Conductor bundle separation device and conductor bundle separation method

Abstract

[Problem] To separate a conductor bundle 4M that is firmly bonded in a slot 2b without chucking a processed stator 1A with excessive force and without causing deformation of a silicon steel plate. [Solution] A conductor bundle separation device 6 separates a conductor bundle 4M from a stator 1 that has a stator core 2 having a center hole 2a and a plurality of slots 2b around the center hole 2a, and a conductor bundle 4M bonded in the slot 2b. The conductor bundle separation device 6 comprises a press unit 30 having a stay 33, a press rod 34 that is vertically driven by a press actuator 31 at an upper portion of the stay 33, and a support 37 at a lower portion of the stay 33. The support 37 has a cavity 37a through which the conductor bundle 4M that is positioned on an axis L of the press rod 34 can pass, and inserts the press rod 34 into the slot 2b by being driven by the press actuator 31 in a state in which the slot 2b is made to coincide with the axis L and the lower surface of the stator core 2 is supported by the support 37.

Description

Conductive wire bundle separating device and conductive wire bundle separating method

[0001] The present invention relates to a stator core having a central hole and slots formed therearound, and a wire bundle separating device and method for separating the wire bundle from a stator having wire bundles bonded in the slots.

[0002] Electric vehicles can be broadly classified into four types, collectively known as xEVs. Hybrid vehicles were the first to be commercially available, but 20 years have passed since their launch, and establishing recycling technology for xEVs is becoming a major challenge. The challenge differs significantly from the dismantling and recycling of conventional automobiles: the dismantling and recycling of batteries and xEV motors.

[0003] Since there are no established technical methods for dismantling and recycling xEV motors, we will first explain the dismantling of motors for home appliances as a reference.

[0004] Since the Home Appliance Recycling Law came into effect, the technology for dismantling cooling compressor motors (hereafter referred to as black motors) used in household and commercial refrigerators, air conditioners, water dispensers, vending machines, etc. has evolved. When dismantling black motors, the most valuable resource is the coiled conductor wire (mainly copper wire).

[0005] The black motor is a device that compresses refrigerant gas to high pressure, and the motor and compressor are sealed together in a welded iron container called a shell. The only inputs and outputs from this shell are the gas intake port, discharge port, and electrical leads, and it is completely sealed to prevent gas leaks. For this reason, it is not easy to disassemble it.

[0006] Generally, the materials are put into a crusher to crush iron, copper, silicon steel, aluminum, and in some cases magnets containing rare earths, and then sorted afterwards. However, because black motors are extremely sturdy, the crusher blades do not last long, and the wires can get tangled, making it difficult to separate them neatly. In addition, copper powder adheres to the iron pieces, making it difficult to separate them completely.

[0007] Another method is to fuse or mechanically cut the black motor's shell, remove the contents, and then further disassemble it. The following is an outline of the black motor disassembly process. First Step: Cutting the Black Motor Shell. Rotary black motors are cut in two places, top and bottom, and reciprocating black motors are cut in one place along the circumference. Cutting methods include gas or plasma fusion, cutting by cutting, or cutting by using a rotary blade to dig in plastically. Second Step: Separating the Motor and Compressor. The stator, with its wound wires, is removed. Third Step: Cutting the Wires. One of the wires coming out of both ends of the stator is cut along the stator surface. Fourth Step: Pulling Out the Wires. The stator is fixed in place, and the wire coming out of the other end of the cut wire is grasped and pulled out.

[0008] The above is the case for black motors, but when it comes to dismantling and recycling xEV motors, disassembly is easy in the first and second steps because the motor is not sealed in a welded container, and the third step can also be handled by applying a cutting machine used for home appliances, but the biggest challenge is the fourth step.

[0009] 1(a) to 1(f) show various types of stators 1 for xEV motors (reference numerals for each component of the stator 1 are attached only in FIG. 1(a)). The stator core 2 is made up of several hundred or more stacked silicon steel sheets, each about 0.1 mm thick. Round or rectangular conductor wires are wound between multiple slots 2b according to a set rule, and upper conductor wires 4U and lower conductor wires 4L are exposed on the upper and lower stator surfaces 3U and 3L of the stator core 2.

[0010] In the case of round conductors, both the top and bottom are fixed to the circumference with string or the like, while in the case of square conductors, since they do not have the flexibility of round conductors, the top and bottom conductors are joined together by welding or the like. Square conductors are the mainstream for xEV motors because they can handle a higher current density.

[0011] JP 2011-062030 A

[0012] The problems with the method of extracting the conductor wires from the stator will be described below.

[0013] Problem 1: To withstand severe vibrations, the windings wound around the stator core 2 of the xEV motor shown in Figure 1 are firmly fixed in the slots 2b with adhesive or the like. Therefore, they cannot be easily pulled out like the conductors of black motors for home appliances, which are not fixed in the slots. In other words, the conductors of an xEV motor cannot be pulled out using a conductor puller for black motors.

[0014] Problem 2: The stator of the black motor can be carried by hand, but the stator 1 of the xEV motor weighs a maximum of 20 kg or more, and although it may be feasible experimentally, it is impossible from a commercial standpoint to continuously move, lift, turn over, and so on by hand. Currently, xEV motors are mainly used in passenger cars, but xEV motors for transport trucks and other vehicles, which are expected to become more widespread in the future, are expected to become even larger and heavier.

[0015] Therefore, in order to establish a wire extraction method that can solve Problem 1, two experiments were conducted.

[0016] Experiment 1: Pull-out method After cutting the winding (upper conductor 4U or lower conductor 4L) extending outward from either the upper or lower stator surface 3U, 3L of the stator core 2 along the stator surface 3U or 3L, a 60-degree circumference of the conductor protruding from the other stator surface 3U or 3L was gripped with a powerful hydraulic gripping mechanism, and several points on the stator surface 3U, 3L nearby were pressed down to receive the reaction force when pulling out. When the gripping mechanism was lifted with a maximum thrust of 2000 kg, it was confirmed that the conductor was lifted slightly out of the stator 1. This proves that the gripping force and thrust are sufficient to move the conductor inside the stator 1.

[0017] However, because the conductors are connected circumferentially at both the top and bottom, there are limited places where the stator 1 can be held down, and as a result, each of the thin silicon steel plates that make up the stator 1 separates and deforms as the conductors move, narrowing the width of the slots 2b. As a result, the resistance of the conductors increases rapidly when they are pulled out, and they stop moving altogether halfway through. This only increases the deformation of the silicon steel plates, and it was found that this method physically prevents the conductors from being removed.

[0018] Experiment 2: Wire Press Extrusion Method for Slot 2b The upper and lower conductors 4U and 4L at both ends of the stator 1 were cut along the stator surfaces 3U and 3L, leaving the slot 2b clearly visible. A conductor bundle 4M (not shown in Figure 1; see Figure 2) adhered with resin or the like remained in the slot 2b. Hereinafter, the stator 1 processed in this manner will be referred to as the processed stator 1A. A hole larger than the slot 2b was drilled in the reference surface, and the processed stator 1A was placed on the reference surface, aligning with the hole. A press rod was then hydraulically pressed from above the slot 2b. In this case, because the area around the slot 2b was in contact with and supported by the reference surface, the silicon steel plate was not deformed, and it was possible to extrude it by applying an appropriate force to the press rod.

[0019] Experiment 1 was conducted within a 60-degree range of the processed stator 1A (equivalent to 8 to 12 slots 2b), but as in Experiment 2, if it was conducted for each slot 2b, it was possible to push out the wire bundle 4M with considerably less force.

[0020] However, the above method causes the following problems 3 to 6.

[0021] Problem 3: As shown in Figure 1, the height 5 of slot 2b is considerably longer than the cross-sectional dimensions of slot 2b. Therefore, when a long, thin press rod is inserted into slot 2b with a large force, the inserted portion is guided by the inner wall of slot 2b and does not bend. However, when the press rod begins to be inserted into slot 2b, most of the press rod is exposed from slot 2b, which can cause the press rod to buckle under pressure. Experiment 2 was performed by inserting multiple short rods in sequence, so no buckling occurred, but it would be difficult to employ a similar method in commercial equipment.

[0022] Problem 4: When the outer diameter of the stator 1 is chucked, the chuck mechanism (chuck housing, etc.) completely shields the top and bottom surfaces of the stator, and the conductor bundle 4M in the slot 2b cannot be pressed out due to interference with the chuck mechanism. In order to maximize magnetic efficiency, the slot 2b is located close to the inner diameter of the stator 1, as shown in Figure 1. Therefore, even when the central hole 2a is chucked from the inside, if the chuck mechanism is even slightly larger outward than the central hole 2a, the pressed out conductor bundle 4M will interfere.

[0023] Problem 5: When the press rod is pushed into the specified slot 2b while the inner or outer diameter of the stator 1 is chucked, the press force is applied to the entire chuck mechanism. If the chucking force is weak, the stator 1 may shift or tilt. On the other hand, if the chucking force is too strong, the silicon steel plate may be deformed.

[0024] Problem 6: To press and push out the conductor bundles 4M in the slots 2b without deforming the silicon steel plate, a support that firmly supports the stator core around the slot is required. To separate the conductor bundles 4M from multiple slots, the stator must be rotated each time the conductor bundles 4M of each slot are separated, but it is undesirable for the stator to come into contact with the support during rotation.

[0025] The present application discloses the following invention: <Aspect 1> A wire bundle separation device for separating a wire bundle from a stator having a stator core having a central hole and a plurality of slots surrounding the central hole, and a wire bundle bonded in the slots, the wire bundle separation device comprising: a stay; a press rod driven up and down by a press actuator attached to an upper part of the stay; and a support attached to a lower part of the stay, the support having a hollow portion positioned on the axis of the press rod through which the wire bundle can pass, the support being configured to align the slots with the axis and support a lower surface of the stator core by driving the press actuator to insert the press rod into the slots, thereby pushing the wire bundle out of the slots. <Aspect 2> The wire bundle separation device of Aspect 1, further comprising: a table having an opening through which the support fixed to the device body can pass; a linear guide that guides the stay fixed to the device body in the up and down direction; and a balance spring that urges the stay upward, wherein the stay is supported such that an upper surface of the support is located below the table due to a balance between the weight of the press unit and the urging force of the balance spring, and the urging force of the press rod is applied to the stator on the table, causing the support to rise to a position where it abuts against the lower surface of the stator core on the table. <Aspect 3> The wire bundle separation device of Aspect 1, further comprising: a chuck unit including: a chuck housing having an outer shape that can pass through the central hole; a plurality of chuck jaws that can slide radially at different angular positions of the chuck housing; and a rotary actuator that intermittently rotates the chuck housing; and a linear actuator that moves the chuck unit up and down between three height positions: an origin height at which an upper end of the chuck housing is positioned below the table; a first operating height at which the chuck jaws can engage with the central hole of the stator placed on the table; and a second operating height that is higher than the first operating height.<Aspect 4> The wire bundle separation device of Aspect 3, wherein the chuck unit includes: a tapered shaft movable up and down within a central axial hole of the chuck housing; a cam follower sliding on the up and down moving tapered shaft to drive the chuck jaws radially outward; and a fluid pressure actuator that drives the tapered shaft up and down within the axial hole. <Aspect 5> The wire bundle separation device of Aspect 4, wherein the rotary actuator further includes: a hollow rotating shaft; and a drive fluid conduit passing through the hollow rotating shaft, one end of the drive fluid conduit being connected to the fluid pressure actuator, and the other end of the drive fluid conduit being connected to a swivel joint. <Aspect 6> The wire bundle separation device of Aspect 1, wherein the press unit further includes a guide member formed on the axis and having a guide hole for guiding the press rod, the press rod having a tip end and a base end having a cross-sectional shape with a larger moment of inertia than the tip end, and the guide hole having a cross-sectional shape that allows both the tip end and the base end to pass through. <Aspect 7> A wire bundle separation method for separating a wire bundle from a stator having a stator core having a central hole and a plurality of slots around the central hole, and wire bundles bonded in the slots, using a wire bundle separation device, wherein the wire bundle separation device has a press unit including: a stay; a press rod that is driven up and down by a press actuator attached to an upper part of the stay; and a support base attached to a lower part of the stay, wherein the support base has a hollow portion that is positioned on the axis of the press rod and allows the wire bundle to pass therethrough, the slots are aligned with the axis, and a lower surface of the stator core is supported by the support base, and the press actuator is driven to insert the press rod into the slots, thereby pushing out the wire bundles from the slots.

[0026] Structure of the stator of various xEV motors. Side cross-sectional view of a wire bundle separation device 6 according to one embodiment of the present invention. Plan view of the wire bundle separation device 6. Shows a chuck unit 10. (a) Plan view of essential parts. (b) Side cross-sectional view. Press unit 30 and advancing / retracting unit 50. (a) Plan view of essential parts. (b) Side cross-sectional view. Side and plan views of a press rod 34 and a guide member 35, and cross-sectional views of the press rod 34 and the guide member 35 at positions C, D, E, and F.

[0027] A wire bundle separating device 6 according to an embodiment of the present invention will now be described.

[0028] 1, the stator 1 has a stator core 2 with a central hole 2a and slots 2b formed around the central hole 2a, and windings 4 wound around the slots 2b and bonded and fixed with resin or the like. The portions of the windings exposed from the upper and lower surfaces 3U and 3L of the stator core 2 are called upper windings 4U and lower windings 4L, respectively.

[0029] The stator 1 is cut or otherwise processed to remove the upper winding 4U and the lower winding 4L from the stator core 2, resulting in a processed stator 1A. Wire bundles 4M, adhered and fixed with resin or the like, remain in the slots 2b of the processed stator 1A. The processed stator 1A is the object to be processed by the wire bundle separation device 6. The wire bundle 4M is the portion of the winding 4 from which the upper winding 4U and the lower winding 4D have been cut and removed. The wire bundle 4M usually has roughly the same cross-sectional shape as the slots 2b. The purpose of the wire bundle separation device 6 is to push out and separate the wire bundle 4M from the slots 2b of the processed stator 1A.

[0030] 2 and 3 show a wire bundle separation device 6 according to one embodiment of the present invention. Fig. 2 is a side view, and Fig. 3 is a plan view. The wire bundle separation device 6 has a device main body 64, a table 60, a press unit 30, and a chuck unit 10. The wire bundle separation device 6 may further have an advance / retract unit 50 for driving the press unit 30 forward and backward, a fluid pressure unit (fluid pressure source) 70 for driving various actuators, a control panel 80 (Fig. 3), etc.

[0031] FIG. 5 shows a press unit 30. The press unit 30 includes a stay 33, a press actuator 31 fixed to the upper portion of the stay 33, a press rod 34 connected to the drive shaft of the press actuator 31 via a cylinder rod joint 41 and a press rod joint 42, and a support 37 having a cavity (or recess) 37a extending from the lower end of the stay 33. The press rod 34 is driven up and down along an axis (drive shaft) L by the press actuator 31. The stay 33 and the support 37 are preferably formed as an integral member. The cavity 37a is located on the axis L of the press rod 34 and has a shape and size that allows the conductor bundle 4M to pass through. To accommodate multiple types of stators 1 having slots 2b of different shapes and sizes, the cavity 37a is preferably shaped and sized to allow the conductor bundles 4M in the slots 2b of multiple shapes and sizes to pass through. Although FIG. 5 shows a linear cavity 37a, the cavity 37a may be curved or bent along the way.

[0032] The advance / retract unit 50 can have a linear guide 39 fixed to the device main body 64, a base 51 that allows the linear guide 39 to slide back and forth, and an up-down linear guide 36 attached to the base 51, and the stay 33 of the press unit 30 can be slid up and down on the linear guide 36.

[0033] The press unit 30 may have a linear position sensor 32 for detecting the position of the stay 33 on the linear guide 36. The advance / retract unit 50 may have an actuator for slidingly driving the base 51 and a sensor for detecting the position of the press unit 30.

[0034] The wire bundle separator 6 may further include a balance spring 38 inserted between the linear guide 39 and the stay 33. That is, the stay 33 is guided up and down by the linear guide 36 and is biased upward by the balance spring 38. Therefore, when the press unit 30 is unloaded, it stops at a height position (balance position) where the weight of the press unit 30 and the biasing force of the balance spring 38 are balanced, and it can be moved up and down from the balance position with a small external load. In the wire bundle separator 6 of this example, the dimensions, strength, etc. of the balance spring 38 are set so that the upper surface 37b of the support 37 is positioned below the table 60 (reference point Hr) when the press unit 30 is in the balance position.

[0035] As shown in FIG. 3, an opening 61 is formed in the table 60. The opening 61 may have a shape / size that allows the chuck housing 15 (FIG. 4) or, further, the support 37 (or the support 37 and the stay 33) to pass through. The opening 61 may have a circular portion 61a through which the chuck housing 15 passes and an additional portion 61b through which the support 37 (or the support 37 and the stay 33) passes. Rollers 65 and 66 are provided on the table 60, and the processed stator 1A can be moved on the table 60 with a small force as shown by the arrow in FIG. 3.

[0036] FIG. 4 shows a chuck unit 10. The chuck unit 10 includes a chuck housing 15 having an outer shape that can pass through the central hole 2a of the processed stator 1A, chuck jaws 11 that can slide within radially extending grooves of the chuck housing 15 at different angular positions, and a rotary actuator 21 that intermittently rotates the chuck housing 15. The chuck unit 10 can grip the processed stator 1A by sliding the chuck jaws 11 radially outward to engage with the central hole 2a. FIG. 4 shows an example of a three-way chuck having three chuck jaws 11 spaced 120 degrees apart, but the angular spacing and the number of chuck jaws 11 can be changed. Because the inner diameter of the central hole 2a may differ depending on the type of stator 1, it is preferable to make the chuck jaws 11 or the tips of the chuck jaws 11 interchangeable depending on the inner diameter of the central hole 2a.

[0037] The wire bundle separation device 6 may further include a linear actuator 23 that drives the chuck unit 10 up and down. The linear actuator 23 can move the chuck unit 10 between three heights H0 to H2: an origin height H0 at which the upper end of the chuck housing 15 is positioned below the table 60; a first operating height H1 at which the chuck jaws can engage with the central hole 2a of the processed stator 1A placed on the table 60; and a second operating height H2 above the first operating height. In the figure, Hr indicates the height position (reference point Hr) of the surface of the table 60. The origin height H0 is slightly below the reference point Hr.

[0038] In order to stabilize and ensure the movement of the chuck unit 10 between the three heights H0 to H2 and / or to facilitate control, it is preferable that the linear actuator 23 be a dual cylinder in which two linear cylinders 23a, 23b are connected in tandem.

[0039] In order to stabilize the operation of the linear actuator 23, it is preferable to provide a guide rod 24 that supports the chuck unit 10 and a linear bushing 25 that guides the guide rod 24.

[0040] The chuck unit 10 may further include a tapered shaft 17 that is movable up and down within an axial hole formed in the center of the chuck housing 15, a cam follower 12 that drives the chuck jaws 11 radially outward by sliding on the tapered shaft 17, and a fluid pressure actuator 28 that drives the tapered shaft 17. The fluid pressure may be, for example, hydraulic or pneumatic, with pneumatic being particularly preferred. The chuck unit 10 may further include a return spring 14 that biases each chuck jaw 11 radially inward.

[0041] When the tapered shaft 17 is raised by driving the fluid pressure actuator 28, the cam follower 12 slides on the tapered shaft 17, driving the chuck jaws 11 radially outward. When the tapered shaft 17 descends, the urging force of the return spring 14 drives the chuck jaws 11 radially inward.

[0042] The cam follower 12 preferably has rollers 12a that slide and rotate on a tapered shaft 17, and a rotation shaft 12b that supports the rollers 12a and has both ends supported by the chuck jaws 11. The tapered shaft 17 preferably has inclined flat surfaces 18 at positions corresponding to the rollers 12a of each chuck jaw 11. Sliding the rollers 12a on the inclined flat surfaces 18 improves sliding stability.

[0043] The rotary actuator 21 has a hollow rotary shaft through which a drive fluid line 20 may be passed. One end of the drive fluid line 20 may be connected to a fluid pressure actuator 28, and the other end may be connected to a swivel joint 22. This allows for fluid pressure control with a simple structure of the fluid pressure actuator 28, which rotates and moves up and down. The swivel joint 22 may be connected to a fluid pressure unit 70 (FIG. 3).

[0044] The press unit 30 may further include a guide member 35 at an intermediate height position of the stay 33. The guide member 35 may be fixed to the stay 33. Figure 6 shows a side view and a plan view of a preferred embodiment of the press bar 34 and guide member 35, as well as cross-sectional views of the press bar 34 and guide member 35 at positions C, D, E, and F.

[0045] The press bar 34 preferably has a tip end 34a and a base end 34b having a cross-sectional shape with a larger moment of inertia than the tip end 34a. In the example shown in the figures, the tip end 34a of the press bar 34 has a shape (e.g., a flat shape) that allows it to be inserted into the slot 2b, and the base end 34b has a shape (e.g., a cross shape) with a larger moment of inertia than the tip end 34a.

[0046] The guide member 35 preferably has a guide hole 35a for guiding the press rod 34. The guide hole 35a is preferably located on the axis L of the press rod 34. The guide hole 35a preferably has a cross-sectional shape that allows both the tip end 34a and the base end 34b of the press rod 34 to pass through.

[0047] When the press rod 34 descends and contacts the stator 1, and then is inserted into the slot 2b, an axial force acts on the press rod 34, which can cause the press rod 34 to buckle. However, in the press unit 30, the tip end 34a is guided by the guide hole 35a, and the base end 34b has a large second moment of area, so buckling of the press rod 34 can be prevented. The length of the tip end 34a should be approximately the same as or slightly longer than the height 5 of the stator core 2. The length of the guide member 35 should be approximately the same as the height 5 of the stator core 2.

[0048] In order to accommodate a plurality of types (models) of treated stators 1A with different slot shapes, the tip portion 34a may have a shape and size that allows it to be inserted into any of the slots 2b of the various treated stators 1A. For example, the tip portion 34a may have a shape and size that allows it to be inserted into any of the slots 2b of the various treated stators 1A.

[0049] In FIG. 6, a rectangular slot 2b (FIGS. 1(a) to 1(c)) is assumed, and the press rods 34 and guide holes 35a are shown with a rectangular combined shape. However, in the case of slots 2b of other shapes (FIGS. 1(d) to 1(f)), the shapes of the press rods 34 and guide holes 35a can be changed accordingly.

[0050] The conductor bundle separating device 6 is preferably provided with a control device (not shown) that is configured with a computer, a storage medium, etc., in order to control the operation of the device by a computer.

[0051] A wire bundle separation method (method of operating the wire bundle separation device 6) according to one embodiment of the present invention will now be described.

[0052] Preparation Step 1: The chuck unit 10 is supported by the rotary actuator 21 at the origin height H0 so that the upper end of the chuck housing 15 is positioned below the table 60. Step 2: The strength of the balance spring 38 is adjusted so that the upper surface 37b of the support 37 is positioned slightly below the table 60. Step 3: The press unit 30 is retracted on the linear guide 39 to the farthest position from the chuck unit 10. Step 4: The press rod 34 and guide member 35 corresponding to the type of processed stator 1A to be worked on are attached to the tip of the press actuator 31 via the cylinder rod joint 41 and the press rod joint 42. Step 5: The press start position of the press rod 34 and the driving distance of the press actuator 31 corresponding to the height 5 of the stator 1 may be stored in advance in a storage medium or the like. By following Steps 1 to 5 above, the processed stator 1A can be freely moved on the table 60 without interfering with the chuck housing 15, support 37, press rod 34, and other components (see arrows in Figure 3).

[0053] Loading, alignment, etc. Step 6: Slide the processed stator 1A on the table 60 and place it at the position of the opening 61a. Step 7: Drive the linear actuator 23 to raise the chuck unit 10 to the first operating height H1. This raises the chuck jaws 11 to a height where they can chuck the central hole 2a. Step 8: Drive the fluid pressure actuator 28 to raise the tapered shaft 17. This moves the chuck jaws 11 radially outward and abuts against the inside of the central hole 2a of the processed stator 1A, chucking the processed stator 1A. Step 9: Drive the linear actuator 23 to raise the chuck unit 10 to the second operating height H2. This separates the processed stator 1A from the table 60. This allows the processed stator 1A to rotate freely without interfering with the table 60. Step 10: Move the press unit 30 forward along the linear guide 39 to a predetermined position depending on the type of processed stator 1A. Fine adjustments may be made manually. If the rotational position of the processed stator 1A is misaligned, the rotary actuator 21 is rotated so that the slot 2b is positioned on the axis L. The rotation may be done manually, and the coincidence may be judged visually.

[0054] Step 11: The press actuator 31 is driven to lower the press rod 34 according to steps 11-1 and 11-2 below. Step 11-1: The press rod 34 descends until its tip contacts the wire bundle 4M. The downward biasing force of the press actuator 31 acts on the treated stator 1A, causing the press unit 30 to rise along the linear guide 36. Because the press unit 30 is supported in a state where its weight and the biasing force of the balance spring 38 are balanced, it moves upward with only a slight force. Therefore, the press rod 34 does not descend, and the tip of the press rod 34 can maintain the position (contact position) where it contacted the wire bundle 4M. During this time, almost no force is applied to the treated stator 1A and the chuck jaws 11. Step 11-2: When the upper surface 37b of the support 37 abuts against the lower surface of the stator core 2, the press unit 30 stops rising, and the press rod 34 begins to descend from the contact position. Because the lower surface of the stator core 2 is supported by the upper surface 37b of the support 37 and cannot move downward, the press rod 34 enters the slot 2b and pushes the conductor bundle 4M from the slot 2b into the cavity 37a. Because the periphery of the slot 2b is supported by the upper surface 37b of the support 37, deformation of the silicon steel plate and the resulting deformation of the shape of the slot 2b are prevented. The pushed-out conductor bundle 4M is collected in the collection box 63 via the chute 62 (Figure 2). Step 12: When the push-out of the conductor bundle 4M is complete, the press actuator 31 is driven to raise the press rod 34 to its initial position. Completion of extrusion can be determined by measuring the height position of the press rod 34 with the linear position sensor 32 and comparing it with the drive distance of the press actuator 31 that is pre-stored for each type of processed stator 1A. Step 13: After confirming that the press rod 34 has risen to its initial position, the rotary actuator 21 is driven to rotate the chuck unit 10 (processed stator 1A) until the next slot 2b coincides with the axis L of the press rod 34. As described in step 9, the processed stator 1A can rotate freely. Step 14: Thereafter, steps 11 to 13 are repeated to separate the wire bundles 4M from all slots 2b.

[0055] Releasing and carrying out the processed stator 1A, etc. Step 15: When separation of the wire bundles 4M from all slots 2b is completed, the linear actuator 23 lowers the chuck unit 10 to the first operating height H1, and then the fluid pressure actuator 28 lowers the tapered shaft 17, thereby releasing the chuck of the processed stator 1A by the chuck unit 10, and then the linear actuator 23 lowers the chuck unit 10 to the origin height H0. Thereafter, it is advisable to retract the press unit 30 to the retracted position on the linear guide 39. Step 16: The processed stator 1A is slid on the table 60 using the rolling of the rollers 65, 66 and carried out of the apparatus.

[0056] Thereafter, by repeating steps 6 to 16, it is possible to separate the conductor bundles 4M from a plurality of processed stators 1A.

[0057] All or part of the steps 6 to 16 can be automatically performed by controlling the actuators 21, 23, 28, 31, etc. using a control device, etc. In particular, it is preferable to automatically perform steps 11 to 15.

[0058] According to the wire bundle separation device 6, the wire bundles 4M are pushed out of the slots 2b by inserting the press rod 34 into the slots 2b while the underside of the stator core 2 (around the slots 2b) is supported by a support 37 having a hollow portion 37a on the axis L of the press rod 34 through which the wire bundles 4M can pass. Therefore, the wire bundles 4M firmly adhered in the slots 2b can be pushed out and separated without causing deformation of the silicon steel plate or chucking the processed stator 1A with excessive force.

[0059] Furthermore, while the stay 33 is guided by the linear guide 36 so that it can move up and down, the stay 33 is supported by the balance spring 38 so that the support 37 is located below the table 60, so that the processed stator 1A can be moved on the table 60 without interfering with the support 37, and the support 37 can support the stator core 2 when the conductor bundle 4M is pushed out and separated. Because the lower surface of the stator core 2 is supported by the support 37, it is possible to push out and separate the conductor bundle 4M with almost no external force acting on the stator core 2 or the chuck jaws 11.

[0060] Furthermore, the chuck housing 15 can pass through the central hole 2a, and the chuck claws 11 engage with the central hole 2a from the inside to chuck the processed stator 1A. The linear actuator 23 can move the chuck housing 15 up and down between the origin height H0, the first operating height H1, and the second operating height H2. This prevents the chuck housing 15 from blocking the slot 2b, and allows the processed stator 1A to be moved on the table 60 without interfering with the chuck housing 15. It also makes it possible to rotate the processed stator 1A without contacting the table 60.

[0061] The chuck jaws 11 are driven radially outward by sliding the cam follower 12 on a tapered shaft that moves up and down by a fluid pressure actuator 28 in a central shaft hole of the chuck housing, thereby preventing excessive gripping force from being applied to the processed stator 1A when chucking the processed stator 1A, and preventing deformation of the silicon steel plate or slot 2b due to excessive gripping force and resulting difficulty in extruding and separating the conductor bundle 4M. To prevent excessive gripping force, it is preferable that the fluid pressure actuator 28 be of the pneumatic type and be operated at a pre-adjusted pressure.

[0062] Furthermore, a hollow rotating shaft is provided in the rotary actuator 21, a driving fluid pipe 20 is passed through the hollow rotating shaft, and both ends of the driving fluid pipe 20 are connected to the fluid pressure actuator 28 and the swivel joint 22, making it possible to supply working fluid to the fluid pressure actuator 28, which moves up and down and rotates.

[0063] Furthermore, a guide member 35 having a guide hole 35a is provided on the axis L, and the base end 34b of the press rod 34 has a larger second moment of area than the tip end 34a, and the guide hole 35a has a cross-sectional shape that allows both the tip end 34a and the base end 34b to pass through, thereby making it possible to prevent buckling of the press rod 34 when the wire bundle 4M is extruded.

[0064] The dimensions, shape, arrangement, number, materials, and the like of the wire bundle separation device 6 and its elements described in the above embodiment are merely examples, and other embodiments are also possible. For example, if a robot or the like is used to load and unload the processed stator 1A and the chuck unit 10 chucks the processed stator 1A at the load position, the table 60 and linear guide 39 can be omitted, and since there is no need to move the chuck unit 10 from the second operating height H2, the linear actuator 23 can also be omitted. If a robot or the like is used to rotate the processed stator 1A, the chuck unit 10 can be omitted.

[0065] DESCRIPTION OF SYMBOLS 1... Stator 1A... Processed stator 2... Stator core 2a... Central hole 2b... Slot 3U, 3L... Stator surface 4... Winding 4U... Upper winding 4L... Lower winding 4M... Wire bundle 5... Slot height 6... Wire bundle separation device 10... Chuck unit 11... Chuck jaws 12... Cam follower 12a... Roller 12b... Rotational axis 14... Return spring 15... Chuck housing 17... Tapered axis 18... Inclined plane 20... Drive fluid pipeline 21... Rotary actuator 22... Swivel joint 23... Linear actuator 24... Guide rod 25... Linear bushing 28... Fluid pressure actuator 30... Press unit 31... Press actuator 32... Linear position sensor 33... Stay 34... Press rod 34a... Tip end 34b... Base end 35... Guide member 35a... Guide hole 36: Linear guide 37: Support 37a: Hollow portion 37b: Surface 38: Balance spring 39: Linear guide 41: Cylinder rod joint 42: Press rod joint 50: Advance / retreat unit 60: Table 61: Opening 61a: Circular portion 61b: Additional portion 62: Shooter 63: Recovery box 64: Device body 65, 66: Rollers 70: Fluid pressure unit 80: Control panel H0: Origin height H1: First operating height H2: Second operating height Hr: Reference point L: Axis

Claims

1. A wire bundle separation device for separating a conductor bundle from a stator having a stator core having a central hole and a number of slots surrounding the central hole, and a conductor bundle bonded in the slots, the wire bundle separation device comprising: a press unit having: a stay; a press bar that is driven up and down by a press actuator attached to an upper part of the stay; and a support attached to a lower part of the stay, the support having a hollow portion located on the axis of the press bar through which the conductor bundle can pass, the slots being aligned with the axis and the underside of the stator core being supported by the support, the press actuator is driven to insert the press bar into the slots, and the conductor bundle is extruded from the slots.

2. The wire bundle separation device of claim 1, further comprising: a table having an opening through which the support fixed to the main body can pass; a linear guide that guides the stay fixed to the main body up and down; and a balance spring that urges the stay upwards, wherein the stay is supported so that the upper surface of the support is located below the table due to the balance between the weight of the press unit and the urging force of the balance spring, and the support is raised to a position where it abuts against the underside of the stator core on the table when the urging force of the press rod is applied to the stator on the table.

3. The wire bundle separation device of claim 1, further comprising: a chuck unit having a chuck housing having an outer shape capable of passing through the central hole, a plurality of chuck jaws capable of sliding radially at different angular positions of the chuck housing, and a rotary actuator for intermittently rotating the chuck housing; and a linear actuator for moving the chuck unit up and down between three height positions: an origin height at which an upper end of the chuck housing is positioned below the table, a first operating height at which the chuck jaws can engage with the central hole of the stator placed on the table, and a second operating height higher than the first operating height.

4. The wire bundle separation device of claim 3, characterized in that the chuck unit comprises: a tapered shaft that is movable up and down within a central axial hole of the chuck housing; a cam follower that drives the chuck jaws radially outward by sliding on the tapered shaft that moves up and down; and a fluid pressure actuator that drives the tapered shaft up and down within the axial hole.

5. The wire bundle separation device according to claim 4, characterized in that the rotary actuator further comprises: a hollow rotating shaft; and a drive fluid pipe passing through the hollow rotating shaft, one end of the drive fluid pipe being connected to the hydraulic actuator, and the other end of the drive fluid pipe being connected to a swivel joint.

6. The wire bundle separation device of claim 1, wherein the press unit further has a guide member having a guide hole formed on the axis for guiding the press rod, the press rod has a tip portion and a base portion having a cross-sectional shape with a larger moment of area than the tip portion, and the guide hole has a cross-sectional shape that allows both the tip portion and the base portion to pass through.

7. A wire bundle separation method for separating a conductor bundle from a stator having a stator core having a central hole and a plurality of slots surrounding the central hole, and a conductor bundle bonded in the slots, using a wire bundle separation device, wherein the wire bundle separation device has a press unit having a stay, a press rod that is driven up and down by a press actuator attached to an upper part of the stay, and a support base attached to a lower part of the stay, the support base having a hollow portion located on the axis of the press rod through which the conductor bundle can pass, the slots are aligned with the axis, the lower surface of the stator core is supported by the support base, and the press actuator is driven to insert the press rod into the slots, thereby pushing out the conductor bundle from the slots.

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