Stator manufacturing method, motor manufacturing method, and stator manufacturing device

Abstract

This stator manufacturing method has a winding step in which a wire material that is fed out from a nozzle (65) is wound onto a magnetic pole of a stator core (11). The winding step includes a first winding step in which rotation of the stator core (11) and movement of the nozzle (65) in the axial direction of the stator core (11) are combined to wind the wire material that is fed out from the nozzle (65) onto the magnetic pole, and a second winding step in which, after the wire material has been wound onto the magnetic pole a prescribed number of times in the first winding step, the nozzle (65) is made to move without passing through a slot adjacent to the magnetic pole while the wire material that is fed out from the nozzle (65) is held by guides (80a, 80b, 90a, 90b) that are positioned facing the magnetic pole in the axial direction, whereby the wire material that is fed out from the nozzle (65) is passed through the slot and wound onto the magnetic pole.

Description

Stator manufacturing method, motor manufacturing method, and stator manufacturing device

[0001] The present invention relates to a stator manufacturing method, a motor manufacturing method, and a stator manufacturing apparatus.

[0002] JP3719122B discloses a winding method for an electric motor in which the coil is wound up to the limit position where the operating path of the winding nozzle can be secured, and then the wound coil is temporarily fixed by a coil holding mechanism in order to wind the coil on the side of each tooth that does not contribute to slot formation, and in this state the winding nozzle is moved to a position that does not directly face the side of the corresponding tooth that contributes to slot formation.

[0003] The winding method described in JP3719122B increases the space factor, but uses a coil holding mechanism that holds and releases the coil, which results in a longer takt time (the time required to manufacture one product).

[0004] An object of the present invention is to shorten the tact time while increasing the space factor.

[0005] According to one aspect of the present invention, there is provided a method for manufacturing a stator having a winding process for winding a wire fed from a nozzle around a magnetic pole of a stator core, the winding process including: a first winding process for winding the wire fed from the nozzle around the magnetic pole by combining rotation of the stator core and movement of the nozzle in the axial direction of the stator core; and a second winding process for winding the wire around the magnetic pole a predetermined number of times in the first winding process, by holding the wire fed from the nozzle with a guide arranged opposite the magnetic pole in the axial direction and moving the nozzle without passing through a slot next to the magnetic pole, thereby passing the wire fed from the nozzle through the slot and winding the wire around the magnetic pole.

[0006] FIG. 1 is a cross-sectional view showing a schematic configuration of a motor according to an embodiment of the present invention. FIG. 2 is a first perspective view of a winding device according to an embodiment of the present invention. FIG. 3 is a second perspective view of a winding device according to an embodiment of the present invention. FIG. 4 is a perspective view showing a core support base of a core rotation device alone. FIG. 5 is an explanatory view of a first winding process. FIG. 6 is a first explanatory view of a second winding process. FIG. 7 is a second explanatory view of the second winding process. FIG. 8 is a view showing a stator core with winding completed. FIG. 9 is a first explanatory view of an opening of the core support base. FIG. 10 is a second explanatory view of an opening of the core support base. FIG. 11 is a view showing a main part of a modified example of an upper guide. FIG. 12 is an explanatory view of the curved shape of the guide.

[0007] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

[0008] FIG. 1 is a cross-sectional view showing a schematic configuration of a motor 100 having a stator 10 manufactured by a manufacturing method for a stator 10 according to an embodiment of the present invention.

[0009] The motor 100 includes a stator 10, a rotor 20 arranged coaxially with the stator 10, and a case 30 that houses the stator 10 and the rotor 20. The stator 10 and the rotor 20 have a generally annular shape, and the stator 10 is arranged to surround the outer periphery of the rotor 20. A rotating shaft 21 is attached to the center of the rotor 20, and the rotating shaft 21 is rotatably supported by the case 30 via bearings 22 and 23.

[0010] The motor 100 is mounted, for example, on a vehicle. The motor 100 can operate as an electric motor that receives power from a battery and drives it to rotate. When the rotor 20 receives rotational energy from the drive wheels, the motor 100 functions as a generator and can charge the battery. The motor 100 may be used as either an electric motor or a generator. The motor 100 can also be mounted on various devices other than vehicles.

[0011] Vehicles in which the motor 100 is mounted include, for example, a battery electric vehicle (BEV), a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), and the like.

[0012] The stator 10 is an inner rotor type (see FIG. 8 ) and is fixed to the inner circumferential surface of the cylindrical portion of the case 30. The stator 10 includes a substantially annular stator core 11 and coils 12 arranged on teeth 11 b (see FIG. 8 ) of the stator core 11.

[0013] The rotor 20 has a plurality of permanent magnets 13 arranged at equal intervals in the circumferential direction. The rotor 20 rotates around a rotation axis 21 due to a reaction force of the permanent magnets 13 generated by a rotating magnetic flux applied from the coil 12 of the stator 10.

[0014] 2 and 3 are first and second perspective views of the winding device 1 as a manufacturing device for the stator 10, and Fig. 4 is a perspective view showing the core support base 54 of the core rotation device 50. The X-axis, Y-axis, and Z-axis shown in the figure are three orthogonal axes, and the Z-axis extends along the vertical direction.

[0015] 2 and 3, the winding device 1 includes a core rotation device 50 that rotates the stator core 11, a nozzle movement device 60 that moves a nozzle 65 from which the wire 121 of the coil 12 is fed, and a guide movement device 70 that moves an upper guide 80 and a lower guide 90 (see FIGS. 9 and 10), and winds the stator core 11. The guide movement device 70 is disposed opposite the nozzle movement device 60 in the X-axis direction, and is installed on a base 2 (see FIG. 2) of the winding device 1 via a support member 3 (see FIGS. 3, 9, and 10).

[0016] The stator core 11 includes an annular yoke 11a and a plurality of teeth 11b that protrude from the inner peripheral surface of the yoke 11a toward the center of the yoke 11a. The teeth 11b are magnetic poles, and a wire 121 is wound around each tooth 11b of the stator core 11 by a winding device 1 to form a coil 12. The wire 121 has an insulating coating (insulating material), and the insulating coating is formed in advance on the surface of the wire 121 using an insulating paint, coating, or the like.

[0017] 2, the core rotation device 50 is provided on the base 2 of the winding device 1 and includes a fixed base 51 fixed on the base 2, a rotating base 52 rotatably provided on the fixed base 51, a drive motor 53 that rotates the rotating base 52, and a core support base 54 that is provided on the rotating base 52 and serves as a core support member that supports the stator core 11. The base 2 is disposed substantially horizontally (substantially parallel to the X-axis and Y-axis), and the axial direction of the core rotation device 50 is set in the vertical direction (Z-axis direction).

[0018] The rotating table 52 is rotatably mounted on the fixed table 51 via bearings or the like, and is rotated by a drive motor 53. As indicated by the dashed line, the drive motor 53 is mounted on the base 2 on the opposite side of the base 2 from the core rotation device 50, that is, on the back side of the base 2 (the lower side in FIG. 2 ), and is disposed coaxially with the rotating table 52. The rotation shaft of the drive motor 53 extends in the Z-axis direction and is connected to the rotating table 52 through a hole formed in the base 2 and the inside of the fixed table 51. A servo motor capable of controlling the rotation speed and rotation position with high precision is used as the drive motor 53.

[0019] The core support base 54 is cylindrical and is attached to the rotating base 52 from above (the upper side in FIG. 2 ) on the opposite side to the fixed base 51. The core support base 54 is positioned in the rotational direction relative to the rotating base 52 via a notch 54 a formed on one end side of the core support base 54 (the lower side in FIG. 4 ), and rotates integrally with the rotating base 52.

[0020] An adapter 4 is attached to the core support base 54 to set the stator core 11 on the core support base 54. The adapter 4 is positioned in the rotational direction on the core support base 54 via a notch 54b formed on the other end side (upper side in FIG. 4 ) of the core support base 54, and rotates integrally with the core support base 54. Therefore, the drive motor 53 rotates the rotary base 52, thereby rotating the stator core 11.

[0021] An opening 54c is formed as a through-hole in the side wall of the core support base 54. The opening 54c is rectangular and large enough to allow guides 90a and 90b, which will be described later, to be inserted therein. A plurality of openings 54c are formed, and the number of openings 54c is the same as the number of teeth 11b. The openings 54c will be described further below.

[0022] The nozzle moving device 60 has a front-rear direction feed unit 61 that performs a feed operation along the front-rear direction (X-axis direction), which is the axial direction of the nozzle 65, a left-right direction feed unit 62 that performs a feed operation along the left-right direction (Y-axis direction), and a up-down direction feed unit 63 that performs a feed operation along the up-down direction (Z-axis direction). The front-rear direction feed unit 61 and the left-right direction feed unit 62 have the same structure as the up-down direction feed unit 63. For this reason, the following description will mainly focus on the up-down direction feed unit 63 as an example.

[0023] The vertical feed unit 63 includes a guide rail 63a extending along the Z-axis, a ball screw 63b extending substantially parallel to the guide rail 63a, a follower 63c threadedly engaged with the ball screw 63b and movable along the guide rail 63a, a connecting member 63d attached to the follower 63c, and a drive motor 63e for rotating the ball screw 63b. A servo motor, for example, is used as the drive motor 63e. The same applies to the drive motor 61e of the front-rear feed unit 61 and the drive motor 62e of the left-right feed unit 62.

[0024] The up-down direction feed section 63 is connected to a connecting member 62d of the left-right direction feed section 62 and is provided so as to be movable in the left-right direction by the left-right direction feed section 62. Similarly, the left-right direction feed section 62 is connected to a connecting member 61d of the front-rear direction feed section 61 and is provided so as to be movable in the front-rear direction by the front-rear direction feed section 61. The front-rear direction feed section 61 is provided on the base 2.

[0025] The connecting member 63d of the vertical feed section 63 extends along the X-axis direction, and a nozzle holding member 64 is attached to the tip of the connecting member 63d. The nozzle holding member 64 extends from the connecting member 63d along the Z-axis direction toward the base 2, and a nozzle 65 is provided at the tip (lower end in FIG. 2 ) of the nozzle holding member 64 along the X-axis direction. The tip side (lower side in FIG. 2 ) of the nozzle holding member 64 is inserted into the stator core 11 together with the nozzle 65, and the wire 121 is guided to the nozzle 65 via a through-hole 63f formed in the connecting member 63d and a diverting pulley, and is paid out from the tip of the nozzle 65.

[0026] As shown in FIG. 3 , the winding device 1 has an upper guide 80 and a lower guide 90 (see FIGS. 9 and 10 ) that hold the wire 121 fed from the nozzle 65 during the process of winding the wire around the teeth 11 b and position the held wire 121 with respect to the teeth 11 b. The upper guide 80 is disposed on one axial side of the stator core 11 (upper side in the Z-axis direction), and the lower guide 90 is disposed on the other axial side of the stator core 11 (lower side in the Z-axis direction). The upper guide 80 and the lower guide 90 have similar structures. For this reason, the following description will mainly focus on the upper guide 80 as an example. In addition, the tooth 11 b that is the target of winding will also be simply referred to as the winding target tooth 11 b.

[0027] The upper guide 80 is disposed facing a surface 11ba (non-facing surface) of the outer circumferential surface of the winding subject tooth 11b that does not face an adjacent tooth 11b, and has a pair of upper left guide 80A and upper right guide 80B arranged side by side in the winding direction (Y-axis direction) of the wire material 121. Furthermore, each of the upper left guide 80A and upper right guide 80B includes a guide 80a arranged parallel to the winding direction (Y-axis direction) of the wire material 121 wound around the winding subject tooth 11b, and a guide 80b arranged parallel to the guide 80a with a gap between them equal to the diameter of the wire material 121. In other words, the guide 80a and the guide 80b are disposed in the direction of the winding axis of the winding subject tooth 11b (radial direction of the stator core 11) with a gap equal to the diameter of the wire material 121.

[0028] A pair of guide movement devices 70 are arranged for moving the pair of upper left guide 80A and upper right guide 80B in three orthogonal axis directions relative to the upper guide 80. The guide movement device 70 includes a winding axis direction movement mechanism 70x that moves the upper guide 80 in the winding axis direction (X-axis direction) of the winding subject tooth 11b, a winding direction movement mechanism 70y that moves the upper guide 80 in the winding direction (Y-axis direction) of the wire 121 to be wound around the winding subject tooth 11b, and a vertical direction movement mechanism 70z that moves the upper guide 80 in the direction toward or away from the winding subject tooth 11b (Z-axis direction).

[0029] The winding axis direction moving mechanism 70x includes a housing 71x supported by the support member 3, a drive motor 72x arranged at an end of the housing 71x, a ball screw 73x connected to the output shaft of the drive motor 72x and extending in the X-axis direction, and a follower 74x that threadably engages with the ball screw 73x and moves along the ball screw 73x.

[0030] The winding direction moving mechanism 70y includes a housing 71y that is coupled to a follower 74x of the winding axis direction moving mechanism 70x and moves along a ball screw 73x, a drive motor 72y that is disposed at an end of the housing 71y, a ball screw 73y that is coupled to the output shaft of the drive motor 72y and extends in the Y-axis direction, and a follower 74y that is threadedly engaged with the ball screw 73y and moves along the ball screw 73y.

[0031] A rod 75 extending in the Y-axis direction is coupled to a follower 74y of the winding direction movement mechanism 70y, and an L-shaped support 76 is coupled to the tip of the rod 75. A vertical direction movement mechanism 70z is disposed on a surface 76a of the support 76 that is perpendicular to the Y-axis direction and a surface 76b that is perpendicular to the X-axis direction.

[0032] The vertical movement mechanism 70z includes guide rails 77a, 77b arranged on the surfaces 76a, 76b of the support body 76, respectively, and extending in the Z-axis direction, and movable bodies 78a, 78b that are guided by the guide rails 77a, 77b and can move along the guide rails 77a, 77b.

[0033] An air cylinder is housed within the support 76. A piston that moves back and forth using compressed air is inserted into the air cylinder, and the piston is connected to the moving bodies 78a and 78b. Therefore, by driving the air cylinder, the moving bodies 78a and 78b move along the guide rails 77a and 77b.

[0034] A guide 80a is coupled to the movable body 78a, and a guide 80b is coupled to the movable body 78b. Therefore, by driving the winding axis direction moving mechanism 70x, the winding direction moving mechanism 70y, and the vertical direction moving mechanism 70z, the guides 80a and 80b can be freely moved in three orthogonal axial directions relative to the surface 11ba of the winding subject tooth 11b. Furthermore, because the guide moving device 70 is provided individually for each of the pair of upper left guide 80A and upper right guide 80B, the pair of upper left guide 80A and upper right guide 80B can be freely moved individually in three orthogonal axial directions relative to the surface 11ba of the winding subject tooth 11b.

[0035] The second guide, the lower guide 90, is disposed opposite the rear surface (non-facing surface) of the front surface 11ba, and is thereby disposed on the other axial side (lower side in the Z-axis direction) of the stator core 11. The lower guide 90 also has a pair of lower left and right guides 90A and 90B (see FIG. 7 ) arranged side by side in the winding direction (Y-axis direction) of the wire 121, and the lower left and right guides 90A and 90B also have guides 90a and 90b, respectively. A guide movement device 70 is also provided individually for each of the pair of lower left and right guides 90A and 90B of the lower guide 90. The guides 80a and 80b correspond to first guides, and the guides 90a and 90b correspond to second guides.

[0036] In this embodiment, the manufacturing method for the stator 10 includes a first winding step and a second winding step described below, and the wire 121 fed from the nozzle 65 is wound around the teeth 11b of the stator core 11. The manufacturing method for the stator 10 is used in a winding device 1, and the operation of the winding device 1 is automatically controlled by a controller 5 shown in FIG.

[0037] When winding the tooth 11b, first, the wire 121 is inserted through the nozzle 65 and fed out from the tip of the nozzle 65, and the end of the fed out wire 121 is held by a chuck (not shown). The nozzle moving device 60 then moves the nozzle 65 until the nozzle 65 is positioned opposite the winding target tooth 11b so that the axial direction of the nozzle 65 is approximately parallel to the winding axis direction of the winding target tooth 11b. From this state, the nozzle 65 is moved to a position where it overlaps with the slot 11c between the winding target tooth 11b and the adjacent tooth 11b in the Z axis direction, and then winding begins.

[0038] 5 is an explanatory diagram of the first winding process. In the first winding process, the wire 121 fed from the nozzle 65 is wound around the teeth 11 b by combining the rotation of the stator core 11 and the movement of the nozzle 65 in the Z-axis direction, which is the axial direction of the stator core 11.

[0039] For example, when the tip of the nozzle 65 is above the slot 11c between the winding subject tooth 11b and the adjacent tooth 11bA on one side, the drive motor 53 starts rotating the stator core 11 in one direction (left side in FIG. 5 ), and the nozzle 65 moves relative to the winding subject tooth 11b to the right side in the drawing. Then, when the tip of the nozzle 65 is positioned above the slot 11c between the winding subject tooth 11b and the adjacent tooth 11bB on the other side, the rotation of the stator core 11 is stopped.

[0040] Next, the nozzle 65 is moved in the Z-axis direction by lowering it using the nozzle moving device 60, and the movement of the nozzle 65 is completed after the tip of the nozzle 65 has come out of the slot 11 c. Thereafter, the stator core 11 is rotated to the other side of the rotation direction (right side in FIG. 5 ), and the nozzle 65 is moved leftward in the drawing relative to the winding target tooth 11 b, and then the nozzle 65 is raised.

[0041] In the first winding process, the rotation of the stator core 11 and the movement of the nozzle 65 in the Z-axis direction are alternately repeated in this manner to cause the nozzle 65 to circle around the teeth 11 b, and the wire 121 fed from the nozzle 65 is wound around the teeth 11 b. The nozzle 65 is moved in the direction of the winding axis of the teeth 11 b (the X-axis direction) by the diameter of the wire 121 each time the wire 121 is wound around the teeth 11 b.

[0042] Therefore, by repeating the winding in this manner, the first layer of wire 121 is wound in an aligned manner around tooth 11b from the tip side to the base side, then the second layer of wire 121 is wound in an aligned manner from the base side to the tip side, and so on until the predetermined number of layers of wire 121 are wound in an aligned manner in the same manner.

[0043] In the first winding process, by rotating the stator core 11 using the drive motor 53, the wire 121 can be wound more quickly than when the nozzle 65 is moved in a circular motion around the teeth 11b using the nozzle moving device 60 to wind the wire 121 around the teeth 11b.

[0044] On the other hand, as the number of layers of wire 121 wound around tooth 11 b increases, the interval between wire 121 wound around tooth 11 b and wire 121 wound around adjacent tooth 11 b, i.e., the width W of slot 11 c, becomes smaller. If the width W of slot 11 c becomes smaller than the width of nozzle 65, nozzle 65 will be unable to move within slot 11 c.

[0045] Even in this case, if the width W of the slot 11c is larger than the diameter of the wire 121, it is possible to insert the wire 121 into the slot 11c and continue winding. Therefore, following the first winding step, winding is performed in the second winding step, which will be described next.

[0046] In the second winding process, after winding the wire 121 a predetermined number of times around the tooth 11b in the first winding process, the wire 121 unwound from the nozzle 65 is held by the upper guide 80 or the lower guide 90 arranged opposite the tooth 11b in the axial direction (Z-axis direction) of the stator core 11, and the nozzle 65 is moved without passing through the slot 11c next to the tooth 11b (i.e., by moving outside the slot 11c), so that the wire 121 unwound from the nozzle 65 passes through the slot 11c and is wound around the tooth 11b.

[0047] Specifically, in the second winding step, winding is performed as shown in FIGS.

[0048] 6 and 7 are explanatory diagrams of the second winding step. Fig. 6(a) shows a state in which, as a result of N layers (N is a natural number) of winding the wire 121 around the winding subject tooth 11b, the width W of the slot 11c has become smaller than the width of the nozzle 65, and the state is immediately before the start of winding the (N+1)th layer around the winding subject tooth 11b. Below, a case in which the wire 121 is wound in the groove D between the end wire 121a and the adjacent wire 121b in the Nth layer will be described.

[0049] First, when starting winding the (N+1)th layer, as shown in Fig. 6(a), the guide movement device 70 is driven to move the pair of guides 80a in the upper guide 80 toward the winding target tooth 11b, and position them side by side in the winding direction (Y-axis direction) of the wire 121. As a result, the guides 80a are positioned axially opposite the tooth 11b.

[0050] 6(b), the nozzle moving device 60 is driven to move the nozzle 65 positioned outside the slot 11c in the Y-axis direction along the surface 11ba of the winding subject tooth 11b (see FIG. 3), so that the wire rod 121 fed from the nozzle 65 comes into contact with the surfaces of the pair of guides 80a. As a result, the wire rod 121 fed from the nozzle 65 is guided onto the Nth layer on the surface 11ba of the winding subject tooth 11b.

[0051] Next, as shown in FIG. 6C , the guide moving device 70 is driven to move the pair of guides 80b of the upper guide 80 toward the winding target tooth 11b. As a result, the guides 80b are positioned opposite the tooth 11b in the axial direction (Z-axis direction) of the stator core 11. Because the distance between the opposing surfaces of the pair of guides 80a and the pair of guides 80b is equal to the diameter of the wire rod 121, the wire rod 121 fed from the nozzle 65 is sandwiched and held between the opposing surfaces of the pair of guides 80a and the pair of guides 80b. The upper guide 80 also positions the held wire rod 121 at a position facing the groove D between the wire rods 121a and 121b in the Nth layer on the front surface 11ba of the winding target tooth 11b. In this manner, the upper guide 80 holds the wire rod 121 and positions it relative to the winding target tooth 11b (positioning step).

[0052] Hereinafter, when winding the wire 121 around the winding subject tooth 11b, the position where the wire 121 should be wound is referred to as the “winding position.” In the second winding process shown in Figures 6 and 7, the groove D between the wires 121 in the Nth layer is the “winding position.”

[0053] 6(d), the nozzle moving device 60 is driven to move the nozzle 65 positioned outside the slot 11c in the winding axis direction (X-axis direction) of the winding target tooth 11b along the opening H1 that opens into the surface of the stator core 11 in the slot 11c, and away from the winding target tooth 11b. At this time, the upper guide 80 maintains its holding of the wire 121, so that the wire 121 held by the upper guide 80 remains positioned at the winding position.

[0054] 6(e), the nozzle moving device 60 is driven to move the nozzle 65 positioned outside the slot 11c in the axial direction (Z-axis direction) of the stator core 11 along the opening H2 that opens to the inner periphery of the stator core 11 in the slot 11c, and the wire 121 fed from the nozzle 65 is inserted into the slot 11c. In this manner, the nozzle 65 operates to insert the fed wire 121 into the slot 11c without passing through the slot 11c (wire insertion process). At this time, the upper guide 80 maintains a state in which it holds the wire 121, so that the wire 121 held by the upper guide 80 remains positioned at the winding position.

[0055] 7(a), the nozzle moving device 60 is driven to move the nozzle 65 located outside the slot 11c in the winding axis direction (X-axis direction) of the winding subject tooth 11b along an opening H3 in the slot 11c that opens on the back surface of the stator core 11. The nozzle 65 is then stopped in a state where the unwound wire 121 faces the groove D between the wire rods 121a and 121b in the Nth layer on one side surface of the winding subject tooth 11b (the surface facing the tooth 11bB).

[0056] In this way, with the wire 121 held by the upper guide 80, the nozzle 65 is moved outside the slot 11c along the openings H1, H2, and H3 of the slot 11c, and the wire 121 being fed out is inserted into the slot 11c, thereby making it possible to guide the wire 121 fed out from the nozzle 65 to a winding position on one side of the winding subject tooth 11b. Therefore, even if the nozzle 65 cannot pass through the slot 11c, the wire 121 can be wound around the winding subject tooth 11b.

[0057] 7A, with the wire 121 fed from the nozzle 65 guided to the winding position on one side of the winding subject tooth 11b, the upper guide 80 is moved away from the winding subject tooth 11b, releasing the upper guide 80 from holding the wire 121. At the same time, the pair of guides 90a in the lower guide 90 are moved toward the winding subject tooth 11b, and are aligned in the winding direction (Y-axis direction) of the wire 121. As a result, the guides 90a are positioned opposite the tooth 11b in the axial direction (Z-axis direction) of the stator core 11.

[0058] 7(b), the nozzle moving device 60 is driven to move the nozzle 65 located outside the slot 11c in the Y-axis direction along the back surface of the winding subject tooth 11b, causing the wire 121 fed from the nozzle 65 to abut against the surfaces of the pair of guides 90a. As a result, the wire 121 fed from the nozzle 65 is guided onto the Nth layer on the back surface of the winding subject tooth 11b. At this time, the wire 121 released from the upper guide 80 is wound at the Nth layer winding position on the front surface 11ba of the winding subject tooth 11b, and the wire 121 inserted into the slot 11c is wound at the Nth layer winding position on one side surface of the winding subject tooth 11b. The nozzle 65 may be moved in the Y-axis direction by rotating the stator core 11 around its axis using the core rotating device 50.

[0059] 7(c), the guide moving device 70 is driven to move the pair of guides 90b of the lower guide 90 toward the winding subject tooth 11b. As a result, the guides 90b are positioned opposite the tooth 11b in the axial direction (Z-axis direction) of the stator core 11. The wire 121 fed from the nozzle 65 is held by being sandwiched between the opposing surfaces of the pair of guides 90a and the pair of guides 90b, and is positioned at a position facing the winding position on the back surface of the winding subject tooth 11b.

[0060] Next, as shown in Figures 7(d) to 7(f), with the wire 121 held by the lower guide 90, the nozzle 65 is moved outside the slot 11c along each of the openings H4, H5, and H6 of the slot 11c, and the wire 121 being fed is inserted into the slot 11c. As a result, the wire 121 fed from the nozzle 65 is guided to the winding position on the other side surface of the winding subject tooth 11b (the surface facing tooth 11bA). Then, as shown in Figure 7(f), the lower guide 90 is moved away from the winding subject tooth 11b, and the wire 121 is released from the lower guide 90.

[0061] Thereafter, each time the wire 121 is wound around the winding subject tooth 11b, the nozzle 65 is moved in the direction of the winding axis of the winding subject tooth 11b (X-axis) by the amount of the diameter of the wire 121, and the upper guide 80 and the lower guide 90 are also moved in the X-axis direction by the amount of the diameter of the wire 121. The above procedure is then repeated to complete the (N+1)th winding layer.

[0062] In this manner, the nozzle 65 is moved around the winding target tooth 11b, thereby winding the (N+1)th layer in line on the Nth layer. From the (N+1)th layer onwards, the winding is completed when the width W of the slot 11c becomes smaller than the diameter of the wire 121. After the winding is completed, the core rotation device 50 rotates the stator core 11 to perform an indexing operation to align the winding axis direction of the next winding target tooth 11b with the X-axis direction.

[0063] According to the second winding step, even if the width W of the slot 11c becomes smaller than the width of the nozzle 65, further winding can be performed, so that the space factor can be increased.

[0064] On the other hand, in the second winding process, winding is performed using the upper guide 80 and the lower guide 90, which results in a longer tact time.

[0065] In this embodiment, as described above, in the first winding process, winding can be performed more quickly than when winding is performed by circulating the nozzle 65. Therefore, even if the takt time is long in the second winding process, by shortening the takt time of the first winding process, it is possible to shorten the takt time while increasing the space factor for the first winding process and the second winding process as a whole.

[0066] The winding is performed on each tooth 11b of the stator core 11, and as shown in FIG. 8, the winding of the stator core 11 is completed when the wire 121 is wound around all the teeth 11b of the stator core 11.

[0067] As an example, the wire 121 is wound around each tooth 11b by ten layers in the first winding process, and then five layers are wound around each tooth 11b in the second winding process. Therefore, even if the reduction in takt time per turn is not significantly greater than when winding is performed by circulating the nozzle 65, for example, if the number of turns of the wire 121 per layer is approximately 10, the takt time can be reduced by 10 times per layer, and if the number of turns is 10, the takt time can be reduced by 100 times. Furthermore, if the stator core 11 has, for example, 12 teeth 11b, the takt time can be reduced by 1,200 times per stator core 11. Therefore, when viewed as a whole, a significant difference can be achieved. The predetermined number can be appropriately set depending on the type of stator and wire being manufactured.

[0068] As shown in Figure 2, by arranging the drive motor 53 coaxially below the stator core 11, the drive motor 53 can rotate the stator core 11 at the same rotational speed as the rotational shaft of the drive motor 53. However, there is no space directly below the stator core 11 to install guides 90a, 90b or a guide movement mechanism that hold the wire 121 from the back side of the winding target tooth 11b.

[0069] In this embodiment, the core support base 54 is disposed between the stator core 11 and the drive motor 53, and as shown in Fig. 9, a guide moving device 70 for moving the guides 90a, 90b is disposed to the side (outside in the X-axis direction) of the core support base 54. An opening 54c is formed in the core support base 54, and as shown in Fig. 10, the guides 90a, 90b are inserted into the core support base 54 from the side through the opening 54c.

[0070] By arranging the guides 90a, 90b in the core support base 54 in this manner, the guides 90a, 90b can face the winding subject tooth 11b from the back side (the lower side in FIGS. 9 and 10), and the guides 90a, 90b can hold the wire 121 from the back side of the winding subject tooth 11b. The guides 90a, 90b can be arranged in the core support base 54 after it is no longer necessary to rotate the stator core 11 by the core rotation device 50 in the first winding step, and are arranged in the core support base 54 at least in the second winding step. Holding the wire 121 with the guides 90a, 90b makes the second winding step possible, and the space factor can be increased.

[0071] The positions of guides 80a, 80b and guides 90a, 90b in the Z-axis direction when holding wire 121 are set according to the number of layers of winding target tooth 11b, and are set in a direction away from winding target tooth 11b by the amount of the increase in thickness for each additional layer.

[0072] On the other hand, there is variation in the wire 121 wound around the winding subject tooth 11 b, and at set positions, the guides 80 a, 80 b and the guides 90 a, 90 b may interfere with the wire 121 having an insulating coating wound around the winding subject tooth 11 b, which may affect the insulation quality. For this reason, the upper guide 80 and the lower guide 90 may be configured as follows.

[0073] Figure 11 is a diagram showing the main parts of a modified example of the upper guide 80. In Figure 11, the upper left guide 80A of the upper guide 80 is used as an example for explanation, but a similar structure can also be applied to the upper right guide 80B of the upper guide 80 and the lower left guide 90A and lower right guide 90B of the lower guide 90. In the case of the lower guide 90, the structure is symmetrical in the Z axis direction to that of Figure 11 (i.e., a structure that is symmetrical up and down).

[0074] In this example, the vertical movement mechanism 70z of the guide movement device 70 (see FIG. 3) has a ball screw 41, a drive motor 42 that rotates the ball screw 41, and a follower 43 that threadably engages with the ball screw 41, and is a ball screw mechanism that converts the rotation of the drive motor 42 into linear motion of the follower 43. The vertical movement mechanism 70z is provided for each of the guides 80a and 80b, with the vertical movement mechanism 70z on the right side of the drawing being provided for the guide 80a and the vertical movement mechanism 70z on the left side of the drawing being provided for the guide 80b.

[0075] These two vertical movement mechanisms 70z are structurally similar to each other, and in Fig. 11, the guide 80a is hidden behind the guide 80b, so the following description of the vertical movement mechanism 70z will mainly use the guide 80b as an example.

[0076] The guide movement device 70 further includes a guide support portion 44 that supports the guide 80b and a holder 45 that holds the guide support portion 44, and the guide 80b is connected to the follower 43 of the vertical movement mechanism 70z via the guide support portion 44 and the holder 45. The guide 80b is provided integrally with the guide support portion 44. The guide 80b may be formed integrally with the guide support portion 44 or may be attached to the guide support portion 44.

[0077] The holding portion 45 has a connecting member 451 provided on the follower 43, an L-shaped support member 452 provided on the connecting member 451 and extending along the X-axis direction and the Z-axis direction, and a holding member 453 provided at the tip end 452a of the support member 452 (the end opposite to the side connected to the connecting member 451) and holding the guide support portion 44.

[0078] The holding member 453 and the guide support portion 44 are provided with a long hole mechanism 46 that engages the guide support portion 44 with the holding member 453 so that the guide support portion 44 can move in the Z-axis direction, and the holding member 453 holds the guide support portion 44 so that the guide support portion 44 can move in the direction away from the stator core 11 (upward in Figure 11) via the long hole mechanism 46.

[0079] A spring 47 is provided between the guide support portion 44 and the holding portion 45 as an elastic member that allows the guide support portion 44 to move in a direction away from the stator core 11 (upper side in FIG. 11 ). The elastic member may be a resin member such as rubber, a coil, or the like, as long as it allows movement between the guide support portion 44 and the holding portion 45. The holding member 453 of the holding portion 45 has a facing portion 453a that faces the guide support portion 44 from the side opposite the stator core 11 (upper side in FIG. 11 ), and the spring 47 is provided on the facing portion 453a of the holding member 453. The spring 47 is provided on the facing portion 453a in a state shortened from its natural length and is disposed in a state in which it biases the guide support portion 44.

[0080] In this example, when the wire 121 is held by the upper left guide 80A, even if the guides 80a and 80b of the upper left guide 80A interfere with the wire 121 wound around the winding subject tooth 11b, the guide support portion 44 moves in a direction (upward in FIG. 11 ) away from the stator core 11. This prevents excessive force from being applied from the guides 80a and 80b to the wire 121 wound around the winding subject tooth 11b, thereby minimizing any impact on insulation quality.

[0081] 12 is an explanatory diagram of the curved shape C of the guide 80b, and as shown in FIGS. 11 and 12, the tip of the guide 80b has the curved shape C. Note that while the guide 80b is used as an example in FIG. 12, the curved shape C is also applied to the guide 80a of the upper guide 80 and the guides 90a and 90b of the lower guide 90 in this modified example. The curved shape C is also applicable to the guides 80a and 80b and the guides 90a and 90b shown in FIG. 3.

[0082] As shown in Fig. 12, the curved shape C is formed to follow the bent portion 121c of the wire 121 formed along the corner E of the tooth 11b. The curved shape C is formed as an arc with a central angle of approximately 90 degrees, and the curved shapes C of the upper left guide 80A and the upper right guide 80B are formed symmetrically with each other. The curved shape C may be formed in such a way that two sides (extensions extending vertically in Fig. 12) are further provided at both ends of the curved shape C along both surfaces (top and side surfaces in Fig. 12) of the tooth 11b that connect to the corner E along the corner E of the tooth 11b. On the other hand, the central angle of the curved shape C may be less than 90 degrees.

[0083] The curved shape C makes it possible to position the wire 121 fed from the nozzle 65 at the bent portion 121c. Therefore, even if the nozzle 65 is operated so that the wire 121 being fed is inserted into the slot 11c without passing through the slot 11c in the second winding process, it is possible to suppress displacement of the wire 121 at the bent portion 121c where the direction of the wire 121 changes.

[0084] In the above-described embodiment, the winding device 1 has been described as being configured so that the axial direction of the stator core 11 is set in the Z direction. However, the axial direction of the stator core 11 may be set in a direction other than the Z direction (for example, horizontally), and the winding device 1 may be configured to wind around the teeth 11b of the stator core 11 whose axial direction is set in a direction other than the Z direction.

[0085] Furthermore, in the above-described embodiment, the stator 10 is described as being an inner rotor type, but the stator 10 may be an outer rotor type, and the winding device 1 may be configured to wind wires on the outer rotor type stator 10.

[0086] The main effects of the method for manufacturing the stator 10 according to the embodiment of the present invention, the method for manufacturing the motor 100, and the winding device 1 as a manufacturing device for the stator 10 will be described below.

[0087] The manufacturing method of the stator 10 includes a winding process for winding the wire 121 unwound from the nozzle 65 around the teeth 11 b of the stator core 11, and the winding process includes a first winding process for winding the wire 121 unwound from the nozzle 65 around the teeth 11 b by combining rotation of the stator core 11 and movement of the nozzle 65 in the axial direction of the stator core 11, and a second winding process for winding the wire 121 around the teeth 11 b a predetermined number of times after the first winding process, while holding the wire 121 unwound from the nozzle 65 with guides 80 a, 80 b and guides 90 a, 90 b arranged axially opposite the teeth 11 b, by moving the nozzle 65 without passing through the slot 11 c next to the teeth 11 b, so that the wire 121 unwound from the nozzle 65 passes through the slot 11 c and is wound around the teeth 11 b.

[0088] According to this method, the wire 121 can be wound more quickly in the first winding process than in the case where the nozzle 65 is moved circulatingly around the teeth 11 b while the wire 121 is wound around the teeth 11 b, and the space factor can then be increased in the second winding process. Therefore, by shortening the takt time of the first winding process, the takt time of the entire first and second winding processes can be shortened.

[0089] In the manufacturing method of the stator 10, the guides 80a and 80b are provided as first guides arranged on one axial side of the stator core 11, and the guides 90a and 90b are provided as second guides arranged on the other axial side of the stator core 11. The stator core 11 is rotated by the drive motor 53 via the core support base 54 arranged on the other axial side of the stator core 11, and the guides 90a and 90b as second guides are arranged in the core support base 54 through openings 54c as through-holes formed in the core support base 54 in the second winding step.

[0090] According to this method, in the second winding process, the guides 90a, 90b are arranged inside the core support base 54 through the opening 54c, so that the guides 90a, 90b can face the winding subject tooth 11b from the back side in the second winding process. Therefore, even if the drive motor 53 is arranged coaxially on the other axial side of the stator core 11, the guides 90a, 90b can hold the wire 121 from the back side of the winding subject tooth 11b, making the second winding process possible and increasing the space factor.

[0091] In the manufacturing method of stator 10, guides 80a, 80b may be moved by guide movement device 70 including guide support portions 44 that support guides 80a, 80b and holding portions 45 that hold guide support portions 44, and springs 47 may be provided between guide support portions 44 and holding portions 45 as elastic members that allow guide support portions 44 to move in a direction away from stator core 11. The same applies to guides 90a, 90b.

[0092] According to this method, even if the guides 80a, 80b or the guides 90a, 90b interfere with the wire 121 wound around the winding target tooth 11b, the guide support portion 44 moves in a direction away from the stator core 11, thereby suppressing the impact on insulation quality.

[0093] In the method for manufacturing the stator 10, the tip end of the guide 80b may have a curved shape C that follows the bent portion 121c of the wire 121 that is formed along the corner E of the tooth 11b. The same applies to the guide 80a and the guides 90a and 90b.

[0094] According to this method, even if the nozzle 65 is operated in the second winding process so that the unwound wire 121 is inserted into the slot 11c without passing through the slot 11c, the positional deviation of the wire 121 can be suppressed at the bending portion 121c where the direction of the wire 121 changes.

[0095] In the method for manufacturing the motor 100 having the stator 10, the stator 10 is manufactured using the above-described method for manufacturing the stator 10.

[0096] According to this method, the manufacturing process for the stator 10 can shorten the takt time, thereby increasing the manufacturing capacity of the motor 100 and reducing the manufacturing cost.

[0097] The winding device 1, which is a manufacturing device for the stator 10, is a device that performs a winding operation of winding a wire 121 around the teeth 11b of the stator core 11, and includes a nozzle 65 that feeds out the wire 121, a core support base 54 that supports the stator core 11, a drive motor 53 that rotates the stator core 11 via the core support base 54, and guides 80a, 80b and 90a, 90b that are arranged opposite the teeth 11b in the axial direction of the stator core 11, where the guides 80a, 80b are provided as first guides that are arranged on one axial side of the stator core 11, and the guides 90a, 90b are provided as second guides that are arranged on the other axial side of the stator core 11, and the guides 90a, 90b are provided as nozzles that feed out the wire 121, a core support base 54 that supports the stator core 11, a drive motor 53 that rotates the stator core 11 via the core support base 54, and guides 80a, 80b and 90a, 90b that are arranged opposite the teeth 11b in the axial direction of the stator core 11, where the guides 80a, 80b are provided as first guides that are arranged on one axial side of the stator core 11, and the guides 90a, 90b are provided as second guides that are arranged on the other axial side of the stator core 11. The winding device 1 can be placed inside the core support base 54 through an opening 54c formed in the nozzle 65. The winding device 1 performs a first winding operation in which the wire 121 fed out from the nozzle 65 is wound around the teeth 11b by combining the rotation of the stator core 11 and the movement of the nozzle 65 in the axial direction of the stator core 11. The winding device 1 performs a second winding operation in which, after a predetermined number of windings of the wire 121 are wound around the teeth 11b by the first winding operation, the wire 121 fed out from the nozzle 65 is held by the guides 80a, 80b or the guides 90a, 90b, and the nozzle 65 is moved without passing through the slot 11c next to the teeth 11b, thereby passing the wire 121 fed out from the nozzle 65 into the slot 11c and winding the wire 121 around the teeth 11b.

[0098] With this configuration, compared to winding the wire 121 around the teeth 11b while circulating the nozzle 65 around the teeth 11b, the first winding process allows for quicker winding of the wire 121, and then the second winding process can increase the space factor. Therefore, by shortening the takt time of the first winding process, the takt time of the entire first and second winding processes can be shortened. Furthermore, even if the drive motor 53 is coaxially disposed on the other axial side of the stator core 11, the guides 90a and 90b can hold the wire 121 from the back side of the winding target tooth 11b, making the second winding process possible and increasing the space factor.

[0099] Although an embodiment of the present invention has been described above, the above embodiment merely shows one application example of the present invention, and is not intended to limit the technical scope of the present invention to the specific configuration of the above embodiment.

[0100] This application claims priority based on Japanese Patent Application No. 2024-148270, filed with the Japan Patent Office on August 30, 2024, the entire contents of which are incorporated herein by reference.

Claims

A method of manufacturing a stator including a winding step of winding a wire fed from a nozzle around a magnetic pole of a stator core, The winding step includes: a first winding step of winding the wire fed from the nozzle around the magnetic pole by combining rotation of the stator core and movement of the nozzle in the axial direction of the stator core; a second winding step in which, after winding a predetermined number of windings of wire around the magnetic pole in the first winding step, the wire fed out from the nozzle is held by a guide arranged opposite the magnetic pole in the axial direction, and the nozzle is moved without passing through a slot next to the magnetic pole, thereby passing the wire fed out from the nozzle through the slot and winding the wire around the magnetic pole. 　 A method for manufacturing a stator according to claim 1, the guide includes a first guide disposed on one axial side of the stator core and a second guide disposed on the other axial side of the stator core, the stator core is rotated by a motor via a core support member disposed on the other axial side of the stator core, A method for manufacturing a stator, wherein the second guide is disposed within the core support member through a through hole formed in the core support member in the second winding process. 　 A method for manufacturing a stator according to claim 1 or 2, the guide is moved by a guide moving device including a guide support portion that supports the guide and a holding portion that holds the guide support portion, A method for manufacturing a stator, wherein an elastic member is provided between the guide support portion and the holding portion, the elastic member allowing the guide support portion to move in a direction away from the stator core. 　 A method for manufacturing a stator according to any one of claims 1 to 3, A method for manufacturing a stator, wherein the tip of the guide has a curved shape that follows the bent portion of the wire formed along the corner of the magnetic pole. 　 A method for manufacturing a motor having a stator, comprising: A method for manufacturing a motor, wherein the stator is manufactured using the method for manufacturing a stator according to any one of claims 1 to 4. 　 A stator manufacturing apparatus that performs a winding operation of winding a wire around a magnetic pole of a stator core, a nozzle for feeding the wire; a core support member that supports the stator core; a motor that rotates the stator core via the core support member; a guide disposed opposite the magnetic pole in the axial direction of the stator core, the guide includes a first guide disposed on one axial side of the stator core and a second guide disposed on the other axial side of the stator core, the second guide is positionable within the core support member through a through hole formed in the core support member; The manufacturing apparatus includes: a first winding operation in which the wire fed from the nozzle is wound around the magnetic pole by combining rotation of the stator core and movement of the nozzle in the axial direction of the stator core; a second winding operation in which, after winding a predetermined number of windings of wire around the magnetic pole by the first winding operation, the wire fed from the nozzle is held by the first guide or the second guide, and the nozzle is moved without passing through a slot adjacent to the magnetic pole, thereby passing the wire fed from the nozzle through the slot and winding the wire around the magnetic pole.

Images