unit 8 are fully inserted into the slots 210 of the stator core 200 by the second pressing operation step S17 described above (see Figure 36), the core transport unit 153 descends and then moves to one side in the X direction as shown in Figure 37, returning to its initial position, thereby making it possible to remove the stator core 200 supported by the core receiving unit 151 of the core supply unit 150.

[0238] Subsequently, the stator is manufactured by welding the multiple legs 5 and 6 that are inserted from the lower opening of the slot 210 of the stator core 200 as appropriate. In this embodiment, as shown in Figure 8, each leg 5 and 6 of the segment coil unit 8 is inserted into the corresponding slot 210 of the stator core 200 via an insulating sheet 220.

[0239] Furthermore, in the unit insertion device 100 with the above configuration, the legs 5 and 6 of the segment coil unit 8 are partially inserted into the corresponding slots 210 of the stator core 200 through the guide grooves 127 of the guide piece 124 of the insertion guide 110. Then, with the guide piece 124 retracted from the inner circumference of the opening 123 of the insertion guide 110, the segment coil unit 8 is pushed in with the coil pusher 170 to fully insert its legs 5 and 6 into the corresponding slots 210 of the stator core 200. As a result, all the legs 5 and 6 of the segment coil unit 8 can be reliably and efficiently inserted into the corresponding slots 210 of the stator core 200 in one go, improving the ease of inserting the legs 5 and 6 into the slots 210 of the stator core 200.

[0240] It should be noted that the present invention is not limited to the embodiments described above, and various modified embodiments are possible within the scope of the gist of the present invention, and such embodiments are also included in the scope of the present invention. [Explanation of Symbols]

[0241] 1. Stator manufacturing equipment 3. First segment coil 4. Second segment coil 5,6 Legs 7 Connecting part 7b One side 7c Other side 8-segment coil unit 10-segment coil unit manufacturing equipment (unit manufacturing equipment) 11 Base section 20. Temporary assembly jig 21 Pillar section 23 Hook part 28 Slope 30,31 Temporary placement section 40 Coil insertion section 45 Pickup section 50 Jig Rotating Part 60 Coil pressing section 70 Annular support plate 71 Lifting section 80 Gap forming section 85 Gap forming tool 100-segment coil unit insertion device (unit insertion device) 110 Insertion Guide 123 Opening 124 Guide Pieces 127 Guide groove 130 Push-up member 140 Unit Supply Unit 143 Unit transport section 144 Unit Lifting Section 145 Chuck 150 Core Supply Unit 151 Core receiving section 153 Core transport section 160 Post section 165 Guide Ribs 166 inclined surface 170 coil pusher 200 stator core 210 slot 220 insulating sheet 221 cuff portion G1 gap G2 clearance

Claims

1. A method for manufacturing a segment coil unit, comprising: pre-assembling a plurality of segment coils, each having a pair of legs and a connecting portion connecting the pair of legs, to fit into slots of an applicable stator core to produce an annular segment coil unit; A temporary assembly jig is used, which has a rotatably supported support column and a plurality of hooks projecting radially from the outer circumference of the support column at predetermined intervals in the circumferential direction, with gaps formed in the circumferential direction between adjacent hooks so as to correspond to the slots of the stator core, and an inclined portion provided above the hooks that slopes downward in the outward direction to allow the connecting portion of the segment coil to slide in the outward direction. The coil insertion operation involves picking up each segment coil one by one and dropping them into the predetermined gap so that the legs are inserted into the gap, A jig rotation operation that rotates the support column by a predetermined angle to change the position of the gap into which the legs of the picked-up segment coil are dropped, A method for manufacturing a segment coil unit, characterized by appropriately repeating a coil pressing operation to restrict the position of a segment coil that has already been dropped by pressing it radially inward when dropping in the segment coil.

2. When stacking the segment coils by appropriately repeating the coil insertion operation, the jig rotation operation, and the coil pressing operation, A gap-forming tool is inserted into the inner diameter side of the segment coil adjacent to the opposite side in the circumferential direction, such that one side of the connecting portion of the segment coil overlaps the outer diameter side of the adjacent segment coil in the circumferential direction, and the other side of the connecting portion of the segment coil enters the inner diameter side of the adjacent segment coil on the opposite side in the circumferential direction. A method for manufacturing a segment coil unit according to claim 1, comprising performing a gap-forming operation to form a gap into which the other side of the connecting portion of the segment coil can be inserted.

3. After the insertion of the segment coil legs into all the gaps of the temporary assembly jig is completed, the annular support plate positioned below the temporary assembly jig is raised to lift the segment coil legs. The method for manufacturing a segment coil unit according to claim 1 or 2, wherein a lift-up operation is performed to lower the annular support plate and support it again on the temporary assembly jig.

4. The segment coils include a first segment coil having a pair of legs inserted into slots a predetermined number of spaces apart, and a second segment coil in which the legs are inserted into slots one space outward from the slots into which the legs of the first segment coil are inserted. The first segment coil and the second segment coil are sequentially picked up and inserted concentrically. Next, the support column is rotated by a predetermined angle to insert the next first segment coil and second segment coil, which are arranged concentrically, in the method for manufacturing a segment coil unit according to claim 1 or 2.

5. A segment coil unit manufacturing apparatus for manufacturing an annular segment coil unit by pre-assembling a plurality of segment coils, each having a pair of legs and a connecting portion connecting the pair of legs, to fit into the slots of an applicable stator core, A temporary assembly jig having a rotatably supported support column and a plurality of hooks projecting radially from the outer circumference of the support column at predetermined intervals in the circumferential direction, with gaps formed in the circumferential direction between adjacent hooks so as to correspond to the slots of the stator core, and an inclined portion provided above the hooks that slopes downward in the outward direction to allow the connecting portion of the segment coil to slide in the outward direction, A coil insertion section picks up each segment coil one by one and drops them in so that their legs are inserted into a predetermined gap, A jig rotating part rotates the support column by predetermined angles to change the position of the gap into which the legs of the picked-up segment coil are dropped, The system includes a coil pressing section that, when dropping in the segment coil, presses the segment coil that has already been dropped in radially inward to regulate the position of the segment coil, A manufacturing apparatus for a segment coil unit, characterized in that it is configured to appropriately repeat the segment insertion operation by the segment insertion device, the jig rotation operation by the jig rotation device, and the coil pressing operation by the coil pressing device.

6. When stacking the segment coils by appropriately repeating the segment insertion operation, the jig rotation operation, and the coil pressing operation, A manufacturing apparatus for a segment coil unit according to claim 1, further comprising a gap-forming device that inserts a gap-forming tool into the inner diameter side of a segment coil adjacent to the opposite side in the circumferential direction, such that one side of the bent portion of the segment coil overlaps the outer diameter side of an adjacent segment in the circumferential direction, and the other side of the bent portion of the segment coil enters the inner diameter side of a segment coil adjacent to the opposite side in the circumferential direction, thereby forming a gap into which the other side of the bent portion of the segment coil enters.

7. The temporary assembly jig has an annular support plate positioned below it, and a lifting mechanism that moves the annular support plate up and down. A manufacturing apparatus for a segment coil unit according to claim 1 or 2, wherein, after the operation of inserting the legs of the segment coil into all the gaps of the temporary assembly jig is completed, the lifting unit raises the annular support plate to lift the legs of the segment coil, and then the lifting unit lowers the annular support plate to support it again in the temporary assembly jig, thereby performing a lift-up operation.

8. The segment coil used includes a first segment coil having a pair of legs inserted into slots a predetermined number of spaces apart, and a second segment coil having legs inserted into slots one space outside the slot into which the legs of the first segment coil are inserted. The manufacturing apparatus for a segment coil unit according to claim 1 or 2, wherein the coil insertion device is configured to sequentially pick up the first segment coil and the second segment coil and insert them concentrically.

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