Apparatus for forming and inserting insulating sheets, method for forming and inserting insulating sheets, and method for manufacturing a rotating electric machine using the same.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Filing Date
- 2026-02-16
- Publication Date
- 2026-05-20
AI Technical Summary
Conventional insulating sheet insertion devices for stator cores in rotating electrical machines face issues with dimensional tolerance, leading to poor fit of insulating sheets in the stator core slots, resulting in inaccurate insulation.
An insulating sheet forming and insertion device that cuts and forms the sheet to fit the inner shape of a stator core slot using first and second rotating bodies with guide members, where a central fold is formed as a reference, and the device is driven by a single unit to improve dimensional accuracy.
The device ensures precise fitting of insulating sheets to stator core slots, enhancing reliability and reducing complexity and cost by using a single drive unit, thus improving dimensional accuracy and insertion efficiency.
Abstract
Description
Insulating sheet forming and insertion device, insulating sheet forming and insertion method
[0001] The present disclosure relates to an insulating sheet forming and insertion device and an insulating sheet forming and insertion method.
[0002] Conventionally, stators used in rotating electrical machines such as automotive motors are formed of an annular stator core and coils fitted in slots between the teeth of the stator core. In addition, since the stator core and the coils need to be insulated from each other, a molded insulating sheet is inserted between them.
[0003] Conventionally, an insulating sheet insertion device for a stator core has been proposed, which cuts the insulating sheet and then forms it using a mold (see, for example, Patent Document 1). The conventional method for inserting an insulating sheet into a stator core disclosed in Patent Document 1 also describes a process of bending both sides of the insulating sheet into an L-shape using rollers that press the insulating sheet in the vertical direction before cutting it, and a process of softening the insulating sheet by heating. A method for forming an insulating sheet using rollers that press the insulating sheet not only in the vertical direction but also in the lateral direction (see, for example, Patent Document 2). In the conventional insulating paper folding device disclosed in Patent Document 2, as shown in FIG. 2 of Patent Document 2, a pair of grooves is formed on the outer periphery of the upper roller at a predetermined interval corresponding to the width of the central portion of the insulating paper, and a groove is formed on the outer periphery of the lower roller at a position corresponding to the groove of the upper roller, and the grooves are pressed into the grooves to form a pair of convex folds. In the conventional insulating paper folding device disclosed in Patent Document 2, a pair of convex folds are formed on both sides of the center of the insulating paper at a predetermined distance.
[0004] JP 2011-160587 A JP 2020-196562 A
[0005] However, in the conventional device disclosed in Patent Document 2, for example, the convex portions on both sides of the insulating paper are used as the forming reference, so the dimensional tolerance between the folds formed between those convex portions depends on the dimensions between the convex portions formed initially, which creates the problem that the insulating paper does not fit the shape of the slot in the stator core.
[0006] The present disclosure discloses technology for solving the above-mentioned problems, and aims to provide a highly reliable insulating sheet molding and insertion device and insulating sheet molding and insertion method that have improved dimensional accuracy and are adapted to the shape of the slots in the stator core.
[0007] The insulating sheet forming and insertion device disclosed herein is an insulating sheet forming and insertion device that cuts an insulating sheet that has been formed to fit the inner shape of a slot in a stator core while inserted into the slot, and is equipped with first and second rotating bodies that form a fold in the insulating sheet while sandwiching it, a drive unit that drives the first and second rotating bodies, and first and second guide members that are arranged at a gap from each other to guide the insulating sheet to the first and second rotating bodies, and is characterized in that a plurality of the first and second rotating bodies are provided in the direction of travel in which the insulating sheet passes between the first and second rotating bodies, and a first fold that serves as a basis for forming is formed in the center of the width of the insulating sheet by the first of the first and second rotating bodies that are arranged in the direction of travel. Further, a method for forming and inserting an insulating sheet according to the present disclosure is a method for forming an insulating sheet to fit the inner peripheral shape of a slot of a stator core, inserting the insulating sheet into the slot, and cutting the insulating sheet, the method including: a forming step of forming the insulating sheet to fit the inner peripheral shape of the slot of the stator core; an inserting step of inserting the formed insulating sheet into the slot from one end face side of the stator core; and a cutting step of cutting the insulating sheet to a length corresponding to a thickness from one end face to the other end face of the stator core, wherein the forming step is performed while the insulating sheet is held in a sandwiched state. the insulating sheet forming and insertion device comprises first and second rotating bodies on which a fold is formed, a drive unit for driving the first and second rotating bodies, and first and second guide members arranged at a gap from each other to guide the insulating sheet to the first and second rotating bodies, wherein a plurality of the first and second rotating bodies are provided in the direction of travel in which the insulating sheet passes between the first and second rotating bodies, and a first fold, which serves as a basis for forming, is formed in the center of the insulating sheet in the width direction by the first of the first and second rotating bodies arranged in the direction of travel.
[0008] The insulating sheet forming and insertion device and insulating sheet forming and insertion method disclosed herein improve dimensional accuracy and provide a highly reliable insulating sheet forming and insertion device and insulating sheet forming and insertion method that are adapted to the shape of the slots in the stator core.
[0009] 11 is a front view showing an insulating sheet forming and insertion device according to embodiment 1. FIG. 12 is a plan view showing an insulating sheet forming and insertion device according to embodiment 1. FIG. 13 is a cross-sectional view showing a first guide component taken along line A-A in FIG. 1. FIG. 14 is a cross-sectional view showing a second guide component according to embodiment 1. FIG. 15 is a cross-sectional view showing line B-B in FIG. 1. FIG. 16 is a cross-sectional view showing line C-C in FIG. 2. FIG. 17 is a rear view of FIG. 1. FIG. 18 is a top view showing an insertion state of an insulating sheet into a slot according to embodiment 1. FIG. 19 is a plan view showing an insulating sheet forming and insertion device according to embodiment 2. FIG. 19 is a cross-sectional view showing line D-D in FIG. 8. FIG. 19 is a rear view of FIG. 8. FIG. 19 is a plan view showing an insulating sheet forming and insertion device according to embodiment 3. FIG. 19 is a cross-sectional view taken along line E-E in FIG. 11. FIG. 19 is a rear view of FIG. 11.
[0010] Hereinafter, an insulating sheet forming and inserting device and an insulating sheet forming and inserting method according to embodiment 1 will be described with reference to the drawings. Note that the same reference numerals in the various drawings indicate the same or equivalent parts.
[0011] Embodiment 1. Fig. 1 is a front view of an insulating sheet forming and insertion device according to embodiment 1, and Fig. 2 is a plan view of the insulating sheet forming and insertion device according to embodiment 1. More specifically, in Fig. 2, 2A shows a plan view of the insulating sheet forming and insertion device, and 2B shows the formed shape of the insulating sheet corresponding to the first and fifth guide components and each pair of clamping rollers. Also, Fig. 3A is a cross-sectional view of the first guide component taken along line A-A in Fig. 1, and Fig. 3B is a cross-sectional view of the second guide component according to embodiment 1. Furthermore, Fig. 4 is a cross-sectional view of the first clamping roller taken along line B-B in Fig. 1, and Fig. 5 is a cross-sectional view of line C-C in Fig. 2. Also, Fig. 6 is a rear view of Fig. 1, and Fig. 7 is a top view showing the insulating sheet inserted into the slot according to embodiment 1.
[0012] 1 to 7 , an insulating sheet forming and insertion device 100 according to a first embodiment is an insulating sheet forming and insertion device 100 that cuts an insulating sheet 1i formed to fit the inner peripheral shape of a slot 42 in a stator core 41 while the insulating sheet 1i is inserted into the slot 42, and includes a first nipping roller 13b and a second nipping roller 14b that are first and second rotating bodies that form folds while sandwiching the insulating sheet 1, a drive source 24b that is a drive unit that drives the first and second rotating bodies, and a first guide member 11a and a second guide member 12a that are arranged at a gap from each other to guide the insulating sheet 1 to the first and second rotating bodies. A plurality of first and second rotating bodies are provided in the direction of travel of the insulating sheet 1 passing between the first and second rotating bodies. The first fold a, which serves as a shaping reference, is formed in the center of the insulating sheet 1b in the width direction by the first and second pinch rollers 60, which are the first first and second rotating bodies arranged in the direction of travel. As shown in Figure 2B, the first fold a is formed on the center line 2, which indicates the center of the insulating sheet 1b.
[0013] As shown in Figure 5, the insulating sheet forming and insertion device 100 according to the first embodiment includes a first guide component 51, a second guide component 52, a third guide component 53, a fourth guide component 54, and a fifth guide component 55. The first guide component 51 includes a first guide member 11a and a second guide member 12a, and the second guide component 52 includes a first guide member 11c and a second guide member 12c. The third guide component 53 includes a first guide member 11e and a second guide member 12e, and the fourth guide component 54 includes a first guide member 11g and a second guide member 12g. The fifth guide component 55 includes a first guide member 11i and a second guide member 12i.
[0014] Each of the first clamping rollers 13b, 13d, 13f, and 13h forms a pair of clamping rollers with a second clamping roller 14b, 14d, 14f, and 14h. A plurality of pairs of clamping rollers are provided in the direction of travel of the insulating sheet 1 passing between a pair of clamping rollers, for example, the pair consisting of the first clamping roller 13b and the second clamping roller 14b. A pair of guide components is provided in front of and behind each pair of clamping rollers in the direction of travel. The first clamping roller 13b and the second clamping roller 14b form the initial first and second clamping rollers 60 in the insulating sheet forming and insertion device 100, and the first clamping roller 13h and the second clamping roller 14h form the final first and second clamping rollers 61 in the insulating sheet forming and insertion device 100. Each pair of clamping rollers at each stage is provided with a driving source 24b, 24d, 24f, 24h, such as a motor, and a rotation transmission drive component 22b, 22d, 22f, 22h, which is a rotation means, and a rotation transmission drive component 23b, 23d, 23f, 23h, and the pair of clamping rollers at each stage operates via these.
[0015] In FIG. 2 , the insulating sheet 1 is inserted into the insulating sheet forming and inserting device 100 from the left side of the drawing. The width of the insulating sheet 1 is the vertical width of the insulating sheet 1 on the drawing. The insulating sheet 1 is inserted into the insulating sheet forming and inserting device 100 from a sheet reel (not shown) or in the form of a cut sheet. As shown in FIGS. 1 and 2 , the insulating sheet 1 is unwound in a strip shape and passes in the shape of the insulating sheet 1a between a pair of first guide members 51, the first guide member 11a and the second guide member 12a, which are installed at a predetermined distance, as shown in FIG. 3A . The insulating sheet 1 is then introduced into the insulating sheet forming and inserting device 100 by a pair of first and second clamping rollers 13b and 14b, which are operated via a drive source 24b, a rotation transmission drive member 22b, and a rotation transmission drive member 23b. The first guide member 11a has side walls spaced apart by a predetermined distance relative to the strip width of the insulating sheet 1a. The insulating sheet 1a moves straight in the direction of travel indicated by the arrow in FIG.
[0016] In the insulating sheet forming and insertion device 100 according to the first embodiment, all pairs of clamping rollers are provided with a drive source. Therefore, the diameters of the first clamping rollers 13b, 13d, 13f, and 13h and the diameters of the second clamping rollers 14b, 14d, 14f, and 14h may be the same, but do not necessarily have to be the same. If the diameters of the pairs of clamping rollers are different, it is sufficient to set the speed of each drive source.
[0017] Next, as shown in FIG. 4 , the insulating sheet 1b passes between a pair of first and second nipping rollers 13b and 14b, forming a first fold a in the center of the insulating sheet 1b. The first nipping roller 13b has a shape that matches the first fold a of the insulating sheet 1b. The second nipping roller 14b is configured to mesh with the first nipping roller 13b. The pair of first and second nipping rollers 13b and 14b are arranged facing each other in the vertical direction. The vertical direction is a direction perpendicular to the direction in which the insulating sheet 1 passes between the pair of first and second nipping rollers 13b and 14b. The insulating sheet forming and insertion device 100 is provided with a pressing means 21b, such as a compression spring, to strengthen the formation of the first fold a in the insulating sheet 1b. The pressing means 21b also serves to increase the frictional force between the pair of pinch rollers and the insulating sheet 1 for feeding in the forward direction. The first pinch roller 13b and the second pinch roller 14b each have a heating means, such as a cartridge heater 44, built in. The first pinch roller 13b and the second pinch roller 14b are heated to soften the insulating sheet 1 so that it can be easily processed.
[0018] The insulating sheet 1 is preferably a synthetic resin sheet such as a PET film or a polyimide film. The insulating sheet 1 is formed by arranging multiple pairs of guide components and multiple pairs of clamping rollers according to the folds or shape of the insulating sheet 1i, which is the final stage. That is, in the insulating sheet forming and insertion device 100 according to embodiment 1, multiple pairs of clamping rollers and multiple pairs of guide components are provided to match the inner peripheral shape of the slot 42 in the stator core 41. When forming each fold, the first central fold a formed by the initial pair of clamping rollers is used as a guide and reference.
[0019] 3B , the pair of second guide components 52, the first guide member 11c and the second guide member 12c, are installed with a predetermined gap between them via the insulating sheet 1b, and have a slit portion 70 and a free portion 71. The slit portion 70 is an area with a predetermined gap between the fold grooves formed by the immediately preceding first and second clamping rollers 13b and 14b, and the free portion 71 is an area without a guide to prevent deformation of the peripheral portions of the second folds b1 and b2 on both sides of the central first fold a formed by the next first and second clamping rollers 13d and 14d.
[0020] Next, the pair of first and second clamping rollers 13d and 14d are a pair of clamping rollers that form second folds b1 and b2 on both sides of the first central fold a. The three already formed folds, the first fold a and folds c1 and c2, serve as guides, so the pair of clamping rollers are shaped to leave a small gap between them and the folds b1 and b2 to be formed. In other words, the gap between the formed portion of the insulating sheet 1d and the pair of clamping rollers is slightly larger for the second folds b1 and b2 than for the first fold a and folds c1 and c2, the three already formed folds. Since no further forming is required for the already formed portions, a gap is left for the insulating sheet 1d to pass through.
[0021] Next, the pair of third guide components 53, the first guide member 11e and the second guide member 12e, are composed of slit sections with a predetermined gap between the grooves of the folds b1 and b2 formed by the immediately preceding first clamping roller 13d and second clamping roller 14d, and free sections for preventing deformation of the third folds d1 and d2 on both sides of the central first fold a formed by the next first clamping roller 13f and second clamping roller 14f.
[0022] Next, as described above, the pair of first and second clamping rollers 13f and 14f are a pair of clamping rollers that form the third folds d1 and d2 on both sides of the first central fold a, and the five folds that have already been deformed, namely the first fold a, folds b1, b2, c1, and c2, act as guides, so the pair of clamping rollers are shaped so that there is a small gap compared to the folds d1 and d2 that are to be formed.
[0023] Next, the pair of first and second pinch rollers 13h and 14h are a pair of pinch rollers that are arranged so that the angles of the first folds c1 and c2 on both sides of the first central fold a formed initially are slightly acute, and are smaller than the angles of c1 and c2. The pair of first and second pinch rollers 13h and 14h are a small pair of pinch rollers that extend to the folds e1 and e2 to be formed, and the folds b1, b2, d1, and d2 are free portions. Furthermore, the first central fold a acts as a guide, so the pair of pinch rollers are shaped to leave a small gap for the insulating sheet 1h to pass through.
[0024] The first guide member 11g and the second guide member 12g, which are a pair of fourth guide parts 54 arranged between the pair of first clamping rollers 13f and second clamping rollers 14f and the pair of first clamping rollers 13h and second clamping rollers 14h, are composed of slit portions with predetermined intervals between them, which are formed folds, namely the first fold a, and grooves of folds c1, c2, b1, b2, d1, and d2, up to the center in the flow direction of the insulating sheet 1f, but the latter half is a free portion except for the area near the central first fold a to avoid deformation at the next first clamping roller 13h and second clamping roller 14h.
[0025] The last pair of fifth guide parts 55, the first guide member 11i and the second guide member 12i, make the folds e1 and e2 formed by the first clamping roller 13h and the second clamping roller 14h even more acute than the folds e1 and e2, so that the insulating sheet 1h has grooves processed in it so that it becomes insulating sheet 1i as it flows.
[0026] Then, as shown in Fig. 7, the insulating sheet 1i is inserted into the stator core 41, and as shown in Fig. 6, the insulating sheet 1i is cut by the cutting component 31 using the cutting component drive source 32 according to the length of the stator core 41. Also, as shown in Fig. 6, the insulating sheet 1i is fed rearward by each pair of clamping rollers using the drive sources 24b, 24d, 24f, 24h or the pressing means 21b, 21d, 21f, 21h. As a means for inserting the insulating sheet 1i into the stator core 41, as described above, for example, the driving sources 24b, 24d, 24f, 24h or the pressing means 21b, 21d, 21f, 21h may be used to feed the insulating sheet rearward, or an insertion means such as a pusher may be used. In addition, the stator core 41 includes a magazine that imitates the stator core 41, and instead of the stator core 41, an insulating sheet 1i molded in a magazine that imitates the stator core 41 can be inserted, or the insulating sheet 1i can be inserted into the stator core 41 using a magazine in a separate process.
[0027] As described above, the insulating sheet forming and insertion device 100 according to the first embodiment is an insulating sheet forming and insertion device 100 that cuts an insulating sheet 1i that has been formed to fit the inner peripheral shape of the slot 42 of the stator core 41 while the insulating sheet 1i is inserted into the slot 42, and includes a first nipping roller 13b and a second nipping roller 14b that are first and second rotating bodies that form folds while sandwiching the insulating sheet 1, a drive source 24b that is a drive unit that drives the first and second rotating bodies, and a first guide member 11a and a second guide member 12a that are arranged at a gap from each other to guide the insulating sheet 1 to the first and second rotating bodies. A plurality of first and second rotating bodies are provided in the direction of travel of the insulating sheet 1 passing between the first and second rotating bodies. The first fold a, which serves as the basis for molding, is formed in the center of the width of the insulating sheet 1b by the first and second clamping rollers 60, which are the first and second rotating bodies arranged in the direction of travel.
[0028] As a result, the insulating sheet forming and inserting device 100 according to embodiment 1 has improved dimensional accuracy, and it is possible to obtain a highly reliable insulating sheet forming and inserting device and insulating sheet forming and inserting method that is adapted to the shape of the slot 42 in the stator core 41. By creating a forming reference in the center of the insulating sheet 1, the other folds are determined by the distance between each pair of clamping rollers and the reference first fold a, improving dimensional accuracy. The insulating sheet forming and insertion method according to the first embodiment is a method of forming the insulating sheet 1 to fit the inner peripheral shape of the slot 42 of the stator core 41, inserting it into the slot 42, and cutting it, and includes a forming step of forming the insulating sheet 1 to fit the inner peripheral shape of the slot 42 of the stator core 41, an inserting step of inserting the formed insulating sheet 1 into the slot 42 from one end face side of the stator core 41, and a cutting step of cutting the insulating sheet 1 to a length corresponding to the thickness from one end face to the other end face of the stator core 41, and the forming step is performed by inserting the insulating sheet 1 between the first and second rotating bodies having folds formed thereon while sandwiching the insulating sheet 1. The insulating sheet forming and inserting device 100 includes a first nipping roller 13b and a second nipping roller 14b, a drive source 24b that is a drive unit that drives the first and second rotors, and a first guide member 11a and a second guide member 12a that are arranged at a gap from each other to guide the insulating sheet 1 to the first and second rotors, and a plurality of the first and second rotors are provided in the direction of travel of the insulating sheet 1 passing between the first and second rotors, and a first fold that serves as a reference for forming is formed in the center of the insulating sheet 1b in the width direction by the first nipping roller 60 that is the first first and second rotors arranged in the direction of travel. As a result, according to the forming process of the insulating sheet forming and inserting method of embodiment 1, the insulating sheet 1 is not opened between the time it is formed and the time it is inserted into the slot 42 of the stator core 41, thereby eliminating incorrect insertion into the slot 42.
[0029] Furthermore, in the insulating sheet forming and insertion device 100 according to embodiment 1, dimensional accuracy is improved by cutting the insulating sheet 1 to a length corresponding to the thickness of the stator core 41. Furthermore, by heating the insulating sheet 1, the insulating sheet 1 is softened and becomes easier to form, thereby improving the accuracy of fold formation. Furthermore, in the insulating sheet forming and insertion method according to embodiment 1, the insulating sheet 1 is inserted into the slot 42 of the stator core 41 in the inserting step, so that the insulating sheet 1i can be inserted in its formed state. Furthermore, by inserting the insulating sheet 1i into the stator core 41 via a magazine simulating the stator core 41, it is expected that the time required for the insertion operation will be shortened.
[0030] Embodiment 2. Figure 8 is a plan view showing an insulating sheet forming and insertion device according to embodiment 2. More specifically, in Figure 8, 8A shows a plan view of the insulating sheet forming and insertion device, and 8B shows the formed shape of the insulating sheet corresponding to the first and fifth guide components and each pair of clamping rollers. Also, Figure 9 is a cross-sectional view showing the first clamping roller taken along line D-D in Figure 8, and Figure 10 is a rear view of Figure 8. The cross-sectional view taken along line C-C in Figure 8 is the same as Figure 5. In Figures 8 to 10, components with the same reference numerals as those used in the description of embodiment 1 indicate the same configuration, and their description will be omitted. Below, the insulating sheet forming and insertion device 100 according to embodiment 2 will be described, focusing on the configurations that differ from embodiment 1.
[0031] 8 and 10 , in the insulating sheet forming and insertion device 100 according to the second embodiment, the first and second clamping rollers 60 are provided with a drive source 24b, while the other pairs of clamping rollers are not provided with a drive source. In the insulating sheet forming and insertion device 100 according to the second embodiment, the device is driven by only the single drive source 24b, and the other pairs of clamping rollers operate their respective rotation transmission drive components 23b, 23d, 23f, and 23h via the rotation transmission rotating components 26b, 26d, 26f, 26g, and 26h of the pairs of clamping rollers at each stage and the rotation transmission rotating components 27d, 27f, 27g, and 27h between the pairs of clamping rollers. Furthermore, by making the diameters of the portions where the pairs of clamping rollers press the insulating sheet 1 the same at each stage, the feed speed of the insulating sheet 1 can be made the same.
[0032] Furthermore, by changing the configuration of rotating parts 26b, 26d, 26f, 26g, 26h and rotating parts 27d, 27f, 27g, 27h so that the rotation speed increases as the stage progresses, it is possible to ensure that insulating sheet 1 always flows backward without slack along the way. Furthermore, insulating sheet forming and insertion device 100 according to embodiment 2 does not include rotation transmission drive parts 22b, 22d, 22f, 22h that are provided in embodiment 1. For example, the rotating means in embodiment 2 for the initial first and second clamping rollers 60 corresponds to rotating part 26b, which is connected to both rotation transmission drive part 23b and rotating part 27d.
[0033] As described above, in the insulating sheet forming and insertion device 100 of the second embodiment, the drive source 24b, which is a drive unit, is provided on the first and second pinch rollers 60, which are the first first and second rotating bodies arranged in the direction of travel, and one drive unit provided on the first and second rotating bodies drives the other first and second rotating bodies other than the first first and second rotating bodies. This solves the problem that the conventional technology requires an increased number of drive units to operate the device by having a mold for forming the insulating sheet, rollers for pressing the lateral sides, etc., which makes the device structure complex and expensive.
[0034] In the insulating sheet forming and inserting device 100 of embodiment 2, it is preferable to connect each pair of clamping rollers using gears or belts so that they can be driven by a single drive source 24b, rather than providing multiple drive sources. Furthermore, it is preferable to make the diameters of the portions of each pair of clamping rollers that press the insulating sheet 1 the same, and to increase the rotation speed of each pair of clamping rollers as the molding process in the insulating sheet forming and inserting device 100 progresses. By using a single drive source rather than providing a drive source for each pair of clamping rollers, the insulating sheet forming and inserting device 100 of embodiment 2 can mold the insulating sheet 1 in accordance with the flow of each pair of clamping rollers, reducing power consumption and facilitating control. Furthermore, by making the diameters of the portions of each pair of clamping rollers that press the insulating sheet 1 the same, the feed speed of the insulating sheet 1 can be made the same, facilitating control. Furthermore, by increasing the rotation speed of each pair of clamping rollers as the molding process progresses, the insulating sheet 1 can be fed without slack.
[0035] Embodiment 3. Figure 11 is a plan view showing an insulating sheet forming and insertion device according to embodiment 3. More specifically, in Figure 11, 11A shows a plan view of the insulating sheet forming and insertion device, and 11B shows the formed shape of the insulating sheet corresponding to the first and fifth guide components and each pair of clamping rollers. Also, Figure 12 is a cross-sectional view of line E-E in Figure 11, and Figure 13 is a rear view of Figure 11. The cross-sectional view of line C-C in Figure 11 is the same as Figure 5. In Figures 11 to 13, components with the same reference numerals as those used in the description of embodiments 1 and 2 indicate the same configuration, and their description will be omitted. Below, the insulating sheet forming and insertion device 100 according to embodiment 3 will be described, focusing on configurations that differ from those of embodiments 1 and 2.
[0036] 11 and 13 , in the insulating sheet forming and insertion device 100 according to the third embodiment, the last first and second clamping rollers 61 are provided with a drive source 24h, while the other pairs of clamping rollers are not provided with drive sources. In the insulating sheet forming and insertion device 100 according to the third embodiment, the device is driven by only one drive source 24h, and the other pairs of clamping rollers operate their respective rotation transmission drive components 23b, 23d, 23f, and 23h via rotating components 26b, 26d, 26f, 26g, and 26h and rotating components 27d, 27f, 27g, and 27h. Furthermore, by making the diameters of the portions where the pairs of clamping rollers press the insulating sheet 1 the same at each stage, the feed speed of the insulating sheet 1 can be made the same.
[0037] Furthermore, by changing the configuration of rotating elements 26b, 26d, 26f, 26g, 26h and rotating elements 27d, 27f, 27g, 27h so that the rotational speed increases as the process progresses, the insulating sheet 1 can be constantly moved backward without slack. Furthermore, by locating drive source 24h at the final first and second clamping rollers 61, the latter half of the forming process can be handled, where the load driving the pair of clamping rollers increases, making it easier to feed the insulating sheet 1. Furthermore, the insulating sheet forming and inserting device 100 according to the third embodiment does not include rotation transmission drive elements 22b, 22d, 22f, 22h, which are provided in the first embodiment. For example, the rotating means in the third embodiment is rotating element 26h, which is connected to both rotation transmission drive element 23h and rotating element 27h, at the final first and second clamping rollers 61.
[0038] As described above, in the insulating sheet forming and insertion device 100 of the third embodiment, the driving source 24h, which is a driving unit, is provided on the last first and second pinch rollers 61, which are the last first and second rotating bodies arranged in the direction of travel, and one driving unit provided on the last first and second rotating bodies drives the other first and second rotating bodies other than the last first and second rotating bodies. This solves the problem that in the prior art, the device required more driving units to operate due to the inclusion of a mold for forming the insulating sheet, rollers for pressing the lateral sides, etc., which made the device structure more complex and expensive.
[0039] The above describes in detail preferred embodiments, but the present invention is not limited to the above-described embodiments, and various modifications and substitutions can be made to the above-described embodiments without departing from the scope of the claims.
[0040] Various aspects of the present disclosure are summarized below as appendices.
[0041] (Supplementary Note 1) An insulating sheet forming and insertion device in which an insulating sheet shaped to fit the inner peripheral shape of a slot in a stator core is inserted into the slot and cut, comprising: first and second rotors that form a fold in the insulating sheet while sandwiching it, a drive unit that drives the first and second rotors, and first and second guide members that are arranged at a gap from each other to guide the insulating sheet to the first and second rotors, wherein a plurality of the first and second rotors are provided in a traveling direction in which the insulating sheet passes between the first and second rotors, and a first fold that serves as a reference for forming is formed in the center of the insulating sheet in the width direction by an initial one of the first and second rotors arranged in the traveling direction. (Supplementary Note 2) The insulating sheet forming and insertion device according to Supplementary Note 1, in which another fold is formed by another one of the first and second rotors that is arranged in the traveling direction, using the first fold as a reference. (Supplementary Note 3) The insulating sheet forming and inserting device according to Supplementary Note 1 or Supplementary Note 2, wherein the first and second rotating bodies are provided with heating means. (Supplementary Note 4) The insulating sheet forming and inserting device according to any one of Supplementary Note 1 to Supplementary Note 3, wherein the drive unit is provided on the first and second rotating bodies that are initially arranged in the traveling direction, and the first and second rotating bodies other than the initial first and second rotating bodies are driven by the single drive unit provided on the initial first and second rotating bodies. (Supplementary Note 5) The insulating sheet forming and inserting device according to any one of Supplementary Note 1 to Supplementary Note 3, wherein the drive unit is provided on the first and second rotating bodies that are initially arranged in the traveling direction, and the first and second rotating bodies other than the final first and second rotating bodies are driven by the single drive unit provided on the final first and second rotating bodies. (Appendix 6) The insulating sheet molding and insertion device described in any one of appendices 1 to 5, characterized in that the first and second rotating bodies have the same diameter at the portions that press the insulating sheet.(Supplementary Note 7) The insulating sheet forming and insertion device according to any one of Supplementary Note 1 to Supplementary Note 6, wherein the rotational speeds of the first and second rotating bodies are set faster than the rotational speeds of the initial first and second rotating bodies as the first and second rotating bodies move toward the last first and second rotating bodies arranged in the traveling direction. (Supplementary Note 8) The insulating sheet forming and insertion device according to any one of Supplementary Note 1 to Supplementary Note 7, wherein the stator core includes a magazine imitating the shape of the stator core, and the formed insulating sheet is inserted into the slot of the stator core or the magazine imitating the shape of the stator core. (Supplementary Note 9) A method for forming and inserting an insulating sheet, which comprises forming the insulating sheet to fit the inner peripheral shape of a slot of a stator core, inserting the insulating sheet into the slot, and cutting the insulating sheet, the method comprising: a forming step of forming the insulating sheet to fit the inner peripheral shape of the slot of the stator core; an inserting step of inserting the formed insulating sheet into the slot from one end face side of the stator core; and a cutting step of cutting the insulating sheet to a length corresponding to the thickness from one end face to the other end face of the stator core, The insulating sheet forming and inserting method according to claim 9, wherein the forming step uses an insulating sheet forming and inserting device comprising first and second rotors that form a fold while sandwiching the insulating sheet, a drive unit that drives the first and second rotors, and first and second guide members that are arranged at a gap from each other to guide the insulating sheet to the first and second rotors, a plurality of the first and second rotors being provided in the direction of travel of the insulating sheet, and a first fold that serves as a reference for forming is formed in the center of the insulating sheet in the width direction by an initial one of the first and second rotors arranged in the direction of travel. (Appendix 10) The insulating sheet forming and inserting method according to claim 9, wherein, in the forming step, another fold is formed by another of the first and second rotors that are provided in the direction of travel, using the first fold as a reference.(Supplementary Note 11) The insulating sheet molding and insertion method according to Supplementary Note 9 or Supplementary Note 10, wherein in the molding step, the first and second rotating bodies are provided with heating means, and the insulating sheet is softened by the heating means. (Supplementary Note 12) The insulating sheet molding and insertion method according to any one of Supplementary Note 9 to Supplementary Note 11, wherein in the molding step, the drive units are provided on the first and second rotating bodies that are initial and arranged in the direction of travel, and one drive unit provided on the initial first and second rotating bodies drives the other first and second rotating bodies other than the initial first and second rotating bodies. (Supplementary Note 13) The insulating sheet molding and insertion method according to any one of Supplementary Note 9 to Supplementary Note 11, wherein in the molding step, the drive units are provided on the first and second rotating bodies that are final and arranged in the direction of travel, and one drive unit provided on the final first and second rotating bodies drives the other first and second rotating bodies other than the final first and second rotating bodies. (Supplementary Note 14) The insulating sheet molding and inserting method according to any one of Supplementary Notes 9 to 13, wherein in the molding step, the first and second rotating bodies have the same diameter at the portions that press the insulating sheet. (Supplementary Note 15) The insulating sheet molding and inserting method according to any one of Supplementary Notes 9 to 14, wherein in the molding step, the rotational speeds of the first and second rotating bodies are set to be faster than the rotational speeds of the initial first and second rotating bodies as the first and second rotating bodies move toward the last first and second rotating bodies arranged in the traveling direction. (Supplementary Note 16) The insulating sheet molding and inserting method according to any one of Supplementary Notes 9 to 15, wherein the stator core includes a magazine that imitates the shape of the stator core, and in the inserting step, the molded insulating sheet is inserted into the slot of the stator core or the magazine that imitates the shape of the stator core.
[0042] Although various exemplary embodiments and examples are described in this disclosure, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are anticipated within the scope of the technology disclosed in this specification. For example, this includes cases where at least one component is modified, added, or omitted, or where at least one component is extracted and combined with components of another embodiment.
[0043] DESCRIPTION OF SYMBOLS 1, 1a, 1b, 1d, 1f, 1h, 1i Insulating sheet, 2 Center line, 11a, 11c, 11e, 11g, 11i First guide member, 12a, 12c, 12e, 12g, 12i Second guide member, 13b, 13d, 13f, 13h First clamping roller, 14b, 14d, 14f, 14h Second clamping roller, 21b, 21d, 21f, 21h Pressing means, 22b, 22d, 22f, 22h Rotational transmission drive component, 23b, 23d, 23f, 23h Rotational transmission drive component, 24b, 24d, 24f, 24h Drive source, 26b, 26d, 26f, 26g, 26h Rotating component, 27d, 27f, 27g, 27h Rotating part, 31 Cutting part, 32 Cutting part driving source, 41 Stator core, 42 Slot, 44 Cartridge heater, 51 First guide part, 52 Second guide part, 53 Third guide part, 54 Fourth guide part, 55 Fifth guide part, 60 Initial first and second nipping rollers, 61 Final first and second nipping rollers, 70 Slit part, 71 Free part, 100 Insulating sheet forming and insertion device, a First fold, b1, b2, c1, c2, d1, d2, e1, e2 Folds
Claims
1. An insulating sheet molding and insertion apparatus for cutting an insulating sheet that has been molded to fit the inner circumference shape of a slot in a stator core, while inserted into the slot, The device comprises first and second rotating bodies that have folds formed while holding the insulating sheet, The first and second rotating bodies are arranged in a plurality in the direction of travel through which the insulating sheet passes between the first and second rotating bodies. An insulating sheet molding and insertion apparatus characterized in that a first fold, which serves as a molding reference, is formed in the center of the insulating sheet in the width direction by the first and second rotating bodies arranged in the direction of travel.
2. A drive unit for driving the first and second rotating bodies, The insulating sheet molding and insertion apparatus according to claim 1, further comprising: first and second guide members arranged with a gap between them for guiding the insulating sheet to the first and second rotating bodies.
3. The insulating sheet molding and insertion apparatus according to claim 1, characterized in that, with respect to the first fold, another fold is formed by another first and second rotating body provided in the direction of travel.
4. The insulating sheet molding and insertion apparatus according to claim 1 or 3, characterized in that heating means are provided for the first and second rotating bodies.
5. The drive unit is provided on the first and second rotating bodies arranged in the direction of travel, The insulating sheet molding and insertion apparatus according to claim 2, characterized in that a single drive unit provided on the first first and second rotating bodies drives other first and second rotating bodies other than the first first and second rotating bodies.
6. The drive unit is provided on the last of the first and second rotating bodies arranged in the direction of travel, The insulating sheet molding and insertion apparatus according to claim 2, characterized in that one of the drive units provided on the last of the first and second rotating bodies drives other first and second rotating bodies other than the last of the first and second rotating bodies.
7. The insulating sheet molding and insertion apparatus according to claim 1 or 3, characterized in that the first and second rotating bodies have the same diameter in the portion that presses the insulating sheet.
8. The insulating sheet molding and insertion apparatus according to claim 1 or 3, characterized in that the rotational speeds of the first and second rotating bodies are set to be faster than the rotational speed of the first and second rotating bodies as one approaches the last of the first and second rotating bodies arranged in the direction of travel.
9. The stator core includes a magazine that mimics the shape of the stator core. The insulating sheet molding and insertion apparatus according to claim 1 or 3, characterized in that the molded insulating sheet is inserted into the slot of the stator core or into the magazine which is shaped to resemble the stator core.
10. A method for forming and inserting an insulating sheet, comprising shaping the insulating sheet to conform to the inner circumference shape of the slot of the stator core, inserting it into the slot, and cutting it, A molding step of shaping the insulating sheet to conform to the inner circumference shape of the slot of the stator core, Insertion step of inserting the molded insulating sheet into the slot from one end face side of the stator core, The process includes a cutting step of cutting the insulating sheet to a length corresponding to the thickness from one end face to the other end face of the stator core, A method for molding and inserting an insulating sheet, characterized in that the molding step uses an insulating sheet molding and insertion apparatus comprising first and second rotating bodies that form a fold while holding the insulating sheet, a plurality of the first and second rotating bodies are provided in the direction of travel through which the insulating sheet passes between the first and second rotating bodies, and a first fold that serves as the molding reference is formed in the center of the insulating sheet in the width direction by the first of the first and second rotating bodies arranged in the direction of travel.
11. The method for molding and inserting an insulating sheet according to claim 10, further comprising: a drive unit for driving the first and second rotating bodies; and first and second guide members arranged with a gap between them to guide the insulating sheet to the first and second rotating bodies.
12. The method for molding and inserting an insulating sheet according to claim 10, characterized in that, in the molding step, another fold is formed by another first and second rotating body provided in the direction of travel, with respect to the first fold.
13. In the molding process, the first and second rotating bodies are provided with heating means. The method for molding and inserting an insulating sheet according to claim 10 or 12, characterized in that the insulating sheet is softened by the heating means.
14. In the molding process, the drive unit is provided on the first and second rotating bodies arranged in the direction of travel. The method for forming and inserting an insulating sheet according to claim 11, characterized in that one of the drive units provided on the first first and second rotating bodies drives another first and second rotating body other than the first first and second rotating body.
15. In the molding process, the drive unit is provided on the last of the first and second rotating bodies arranged in the direction of travel, The method for forming and inserting an insulating sheet according to claim 11, characterized in that one of the drive units provided on the last of the first and second rotating bodies drives another of the first and second rotating bodies other than the last of the first and second rotating bodies.
16. The molding and insertion method for an insulating sheet according to claim 10 or 12, characterized in that, in the molding step, the diameter of the portion that presses the insulating sheet is the same for the first and second rotating bodies.
17. The molding step is characterized in that the rotational speeds of the first and second rotating bodies are set to be faster than the rotational speed of the first and second rotating bodies as one approaches the last of the first and second rotating bodies arranged in the direction of travel, as described in claim 10 or 12.
18. The stator core includes a magazine that mimics the shape of the stator core. The method for molding and inserting an insulating sheet according to claim 10 or 12, characterized in that, in the insertion step, the molded insulating sheet is inserted into the slot of the stator core or into the magazine which is shaped to resemble the stator core.
19. A method for manufacturing a rotating electric machine, comprising insulating the stator core and coil of the rotating electric machine using the method for forming and inserting an insulating sheet described in Claim 10, A method for manufacturing a rotating electric machine, characterized in that the stator core and the coil are insulated by inserting the molded insulating sheet into the slot to match the inner circumference shape of the slot of the stator core.