Alignment coil manufacturing equipment

Abstract

To easily manufacture an aligned coil that is formed of a plurality of aligned segment coils, and easily change the radius of the aligned coil being formed.SOLUTION: An aligned coil manufacturing device comprises: a plurality of slits that are provided for respective slots provided in a stator core and that are arranged in a radial form at a predetermined angular interval; an inner diameter side guide that guides a leg of a segment coil inserted into each slit from an inner diameter side in a variable manner; and an outer diameter side guide that guides the leg of the segment coil inserted into the slit from an outer diameter side in a variable manner.SELECTED DRAWING: Figure 4

Description

Technical Field

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[0001] The present invention relates to an aligned coil manufacturing apparatus.

Background Art

[0002] Patent Document 1 below discloses a stator coil manufacturing apparatus including an outer jig having a plurality of partition members arranged radially at intervals into which one leg of a segment coil can be inserted, and an inner jig arranged radially inside the plurality of partition members and having a plurality of hole members having holes into which the other leg of the segment coil is inserted.

Prior Art Document

Patent Document

[0007] [Figure 1] External perspective view of a coil manufacturing apparatus according to one embodiment. [Figure 2] External perspective view of the alignment device included in the alignment coil manufacturing apparatus 10 according to one embodiment. [Figure 3] External perspective view of the alignment device (with the blade rotor removed) of an alignment coil manufacturing apparatus according to one embodiment. [Figure 4] Partially enlarged plan view of the alignment device included in one embodiment of the aligned coil manufacturing apparatus. [Figure 5] Partially enlarged cross-sectional view of the alignment device (with the blade rotor and the upper housing of the outer diameter side housing removed) included in an alignment coil manufacturing apparatus according to one embodiment. [Figure 6A] External perspective view of the inner diameter guide and outer diameter guide of an alignment coil manufacturing apparatus according to one embodiment. [Figure 6B] This is a plan view of the inner diameter guide and outer diameter guide included in an alignment coil manufacturing apparatus according to one embodiment. [Figure 7A] External perspective view of the inner diameter guide and outer diameter guide of an alignment coil manufacturing apparatus according to one embodiment. [Figure 7B] This is a plan view of the inner diameter guide and outer diameter guide included in an alignment coil manufacturing apparatus according to one embodiment. [Figure 8A] External perspective view of the inner diameter guide and outer diameter guide of an alignment coil manufacturing apparatus according to one embodiment. [Figure 8B] Plan view of the inner diameter guide and outer diameter guide included in an alignment coil manufacturing apparatus according to one embodiment. [Figure 9] A diagram illustrating a method for aligning segment coils using an alignment coil manufacturing apparatus according to one embodiment. [Figure 10]Flowchart showing the procedure for manufacturing aligned coils using an aligned coil manufacturing apparatus according to one embodiment. [Figure 11] A perspective view showing the insertion of the first segment coil into the slit of the blade rotor in a method for manufacturing aligned coils according to one embodiment. [Figure 12] A plan view showing the state after the first segment coil has been inserted into the slit of the blade rotor in a method for manufacturing aligned coils according to one embodiment. [Figure 13] A perspective view showing the rotation of a blade rotor into which the first segment coil is inserted in a counterclockwise direction in a method for manufacturing aligned coils according to one embodiment. [Figure 14] A plan view showing the state after the blade rotor into which the first segment coil is inserted has been rotated counterclockwise in a method for manufacturing aligned coils according to one embodiment. [Figure 15] A perspective view showing the insertion of the second segment coil into the slit of the blade rotor in a method for manufacturing aligned coils according to one embodiment. [Figure 16] A perspective view showing the rotation of a blade rotor into which a second segment coil is inserted in a counterclockwise direction in a method for manufacturing an aligned coil according to one embodiment. [Figure 17] A perspective view showing the insertion of the last segment coil into the slit of the blade rotor in a method for manufacturing aligned coils according to one embodiment. [Modes for carrying out the invention]

[0008] One embodiment of the present invention will be described below with reference to the drawings.

[0009] (Configuration of the coil manufacturing apparatus 10) Figure 1 is an external perspective view of an aligned coil manufacturing apparatus 10 according to one embodiment. The aligned coil manufacturing apparatus 10 shown in Figure 1 is an apparatus for manufacturing an annular aligned coil 30 consisting of a plurality of segment coils 20. The aligned coil manufacturing apparatus 10 comprises a support base 11, an alignment device 100, and an insertion device 12.

[0010] The support table 11 supports the alignment device 100 and the insertion device 12. The support table 11 includes a horizontal flat top plate 11A at the uppermost part. The alignment device 100 and the insertion device 12 are installed on the upper surface of the top plate 11A.

[0011] The alignment device 100 is a device for aligning a plurality of segment coils 20 in an annular shape. The alignment device 100 has a rotatable blade rotor 120. The blade rotor 120 has a plurality of slits 121 arranged radially at a predetermined angular interval.

[0012] The insertion device 12 is a device for inserting the segment coils 20 one by one into the blade rotor 120 of the alignment device 100. The insertion device 12 has an arm 12A extending above the blade rotor 120 and a gripping portion 12B provided at the tip of the arm 12A. The insertion device 12 can insert the two legs 21 of the segment coil 20 into the two slits 121 of the blade rotor 120 by moving the arm 12A downward while gripping the segment coil 20 with the gripping portion 12B. Note that the insertion device 12 is configured such that the arm 12A is extendable. Thereby, the insertion device 12 can change the insertion position of the segment coil 20 in the radial direction of the blade rotor 120 by extending the arm 12A.

[0013] The alignment coil manufacturing device 10 can manufacture an annular alignment coil 30 composed of a plurality of segment coils 20 by inserting the segment coil 20 into the blade rotor 120 by the insertion device 12 every time the blade rotor 120 provided in the alignment device 100 is rotated by a predetermined angle.

[0014] (Configuration of the alignment device 100) Figure 2 is an external perspective view of the alignment device 100 included in the alignment coil manufacturing apparatus 10 according to one embodiment. Figure 3 is an external perspective view of the alignment device 100 included in the alignment coil manufacturing apparatus 10 according to one embodiment (with the blade rotor 120 removed). Figure 4 is a partially enlarged plan view of the alignment device 100 included in the alignment coil manufacturing apparatus 10 according to one embodiment. Figure 5 is a partially enlarged cross-sectional view of the alignment device 100 included in the alignment coil manufacturing apparatus 10 according to one embodiment (with the blade rotor 120 and the upper housing 142A of the outer diameter side housing 142 removed).

[0015] As shown in Figures 2 and 3, the alignment device 100 comprises an inner diameter guide 130, an outer diameter guide 140, and a blade rotor 120.

[0016] <Blade Rotor 120> The blade rotor 120 is a generally disc-shaped member that has approximately the same diameter as the central opening 142C of the outer diameter housing 142 provided by the outer diameter guide 140, and is mounted on top of the central opening 142C of the outer diameter housing 142. The blade rotor 120 is mounted so as to be rotatable relative to the inner diameter guide 130 and the outer diameter guide 140.

[0017] The blade rotor 120 has a plurality of slits 121 arranged radially at regular angular intervals. Each of the plurality of slits 121 has an opening shape that penetrates the blade rotor 120 in the vertical direction and has a groove shape that extends in the radial direction.

[0018] Furthermore, the blade rotor 120 has multiple slits 121, and between each of two adjacent slits 121, it has radially extending blade-shaped blades 122. In other words, the blade rotor 120 has multiple blades 122 arranged radially at regular angular intervals.

[0019] The blade rotor 120 can position the circumferential position of the two legs 21 of the segment coil 20 by inserting one leg 21 of the segment coil 20 into one slit 121, and inserting the other leg 21 of the segment coil 20 into another slit 121 located a predetermined number of spaces away from the first slit 121.

[0020] Furthermore, by rotating the blade rotor 120 counterclockwise in predetermined angle increments, the insertion position of the segment coil 20 in the blade rotor 120 can be shifted in units of slit 121.

[0021] Furthermore, by inserting the segment coil 20 around the blade rotor 120, a ring-shaped aligned coil 30 consisting of multiple segment coils 20 can be formed.

[0022] The slits 121 and blades 122 are provided for each slot of the target stator core. As an example, in this embodiment, corresponding to the target stator core having 48 slots, the blade rotor 120 has 48 slits 121 and 48 blades 122.

[0023] <Inner diameter side guide 130> As shown in Figure 3, the inner diameter side guide 130 is provided on the inner diameter side (within the central opening 142C of the outer diameter side housing 142 provided by the outer diameter side guide 140) and variably guides the legs 21 of the segment coil 20 inserted into the slit 121 of the blade rotor 120 from the inner diameter side. The inner diameter side guide 130 has a plurality of radially arranged inner diameter side guide members 131 and an inner diameter side housing 132 that holds the plurality of inner diameter side guide members 131 from the inner diameter side.

[0024] Each of the multiple inner diameter guide members 131 is a resin rod-shaped member that extends linearly in the radial direction. Each of the multiple inner diameter guide members 131 has its tip portion 131A facing the outer diameter side, that is, it is positioned opposite the outer diameter guide 140. As a result, the outer circumferential surface of the inner diameter guide 130 is composed of the tip portions 131A of the multiple inner diameter guide members 131, which are arranged in an annular shape. Furthermore, each of the multiple inner diameter guide members 131 has a shape in which the width of the tip portion 131A is partially widened (i.e., T-shaped). Each of the multiple inner diameter guide members 131 is provided to be movable in the radial direction, thereby allowing the radius of the outer circumferential surface of the inner diameter guide 130 to be changed.

[0025] As shown in Figure 5, the inner diameter guide 130 is arranged with alternating inner diameter guide members 131 having a single flat tip portion 131A1 and inner diameter guide members 131 having two tips portion 131A2 with two plates positioned above and below. The inner diameter guide 130 is configured such that, in two adjacent inner diameter guide members 131, the two plates of the tip portion 131A2 of one inner diameter guide member 131 sandwich the tip portion 131A1 of the other inner diameter guide member 131. As a result, in two adjacent inner diameter guide members 131, the inner diameter guide 130 prevents a gap from forming between the tip portion 131A2 of one inner diameter guide member 131 and the tip portion 131A1 of the other inner diameter guide member 131, thereby preventing the legs 21 of the segment coil 20 from slipping out of the gap.

[0026] The inner diameter side housing 132 is a hollow, cylindrical, resin-made, container-like member that holds a plurality of inner diameter side guide members 131 from the inner diameter side. Specifically, the inner diameter side housing 132 holds the end portions of each of the radially arranged inner diameter side guide members 131 inside the inner diameter side housing 132, so that each of the plurality of inner diameter side guide members 131 can move radially, with each end portion of the inner diameter side guide members 131 protruding from the outer circumferential surface of the inner diameter side housing 132 toward the outer diameter side (in the space between the inner diameter side housing 132 and the outer diameter side housing 142).

[0027] <Outer diameter side guide 140> As shown in Figure 3, the outer diameter side guide 140 is provided on the outer diameter side and variably guides the legs 21 of the segment coil 20 inserted into the slit 121 of the blade rotor 120 from the outer diameter side. The outer diameter side guide 140 has a plurality of radially arranged outer diameter side guide members 141 and an outer diameter side housing 142 that holds the plurality of outer diameter side guide members 141 from the outer diameter side.

[0028] Each of the multiple outer diameter guide members 141 is a resin rod-shaped member that extends linearly in the radial direction. Each of the multiple outer diameter guide members 141 has its tip portion 141A facing the inner diameter side, that is, it is positioned opposite the inner diameter guide 130. As a result, the inner circumferential surface of the outer diameter guide 140 is composed of the tip portions 141A of the multiple outer diameter guide members 141, which are arranged in an annular shape. Furthermore, each of the multiple outer diameter guide members 141 has a shape in which the width of the tip portion 141A is partially widened (i.e., T-shaped). Each of the multiple outer diameter guide members 141 is provided to be movable in the radial direction, thereby changing the radius of the inner circumferential surface of the outer diameter guide 140.

[0029] As shown in Figure 5, the outer diameter guide 140 is arranged in alternating pairs: an outer diameter guide member 141 with a single flat tip portion 141A1, and an outer diameter guide member 141 with two tips 141A2 having two plates positioned above and below it. The outer diameter guide 140 is configured such that, in two adjacent outer diameter guide members 141, the two plates of the tip portion 141A2 of one outer diameter guide member 141 sandwich the tip portion 141A1 of the other outer diameter guide member 141. As a result, in two adjacent outer diameter guide members 141, there is no gap between the tip portion 141A2 of one outer diameter guide member 141 and the tip portion 141A1 of the other outer diameter guide member 141, thereby preventing the legs 21 of the segment coil 20 from slipping out of the gap.

[0030] The outer diameter side housing 142 is a hollow, cylindrical, resin-made, container-shaped member that holds a plurality of outer diameter side guide members 141 from the outer diameter side. Specifically, the outer diameter side housing 142 holds the end portions of each of the radially arranged outer diameter side guide members 141 inside the outer diameter side housing 142, so that each of the plurality of outer diameter side guide members 141 can move radially, with each end portion of the outer diameter side guide members 141 protruding from the inner circumferential surface of the outer diameter side housing 142 toward the inner diameter side (in the space between the inner diameter side housing 132 and the outer diameter side housing 142). The inner diameter side guide 130 is positioned inside the central opening 142C of the outer diameter side housing 142.

[0031] Multiple fixing holes 142D are formed on the outer peripheral edge of the outer diameter housing 142. Each of the multiple fixing holes 142D has an elongated shape that extends in a curved manner in the circumferential direction. The outer diameter housing 142 is fixed to the upper surface of the top plate 11A of the support base 11 by each of the multiple bolts 144 that pass through each of the multiple fixing holes 142D.

[0032] <Gap 101> As shown in Figures 3 to 5, the alignment device 100 has an annular gap 101 with a constant width in the radial direction, formed in the space between the inner diameter side housing 132 and the outer diameter side housing 142, between the outer circumferential surface of the inner diameter side guide 130 and the inner circumferential surface of the outer diameter side guide 140. Each time a segment coil 20 is inserted into the alignment device 100, the two legs 21 of that segment coil 20 are positioned in the gap 101. Finally, the two legs of each of the multiple segment coils 20 constituting the annular alignment coil 30 are aligned and positioned in the gap 101. The alignment device 100 can change the radius of the gap 101 by moving the multiple inner diameter side guide members 131 radially to change the radius of the outer circumferential surface of the inner diameter side guide 130, and by moving the multiple outer diameter side guide members 141 radially to change the radius of the inner circumferential surface of the outer diameter side guide 140, thereby changing the radius of the formed alignment coil 30.

[0033] (Configuration of inner diameter guide 130 and outer diameter guide 140) Figures 6A, 7A, and 8A are external perspective views of the inner diameter guide 130 and outer diameter guide 140 provided in the aligned coil manufacturing apparatus 10 according to one embodiment. Figures 6B, 7B, and 8B are plan views of the inner diameter guide 130 and outer diameter guide 140 provided in the aligned coil manufacturing apparatus 10 according to one embodiment.

[0034] However, Figures 7A and 7B show the inner diameter guide 130 with the upper housing 132A removed, and the outer diameter guide 140 with the upper housing 142A removed.

[0035] Furthermore, Figures 8A and 8B show the inner diameter guide 130 with the upper housing 132A and some of the inner diameter guide members 131 removed, and the outer diameter guide 140 with the upper housing 142A and some of the outer diameter guide members 141 removed.

[0036] <Configuration of the inner diameter side guide 130> The inner diameter side housing 132 of the inner diameter side guide 130 is configured to be divisible into two parts, an upper housing 132A and a lower housing 132B. The lower housing 132B is a tray-shaped member that supports the end portions of each of the multiple inner diameter side guide members 131 from below. The upper housing 132A is a cover-shaped member that covers the lower housing 132B and the end portions of each of the multiple inner diameter side guide members 131.

[0037] The inner diameter side guide 130 has an inner diameter side link plate 133 inside the inner diameter side housing 132. The inner diameter side link plate 133 is a disc-shaped member that is rotatably positioned inside the inner diameter side housing 132. Multiple inner diameter side guide members 131 are arranged radially on the upper surface of the inner diameter side link plate 133. Multiple inner diameter side guide grooves 133A are formed on the upper surface of the inner diameter side link plate 133, provided for each inner diameter side guide member 131. An inner diameter side connecting pin 131B, which protrudes downward from the rear end of the inner diameter side guide member 131, is inserted into each of the multiple inner diameter side guide grooves 133A. Each of the multiple inner diameter side guide grooves 133A extends in a direction inclined with respect to the radial direction in which the inner diameter side guide member 131 extends. As a result, each of the multiple inner diameter side guide grooves 133A allows the inner diameter side guide member 131 to move radially by sliding the inner diameter side connecting pin 131B of the inner diameter side guide member 131 within the inner diameter side guide groove 133A as the inner diameter side link plate 133 rotates.

[0038] In this manner, the inner diameter side guide 130 has multiple inner diameter side guide members 131 connected to the inner diameter side link plate 133. This allows the inner diameter side guide 130 to move all of the multiple inner diameter side guide members 131 simultaneously in the radial direction (inward or outward direction) by rotating the inner diameter side link plate 133. In other words, it is possible to change the radius of the outer surface of the inner diameter side guide 130 while maintaining its annular shape.

[0039] <Configuration of the outer diameter side guide 140> The outer diameter side housing 142 of the outer diameter side guide 140 is configured to be divisible into two parts, an upper housing 142A and a lower housing 142B. The lower housing 142B is a tray-shaped member that supports the end portions of each of the multiple outer diameter side guide members 141 from below. The upper housing 142A is a cover-shaped member that covers the lower housing 142B and the end portions of each of the multiple outer diameter side guide members 141.

[0040] The outer diameter side guide 140 has an outer diameter side link plate 143 inside the outer diameter side housing 142. The outer diameter side link plate 143 is a disc-shaped member that is rotatably positioned inside the outer diameter side housing 142. Multiple outer diameter side guide members 141 are arranged radially on the upper surface of the outer diameter side link plate 143. Multiple outer diameter side guide grooves 143A are formed on the upper surface of the outer diameter side link plate 143, provided for each outer diameter side guide member 141. An outer diameter side connecting pin 141B, which is provided protruding downward from the rear end of the outer diameter side guide member 141, is inserted into each of the multiple outer diameter side guide grooves 143A. Each of the multiple outer diameter side guide grooves 143A extends in a direction inclined with respect to the radial direction in which the outer diameter side guide member 141 extends. As a result, each of the multiple outer diameter side guide grooves 143A allows the outer diameter side connecting pin 141B of the outer diameter side guide member 141 to slide within the outer diameter side guide groove 143A as the outer diameter side link plate 143 rotates, thereby moving the outer diameter side guide member 141 in the radial direction.

[0041] In this manner, the outer diameter side guide 140 has multiple outer diameter side guide members 141 connected to the outer diameter side link plate 143. This allows the outer diameter side guide 140 to move all of the multiple outer diameter side guide members 141 simultaneously in the radial direction (inward or outward direction) by rotating the outer diameter side link plate 143. In other words, it is possible to change the radius of the inner circumferential surface of the outer diameter side guide 140 while maintaining its annular shape.

[0042] (Method of aligning segment coil 20) Figure 9 is a diagram illustrating a method for aligning segment coils 20 using an alignment coil manufacturing apparatus 10 according to one embodiment.

[0043] As shown in Figure 9, in the inner diameter side guide 130, a V-shaped guide groove 131C formed on the tip portion 131A of the inner diameter side guide member 131 is positioned at the insertion position of the front leg 21 in the direction of travel (counterclockwise direction) of the segment coil 20. As a result, the aligned coil manufacturing apparatus 10 according to one embodiment can insert the segment coil 20 into the slit 121 of the blade rotor 120 after rotating (spinning) it counterclockwise by a predetermined angle (14° in this embodiment) with respect to the circumference of the gap portion 101 (i.e., the circumference of the aligned coil 30 to be formed). Therefore, the aligned coil manufacturing apparatus 10 according to one embodiment can insert a new segment coil 20 into the slit 121 of the blade rotor 120 without interfering with the segment coil 20 already aligned on the circumference of the gap portion 101.

[0044] Furthermore, as shown in Figure 9, the guide groove 131C has a tapered surface 131D on the side of the segment coil 20 in the direction of travel (counterclockwise direction). As a result, in one embodiment of the aligned coil manufacturing apparatus 10, as shown in Figure 9, after inserting the segment coil 20 into the slit 121 of the blade rotor 120, the blade rotor 120 is rotated by a predetermined angle counterclockwise, and the segment coil 20 is fed (revolved) in the counterclockwise direction together with the blade rotor 120, the front leg 21 of the segment coil 20 in the direction of travel is brought into contact with the tapered surface 131D and moved toward the outer diameter, thereby causing the segment coil 20 to rotate (rotate) by a predetermined angle (14° in this embodiment) clockwise. As a result, the inclination of the gap portion 101 of the segment coil 20 from the circumference is eliminated, and the two legs 21 of the segment coil 20 can be aligned on the circumference of the gap portion 101.

[0045] As shown in Figure 9, when the segment coil 20 is inserted at an angle, the rear legs 21 of the segment coil 20 protrude outwards. The tip portion 141A of the outer diameter side guide member 141, which is positioned at the insertion point of the rear legs 21, is also provided with a guide groove and a tapered surface similar to the guide groove 131C and tapered surface 131D, so as not to interfere with the rear legs 21, and so as to allow the rear legs 21 to come into contact with and move inwards.

[0046] (Procedure for manufacturing the aligned coil 30) Next, with reference to Figures 10 to 17, the procedure for manufacturing aligned coils 30 using an aligned coil manufacturing apparatus 10 according to one embodiment will be described.

[0047] Figure 10 is a flowchart showing the procedure for manufacturing aligned coils 30 using an aligned coil manufacturing apparatus 10 according to one embodiment.

[0048] Figure 11 is a perspective view showing the insertion of the first segment coil 20 into the slit 121 of the blade rotor 120 in a manufacturing method of an alignment coil 30 according to one embodiment. Figure 12 is a plan view showing the state after the first segment coil 20 has been inserted into the slit 121 of the blade rotor 120 in a manufacturing method of an alignment coil 30 according to one embodiment.

[0049] Figure 13 is a perspective view showing the blade rotor 120 into which the first segment coil 20 is inserted being rotated counterclockwise in a manufacturing method of an alignment coil 30 according to one embodiment. Figure 14 is a plan view showing the state after the blade rotor 120 into which the first segment coil 20 is inserted has been rotated counterclockwise in a manufacturing method of an alignment coil 30 according to one embodiment.

[0050] Figure 15 is a perspective view showing the insertion of the second segment coil 20 into the slit 121 of the blade rotor 120 in a manufacturing method of the alignment coil 30 according to one embodiment. Figure 16 is a perspective view showing the rotation of the blade rotor 120, into which the second segment coil 20 has been inserted, in a counterclockwise direction in a manufacturing method of the alignment coil 30 according to one embodiment.

[0051] Figure 17 is a perspective view showing the insertion of the last segment coil 20 into the slit 121 of the blade rotor 120 in a manufacturing method of an aligned coil 30 according to one embodiment.

[0052] First, the outer diameter side link plate 143 of the outer diameter side guide 140 is rotated to match the radius of the alignment coil 30 that is formed, thereby moving the multiple outer diameter side guide members 141 of the outer diameter side guide 140 simultaneously in the outer diameter direction (step S201).

[0053] Next, by rotating the inner diameter link plate 133 of the inner diameter guide 130 to match the radius of the formed alignment coil 30, the multiple inner diameter guide members 131 of the inner diameter guide 130 are simultaneously moved in the outer diameter direction (step S202).

[0054] Next, the insertion device 12 inserts one segment coil 20 into a slit 121 of the blade rotor 120 (step S203). Specifically, as shown in Figures 11 and 12, the insertion device 12 inserts one leg 21 of the segment coil 20 into a slit 121 located at a predetermined insertion position, and inserts the other leg 21 of the segment coil 20 into another slit 121 located a predetermined number of spaces away from the first slit 121. At this time, as shown in Figure 12, the segment coil 20 is inserted into the slit 121 of the blade rotor 120 while rotated (rotated) by a predetermined angle (14° in this embodiment) counterclockwise with respect to the circumference of the gap 101 (i.e., the circumference of the aligned coil 30 that will be formed). As a result, as shown in Figure 12, the front leg 21 of the segment coil 20 in the direction of travel is inserted into the guide groove 131C of the inner diameter side guide member 131 provided at the insertion position of the leg 21.

[0055] Next, by rotating the blade rotor 120 counterclockwise by a predetermined angle, the single segment coil 20 inserted in step S203 is sent out (revolved) in a counterclockwise direction together with the blade rotor 120 (step S204). At this time, as shown in Figure 14, the front leg 21 of the segment coil 20 in the direction of travel comes into contact with the tapered surface 131D of the guide groove 131C, causing the segment coil 20 to rotate (rotate) clockwise by a predetermined angle (14° in this embodiment), and the inclination of the segment coil 20 from the circumference of the gap 101 is eliminated, so that the two legs 21 of the segment coil 20 are aligned on the circumference of the gap 101.

[0056] Next, it is determined whether or not one full rotation of the segment coil 20 has been inserted and ejected (step S205).

[0057] If it is determined in step S205 that one full rotation of segment coils 20 has not been inserted and fed out (step S205: NO), the process returns to step S203, and steps S203 and S204 are re-executed. That is, as shown in Figure 15, the next segment coil 20 is inserted into the slit 121 of the blade rotor 120, and as shown in Figure 16, the blade rotor 120 is rotated counterclockwise by a predetermined angle, thereby rotating (revolving) the next segment coil 20 together with the blade rotor 120 in a counterclockwise direction and aligning it on the circumference of the gap 101. By repeating this, an annular aligned coil 30 can be gradually formed on the circumference of the gap 101. Then, as shown in Figure 17, the last segment coil 20 is inserted into the slit 121 of the blade rotor 120, and the blade rotor 120 is rotated counterclockwise by a predetermined angle, thereby aligning the last segment coil 20 on the circumference of the gap 101 and completing the annular aligned coil 30.

[0058] In step S205, if it is determined that one full rotation of the segment coil 20 has been inserted and fed out, that is, if an annular aligned coil 30 has been formed (step S205: YES), the series of processes shown in Figure 10 is terminated.

[0059] The alignment coil 30 manufactured by the above procedure can be pulled upward from the alignment device 100, allowing the legs 21 of each of the segment coils 20 to be inserted collectively into the slits of the stator core while maintaining the annular alignment of the segment coils 20.

[0060] Furthermore, if you wish to manufacture a larger radius alignment coil 30, you can simply repeat the series of processes shown in Figure 10. In this case, in step S201, move the multiple outer diameter guide members 141 simultaneously in the outer diameter direction, and in step S202, move the multiple inner diameter guide members 131 simultaneously in the outer diameter direction, so that the radius of the gap 101 corresponds to the radius of the new alignment coil 30.

[0061] Furthermore, each step in the series of processes shown in Figure 10 may be automatically executed by the control of a computer (not shown) provided in the aligned coil manufacturing apparatus 10, or it may be manually executed by an operator.

[0062] As described above, the aligned coil manufacturing apparatus 10 according to one embodiment includes a plurality of slits 121 provided for each slot of the stator core and arranged radially at predetermined angular intervals, an inner diameter side guide 130 that variably guides the legs 21 of the segment coils 20 inserted into the slits 121 from the inner diameter side, and an outer diameter side guide 140 that variably guides the legs 21 of the segment coils 20 inserted into the slits 121 from the outer diameter side.

[0063] As a result, the aligned coil manufacturing apparatus 10 according to one embodiment can change the radius of the formed aligned coil 30 by moving the guide positions of the inner diameter guide 130 and the outer diameter guide 140 in the radial direction. Then, by guiding the legs 21 of the segment coil 20 inserted into the slit 121 with the inner diameter guide 130 and the outer diameter guide 140, the segment coil 20 can be arranged on the circumference of the formed aligned coil 30. Therefore, according to the aligned coil manufacturing apparatus 10 according to one embodiment, an aligned coil 30 in which a plurality of segment coils 20 are aligned can be easily manufactured, and the radius of the formed aligned coil 30 can be easily changed.

[0064] Furthermore, the aligned coil manufacturing apparatus 10 according to one embodiment includes a blade rotor 120 that is rotatably mounted and has a plurality of slits 121, and by inserting the segment coils 20 into the slits 121 each time the blade rotor 120 is rotated by a predetermined angle, an annular aligned coil 30 can be formed in which a plurality of segment coils 20 are aligned.

[0065] As a result, the aligned coil manufacturing apparatus 10 according to one embodiment can easily arrange multiple segment coils 20 on the circumference of the aligned coil 30 that is formed.

[0066] Furthermore, in the aligned coil manufacturing apparatus 10 according to one embodiment, the inner diameter side guide 130 has a plurality of inner diameter side guide members 131 arranged radially and movable in the radial direction, and the outer diameter side guide 140 has a plurality of outer diameter side guide members 141 arranged radially and movable in the radial direction.

[0067] As a result, the aligned coil manufacturing apparatus 10 according to one embodiment can guide the legs 21 of the segment coil 20 inserted into the slit 121 from both the inner and outer diameter sides over the entire circumference of the aligned coil 30 that is formed.

[0068] Furthermore, in the coil alignment manufacturing apparatus 10 according to one embodiment, the inner diameter side guide 130 has an inner diameter side link plate 133 that rotates to move a plurality of inner diameter side guide members 131 simultaneously in the radial direction, and the outer diameter side guide 140 has an outer diameter side link plate 143 that rotates to move a plurality of outer diameter side guide members 141 simultaneously in the radial direction.

[0069] As a result, the aligned coil manufacturing apparatus 10 according to one embodiment can easily change the guide positions of the multiple inner diameter guide members 131 and the multiple outer diameter guide members 141.

[0070] Furthermore, in the coil alignment apparatus 10 according to one embodiment, the inner diameter side guide 130 has the tips 131A of two adjacent inner diameter side guide members 131 overlapping, and the outer diameter side guide 140 has the tips 141A of two adjacent outer diameter side guide members 141 overlapping.

[0071] As a result, the aligned coil manufacturing apparatus 10 according to one embodiment can prevent the legs 21 of the segment coil 20 from falling off the inner and outer diameter sides of the circumference of the aligned coil 30 being formed.

[0072] Furthermore, in the alignment coil manufacturing apparatus 10 according to one embodiment, the segment coil 20 is inserted into the slit 121 at a predetermined angle inclination from the circumference of the alignment coil 30 to be formed, and then rotates together with the blade rotor 120 to align on the circumference.

[0073] As a result, the aligned coil manufacturing apparatus 10 according to one embodiment can insert a new segment coil 20 into the slit 121 without interfering with the segment coils 20 that are already aligned on the circumference. Furthermore, the segment coils 20 can be easily aligned on the circumference simply by rotating the blade rotor 120.

[0074] Furthermore, in the aligned coil manufacturing apparatus 10 according to one embodiment, the inner diameter side guide 130 has a tapered surface 131D at the insertion position of the legs 21 of the segment coil 20, and when the segment coil 20 rotates together with the blade rotor 120, the legs 21 of the segment coil 20 come into contact with the tapered surface 131D, thereby aligning them on the circumference.

[0075] As a result, the aligned coil manufacturing apparatus 10 according to one embodiment can easily align the segment coils 20 on a circular surface simply by inserting the segment coils 20 into the slits 121 and then rotating the blade rotor 120.

[0076] Although preferred embodiments of the present invention have been described in detail above, the present invention is not limited to these embodiments, and various modifications or changes are possible within the scope of the gist of the present invention as described in the claims. [Explanation of Symbols]

[0077] 10 Alignment coil manufacturing apparatus 11 Support stand 11A Top plate 12 Insertion device 12A arm 12B Grip part 20-segment coil 21 pairs 30 Alignment coils 100 Alignment device 101 Gap 120 blade rotor 121 Slit 122 Blades 130 Inner diameter side guide 131 Inner diameter side guide member 131A Tip 131B Inner diameter connecting pin 131C Guide groove 131D Tapered surface 132 Inner diameter side housing 132A Upper Housing 132B Lower Housing 133 Inner diameter side link plate 133A Inner diameter side guide groove 140 Outer diameter side guide 141 Outer diameter side guide member 141A Tip 141B Outer diameter connecting pin 142 Outer diameter side housing 142A Upper Housing 142B Lower Housing 142C center opening 142D fixing hole 143 Outer diameter side link plate 143A Outer diameter side guide groove 144 volts

Claims

1. A plurality of slits are provided in each slot of the stator core and are arranged radially at predetermined angular intervals, An inner diameter side guide that variably guides the legs of the segment coil inserted into the slit from the inner diameter side, An outer diameter side guide that variably guides the legs of the segment coil inserted into the slit from the outer diameter side, A coil manufacturing apparatus comprising: A rotatably mounted blade rotor having the plurality of slits, Each time the blade rotor is rotated by a predetermined angle, the segment coils are inserted into the slits, thereby forming an annular aligned coil in which multiple segment coils are aligned. The inner diameter side guide is It has a plurality of inner diameter side guide members arranged radially and movable in the radial direction, The outer diameter side guide is It has multiple outer diameter guide members arranged radially and movable in the radial direction, The inner diameter side guide is It has an inner diameter side link plate that rotates to move the plurality of inner diameter side guide members simultaneously in the radial direction, The outer diameter side guide is The outer diameter side link plate rotates to simultaneously move the multiple outer diameter side guide members in the radial direction. A coil manufacturing apparatus characterized by the following features.

2. A plurality of slits provided in each slot of the stator core and arranged radially at predetermined angular intervals, An inner diameter side guide that variably guides the legs of the segment coil inserted into the slit from the inner diameter side, An outer diameter side guide that variably guides the legs of the segment coil inserted into the slit from the outer diameter side, A coil manufacturing apparatus comprising: A rotatably mounted blade rotor having the plurality of slits, Each time the blade rotor is rotated by a predetermined angle, the segment coils are inserted into the slits, thereby forming an annular aligned coil in which multiple segment coils are aligned. The inner diameter side guide is It has a plurality of inner diameter side guide members arranged radially and movable in the radial direction, The outer diameter side guide is It has multiple outer diameter guide members arranged radially and movable in the radial direction, The inner diameter side guide is The tips of two adjacent inner diameter guide members overlap. The outer diameter side guide is The tips of two adjacent outer diameter guide members are overlapping. A coil manufacturing apparatus characterized by the following features.

3. The segment coil is After being inserted into the slit at a predetermined angle from the circumference of the formed alignment coil, it rotates together with the blade rotor to align on the circumference. The aligned coil manufacturing apparatus according to claim 1 or 2.

4. The inner diameter side guide is The segment coil has a tapered surface at the insertion position of the leg, The segment coil is When it rotates together with the blade rotor, the legs of the segment coil come into contact with the tapered surface, thereby aligning on the circumference. The aligned coil manufacturing apparatus according to feature 3.

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