Method for manufacturing stator and method for manufacturing motor

Abstract

This method for manufacturing a stator (220) comprises: a main guide preparation step in which a pair of main guides (51) for guiding a wire (2) to an opening (31) are disposed with respect to a stator core (30) so as to face each other with a first guide gap (CL1) therebetween; a sub-guide preparation step in which a pair of sub-guides (61) for guiding the wire (2) at a position offset in a rotation position of a rotary shaft (22) from the opening (31) are disposed so as to face the stator core (30) with a second guide gap (CL2) therebetween; and a winding step of relatively moving the position of the first guide gap (CL1) and the position of the second guide gap (CL2) along the axial direction of the rotary shaft (22), thereby winding the wire (2) inserted into the slot (33) through the first and second guide gaps (CL1, CL2) around a bottom part (32) while adjusting the winding position of the wire (2) in the slot (33).

Description

Method for manufacturing a stator and method for manufacturing a motor

[0005]

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

[0002] Japanese Patent No. 4771137 discloses a method for manufacturing a motor in which a winding is pushed radially outward beyond a virtual straight line connecting both circumferential ends of the inner circumferential surface of an outer peripheral core.

[0003] In the above method, when pushing the winding radially outward beyond the virtual straight line, the nozzle is stopped or decelerated near the teeth, which hinders the high-speed winding.

[0004] An object of the present invention is to achieve high-speed winding.

[0005] According to an aspect of the present invention, there is provided a method for manufacturing a stator in which a stator core having slots with a width of an opening portion narrower than a width of an opposing bottom portion is held on an axis of a rotating shaft, and a wire rod fed from a nozzle is guided into the slots and wound around the bottom portion, the method including: a main guide preparation step of arranging, with a first guide gap therebetween, a pair of main guides for guiding the wire rod into the opening portion, the pair of main guides being opposed to each other with respect to the stator core held on the axis of the rotating shaft; a sub-guide preparation step of arranging, with a second guide gap therebetween, a pair of sub-guides for guiding the wire rod at a position shifted from the opening portion in the rotational direction of the rotating shaft, the pair of sub-guides being opposed to each other with respect to the stator core held on the axis of the rotating shaft; and a winding step of winding the wire rod around the bottom portion while adjusting a winding position of the wire rod in the slots inserted into the slots through the first guide gap and the second guide gap by relatively moving positions of the first guide gap and the second guide gap along an axial direction of the rotating shaft.

[0006] According to this aspect, in order to adjust the winding position of the wire rod inserted into the slots through between the pair of main guides according to the relative position between the first guide gap and the second guide gap, it is not necessary to reduce the winding speed when winding at the corner portion of the slot bottom portion where the width of the opening portion is narrower than the width of the opposing bottom portion, and high-speed winding becomes possible.

[0007] This is a schematic diagram of a winding device according to an embodiment of the present invention. This is a cross-sectional view showing a stator core according to an embodiment of the present invention. This is a cross-sectional view showing a motor according to an embodiment of the present invention. This is a first side view of a rotating device according to an embodiment of the present invention. This is a second side view of a rotating device according to an embodiment of the present invention. This is a perspective view of a pallet according to an embodiment of the present invention. This is an explanatory diagram of the main guide preparation process and the sub-guide preparation process according to an embodiment of the present invention. This is a first explanatory diagram of the winding process according to an embodiment of the present invention. This is a second explanatory diagram of the winding process according to an embodiment of the present invention. This is a third explanatory diagram of the winding process according to an embodiment of the present invention. This is an explanatory diagram of aligned winding performed by adjusting the winding position within the slot. This is a diagram showing a first example of setting the rotation speed of the stator core during aligned winding according to an embodiment of the present invention. This is a diagram showing a second example of setting the rotation speed of the stator core during aligned winding according to an embodiment of the present invention. This is a diagram showing a first example of setting the rotation speed of the stator core during the winding process incorporating a stripping process according to an embodiment of the present invention. This is a diagram showing a second example of setting the rotation speed of the stator core during the winding process incorporating a stripping process according to an embodiment of the present invention. This is an explanatory diagram of the stator core loading and unloading process according to an embodiment of the present invention. This is a flowchart showing the manufacturing method of a motor according to an embodiment of the present invention.

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

[0009] The winding device 1 is a device for manufacturing aligned-winding coils by winding wire 2, which is fed out from a nozzle 3, onto a stator core 30 in an aligned manner. As shown in Figure 1, it comprises a nozzle 3 that feeds out wire 2 from its tip 3a, a nozzle moving device 10 that moves the nozzle 3, a rotating device 20 that rotates the stator core 30 around a spindle 22 which serves as a rotation axis, a stripping device 70 that strips the insulating coating from the wire 2, and a wire feeding device 80 that feeds out the wire 2 while applying tension to it.

[0010] The nozzle 3 is a cylindrical member and has a through hole (not shown) that penetrates axially. The nozzle 3 is attached to the nozzle moving device 10 such that the tip portion 3a, which has one end of the through hole open, faces the stator core 30, and guides the wire 2 supplied from the wire feeding device 80 through the tip portion 3a to the stator core 30.

[0011] The nozzle moving device 10 is an electric slider capable of reciprocating a movable base 11 along the axial direction AX of the spindle 22. The nozzle 3 and the peeling device 70 are attached to the movable base 11. The nozzle moving device 10 is supported on the base 5 via a support column 6.

[0012] The rotating device 20 is a spindle unit and includes an electric motor 21, a spindle 22 which also serves as the rotation axis of the electric motor 21, a spindle flange 23 attached to the tip of the spindle 22, an actuator unit 24 provided on the spindle flange 23 that drives the rotating body 64 of the sub-guide mechanism 60 (described later) in the axial direction AX of the spindle 22, and a cover 25 that houses the electric motor 21, spindle 22, spindle flange 23, and actuator unit 24. The electric motor 21 may also have a separate rotation axis from the spindle 22 to rotate the spindle 22.

[0013] The winding device 1 is provided with a pair of rotating devices 20, 20B, which are arranged opposite each other with spindles 22 sharing a common axis. Rotating device 20A is supported on the base 5 via a support base 7, and rotating device 20B is supported on the base 5 via a support base 8. The pair of rotating devices 20 rotate synchronously. One of the pair of rotating devices 20 (20A, 20B) may be a rotating device that does not have an electric motor 21 as a drive source.

[0014] As shown in Figures 1 and 2, the wire 2 unwound from the nozzle 3 is wound around the stator core 30. Figure 2 is a view of the stator core 30 from a cross-sectional direction. The stator core 30 is a segmented core, and as shown in Figure 2, when the stator core 30 is viewed from a cross-sectional direction, a slot 33 is formed in which the width W1 of the opening 31 is narrower than the width W2 of the opposing bottom 32. The cross-sectional direction is defined as the cross-sectional direction that intersects (is perpendicular to) the opening 31 and the bottom 32. The cross-sectional direction is defined as the cross-sectional direction that intersects (is perpendicular to) the longitudinal direction of the stator core 30 (up and down direction in Figure 1).

[0015] The opening 31 of the slot 33 communicates with the inside of the slot 33, and the bottom 32 of the slot 33 faces the opening 31 on its front side, with the opening 31 side (upper side in Figure 2) being the front side. The opening 31 has a width W1 and extends to both ends in the longitudinal direction (up and down direction in Figure 1) of the stator core 30, and is located in the center of the bottom 32 in the axial direction AX of the spindle 22.

[0016] The stator core 30 has flanges 34 and 35 extending from the bottom 32. The flanges 34 and 35 extend inclined inward from the bottom 32 in the axial direction AX of the spindle 22 at the front side (upper side in Figure 2) of the bottom 32, forming an opening 31 between their tips. Together with the bottom 32, the flanges 34 and 35 form a trapezoidal slot 33 that opens at the opening 31 when viewed from the longitudinal direction of the stator core 30 (i.e., when the stator core 30 is viewed from the cross-sectional direction). The slot 33 extends in the longitudinal direction of the stator core 30 and also opens at both ends in the longitudinal direction of the stator core 30.

[0017] The stator core 30 further has flange portions 36 and 37 that extend substantially vertically from the bottom portion 32 on the back side of the bottom portion 32 (lower side in Figure 2). The flange portions 36 and 37, together with the bottom portion 32, form a slot 38 on the back side of the bottom portion 32, and an opening 39 of the slot 38 is formed between the tips of the flange portions 36 and 37.

[0018] The slot 38 is formed in a rectangular shape with an opening 39 when viewed from the longitudinal direction of the stator core 30. The opening 39 has a width W3 that is the same as the width W2 of the bottom 32 and extends to both ends in the longitudinal direction of the stator core 30. The slot 38 extends in the longitudinal direction of the stator core 30 and also opens at both ends in the longitudinal direction of the stator core 30.

[0019] The wire 2 is wound around the bottom portion 32. The wire 2 is inserted into the slot 33 through the opening 31 and folded back to the back side of the bottom portion 32 (lower side in Figure 2) at one longitudinal end of the stator core 30. The wire 2 folded back to the back side of the bottom portion 32 is inserted into the slot 38 through the opening 39 and folded back to the front side of the bottom portion 32 (upper side in Figure 2) at the other longitudinal end of the stator core 30 and inserted into the slot 33 again. This process is repeated so that the wire 2 is wound around the bottom portion 32 multiple times.

[0020] As shown in Figure 3, the stator core 30 is incorporated into the motor 200 after winding. The motor 200 is an electric motor and includes a rotor 210, a stator 220 that houses the rotor 210, a shaft 230 that rotates integrally with the rotor 210, and a cylindrical housing 240 that covers the outer circumference of the stator 220.

[0021] The stator 220 includes a holder 221 that accommodates a plurality of stator cores 30 as a plurality of segmented cores, and a plurality of wound stator cores 30 housed in the holder 221. The holder 221 has a plurality of core housing sections 221a arranged radially for housing the stator cores 30, and the wound stator cores 30 are housed in the core housing sections 221a.

[0022] The core housing portion 221a is formed to match the outer shape of the stator core 30, and is narrower on the radially inner side of the motor 200 than on the radially outer side. The stator 220 is assembled into the housing 240 with the multiple wound stator cores 30 housed in the multiple core housing portions 221a of the holder 221. The multiple wound stator cores 30 are installed in the motor 200 with their circumferential, radial, and axial positions restricted.

[0023] As shown in Figures 4 and 5, the rotating device 20 includes a holding mechanism 40 (see Figure 5) for holding the stator core 30, and a main guide mechanism 50 and a sub-guide mechanism 60 for guiding the wire 2 into the slots 33 of the stator core 30.

[0024] As shown in Figure 5, the holding mechanism 40 includes a clamping portion 41 that clamps the stator core 30 (see Figure 1), an arm 42 that supports the clamping portion 41 at its tip and is attached to the spindle flange 23 (see Figure 1) at its base, and an actuator portion 43 that moves the clamping portion 41 in the axial direction AX of the spindle 22 relative to the arm 42.

[0025] The clamping portion 41 is supported by the arm 42 via the actuator portion 43. The arm 42 is positioned beside the rotating body 64 of the sub-guide mechanism 60 and extends in the axial direction AX of the spindle 22. The arm 42 bends in a crank shape towards the tip of the rotating body 64 and is offset radially inward from the spindle 22. The actuator portion 43 is fixed to the arm 42 and drives the clamping portion 41 in the axial direction AX of the spindle 22.

[0026] The winding device 1 is provided with a pair of holding mechanisms 40, which consist of a holding mechanism 40A provided on the rotating device 20A and a holding mechanism 40B provided on the rotating device 20B. The stator core 30 (see Figure 1) is held by a pair of clamping portions 41 of the pair of holding mechanisms 40. The stator core 30 is held by the pair of clamping portions 41 from both sides of the axial direction AX of the spindle 22, with the opening 31 facing the radial direction of the spindle 22. In Figure 1, the opening 31 is shown being held in this position and visible from the front.

[0027] As shown in Figure 4, the main guide mechanism 50 includes a main guide 51, an arm 52 that supports the main guide 51 at its tip and is attached to the spindle flange 23 (see Figure 1) at its base, and an actuator (not shown) that moves the main guide 51 in the axial direction AX of the spindle 22 relative to the arm 52.

[0028] The main guide 51 guides the wire 2 into the opening 31 of the stator core 30 (see Figure 1). The main guide 51 has a tip guide portion 51a that slopes toward the spindle 22 towards the tip. The tip guide portion 51a is formed in a tapered shape with a narrower width at the tip, and the main guide 51 rotates around the spindle 22, which acts as the axis of rotation, while the tip guide portion 51a guides the wire 2 into the opening 31 of the stator core 30.

[0029] The main guide 51 is supported by an arm 52 via an actuator. The arm 52 is positioned beside the rotating body 64 of the sub-guide mechanism 60 and extends in the axial direction AX of the spindle 22. The arm 52 bends in a crank shape towards its tip relative to the rotating body 64 and is offset radially inward from the spindle 22. The actuator is fixed to the arm 52 and drives the main guide 51 in the axial direction AX of the spindle 22.

[0030] The winding device 1 is provided with a pair of main guide mechanisms 50, which consist of a main guide mechanism 50A provided on the rotating device 20A and a main guide mechanism 50B provided on the rotating device 20B. The wire 2 is guided through the opening 31 of the stator core 30 (see Figure 1) by the pair of main guides 51 of the pair of main guide mechanisms 50.

[0031] As shown in Figures 4 and 5, the sub-guide mechanism 60 includes a rotating body 64 provided on the spindle flange 23 (see Figure 1) via an actuator unit 24 (see Figure 1), a sub-guide 61, and an arm 62 that supports the sub-guide 61 at its tip and is attached at its base end to a slide block (not shown) that slidably supports the arm 62 relative to the rotating body 64 in the radial direction of the spindle 22.

[0032] The subguide 61 has a guide surface 61a that guides the wire 2, and a guide claw 61b formed at the tip of the subguide 61 and connected to the guide surface 61a. The guide surface 61a is formed as the outer surface of the tapered portion of the subguide 61 that guides the wire 2 toward the tip while rotating around the spindle 22, which is the axis of rotation, and the guide claw 61b extends radially toward the axial side of the spindle 22 (see Figure 1) at the tip of the subguide 61.

[0033] The arm 62 extends axially AX of the spindle 22 and is fixed to the slide block at its base end. The slide block is housed in the rotating body 64 so as to be slidable radially with respect to the spindle 22.

[0034] The rotating body 64 holds the slide block so as to be slidable in the radial direction of the spindle 22, and rotates integrally with the subguide 61 via the slide block and arm 62. The actuator unit 24 (see Figure 1) drives the rotating body 64 in the axial direction AX of the spindle 22, thereby causing the subguide 61, which is provided on the rotating body 64 via the slide block and arm 62, to move in the axial direction AX of the spindle 22.

[0035] The actuator unit 24 is further configured to drive the slide block in the radial direction of the spindle 22. When the actuator unit 24 drives the slide block in the radial direction of the spindle 22, the sub-guide 61, which is provided on the slide block via the arm 62, moves in the same direction.

[0036] The sub-guide 61 is positioned offset from the main guide 51 in the rotational direction of the spindle 22 (see Figure 1). The sub-guide 61 is positioned offset from the main guide 51 by 90 degrees in the rotational direction of the spindle 22.

[0037] The winding device 1 is provided with a pair of sub-guide mechanisms 60, which consist of a sub-guide mechanism 60A provided on the rotating device 20A and a sub-guide mechanism 60B provided on the rotating device 20B. The wire 2 is guided in the slot 33 of the stator core 30 (see Figure 2) by a pair of sub-guides 61 of the pair of sub-guide mechanisms 60.

[0038] The sub-guide mechanisms 60 are provided at positions offset from the main guide mechanism 50 in the forward and reverse directions of rotation of the spindle 22 (see Figure 1). Therefore, the winding device 1 is provided with a total of four sub-guide mechanisms 60 (two pairs in total): sub-guide mechanisms 60A, 60B, 60C, and 60D. The sub-guide mechanisms 60 are provided at positions offset from the main guide mechanism 50 in the forward and reverse directions of rotation of the spindle 22. The rotating body 64 is common between the sub-guide mechanisms 60A and 60C on the rotating device 20A side, and between the sub-guide mechanisms 60B and 60D on the rotating device 20B side.

[0039] As shown in Figure 1, the stripping device 70 is mounted on a movable base 11 and moves together with the nozzle 3. The stripping device 70 includes a cutter 71 pressed against the wire 2, a rotating mechanism 72 that rotates the cutter 71 around the wire 2 and uses centrifugal force during rotation to press the cutter 71 against the wire 2, a motor 73 that rotates the cutter 71 via the rotating mechanism 72, and an electric slider 74 that moves the cutter 71 along the wire 2 via the rotating mechanism 72. The device strips the insulating coating from the wire 2 by moving the cutter 71, which is pressed against the wire 2, along the wire 2 while rotating it around the wire 2.

[0040] The wire feeding device 80 includes a spool 81 that is rotated by an electric motor (not shown) to feed out the wound wire 2, and a tensioning device 82 that applies tension to the wire 2 as it is unwound from the spool 81, feeding the wire 2 toward the stripping device 70. The wire feeding device 80 is supported on a base 5 via a support base 9, and the tensioning device 82 applies tension to the wire 2 between the spool 81 and the stripping device 70. The wire 2 fed out from the wire feeding device 80 is fed out from the nozzle 3 through the stripping device 70. The tip of the wire 2 fed out from the nozzle 3 is gripped by a chuck device (not shown).

[0041] For the winding device 1, there are provided a transfer device 90 for carrying the stator core 30 into and out of the winding device 1, a lifting device 100 as a reciprocating device for moving the holding portion 123 of the pallet 110 carried by the transfer device 90 between a pair of clamping portions 41 of the winding device 1, and a controller 150 for controlling the winding device 1, the transfer device 90, and the lifting device 100. The transfer device 90 and the lifting device 100 may be controlled by a controller different from the controller 150 and may be connected to communicate with the controller 150.

[0042] The transfer device 90 transfers the pallet 110 in a transfer direction across between a pair of clamping portions 41 of the rotating devices 20A and 20B. The transfer device 90 is disposed opposite to the nozzle 3 with the axis of the spindle 22 interposed therebetween. The transfer device 90 is supported by the base 5 and disposed below the axis of the spindle 22.

[0043] The transfer device 90 includes a transfer belt 91 for transferring the pallet 110, a drive device 92 for supporting the transfer belt 91 via both end pulleys (not shown) installed apart in the transfer direction and rotationally driving the transfer belt 91 around the both end pulleys, and a linear guide 93 for guiding the pallet 110 in the transfer direction. When the drive device 92 rotationally drives the transfer belt 91, the pallet 110 fixed to the movable block of the linear guide 93 and engaged with the transfer belt 91 moves in the transfer direction. The drive device 92 can rotationally drive the transfer belt 91 in the forward rotation direction and the reverse rotation direction, and the pallet 110 reciprocates along the transfer direction. The transfer belt 91 may utilize an exemplified toothed belt with irregularities, or alternatively, a chain belt or a ball screw may be used instead.

[0044] As shown in FIGS. 1 and 6, the pallet 110 has a holding unit 120 for holding the stator core 30. The holding unit 120 is provided on one end side (the left side in FIGS. 1 and 6) of the pallet 110 in the axial direction AX of the spindle 22, and on the back side (the lower side in FIGS. 1 and 6) of the other end side (the right side in FIGS. 1 and 6) of the pallet 110 in the axial direction AX of the spindle 22, a movable block of the linear guide 93 (see FIG. 1) is fixed.

[0045] As shown in Fig. 6, the holding unit 120 includes a flanged cylindrical base 121 attached through the pallet 110, a shaft 122 inserted into the base 121, a holding portion 123 provided at the tip of the shaft 122 for holding the stator core 30, a flange 124 provided between the base 121 and the holding portion 123 and abutting against the base 121, a roller unit 125 provided at the base end of the shaft 122, and a return spring 126 provided between the base 121 and the roller unit 125.

[0046] The base 121 is a linear ball bearing that supports the shaft 122 for linear movement. The base 121 has a cylindrical portion 121a provided through the pallet 110 and a flange portion 121b that is housed and fixed in the concave mounting portion 110a of the pallet 110 with its surface exposed on the front side (upper side in Fig. 6) of the pallet 110.

[0047] The holding portion 123 and the flange 124 are provided on the front side of the pallet 110 and fixed to the tip side of the shaft 122. By holding the end portion of the stator core 30 in the longitudinal direction (vertical direction in Fig. 1) in the holding portion 123, the stator core 30 is held in a standing state, and the flange 124 abuts against the flange portion 121b of the base 121.

[0048] The roller unit 125 includes a roller 125a that rotates in the conveying direction of the conveying device 90 (see Fig. 1) and a holding member 125b that rotatably holds the roller 125a. The return spring 126 is provided between the cylindrical portion 12`1a of the base 121 and the holding member 125b of the roller unit 125, and generates a spring force in the direction in which the roller unit 125 moves away from the pallet 11`.

[0049] As shown in Fig. 1, the lifting device 100 is disposed opposite between a pair of clamping portions 41 from the radial direction of the spindle 22. The lifting device 100 is supported by the base 5 and disposed below between the pair of clamping portions 41. The lifting device 100 includes a cylinder 101 and a pressing jig 102 attached to the rod tip of the cylinder 101.

[0050] The pallet 110 has a fixed position in the transport direction of the transport device 90 where the holding unit 120 is aligned with the spindle 22. When the cylinder 101 extends relative to the pallet 110 in its fixed position, the pushing jig 102 contacts the roller 125a of the holding unit 120 and pushes the holding part 123. Therefore, the lifting device 100 moves the holding part 123 in the forward and backward direction relative to the pallet 110 in its fixed position by extending and retracting.

[0051] As shown in Figure 6, the pallet 110 is provided with a pair of holding units 120: a first holding unit 120A for holding the stator core 30 before winding, and a second holding unit 120B for holding the stator core 30 after winding.

[0052] The pair of holding units 120 first receive the wound stator core 30 from the pair of clamping parts 41 (see Figure 1) by the second holding unit 120B, and then the first holding unit 120A supplies the stator core 30 before winding to the pair of clamping parts 41. For this reason, the first holding unit 120A is installed on the side of the transport device 90 that is in the transport direction relative to the second holding unit 120B.

[0053] The pushing jig 102 of the lifting device 100 shown in Figure 1 is formed in a flange shape that simultaneously contacts the rollers 125a of the first and second holding units 120A and 120B (see Figure 6). Therefore, the lifting device 100 simultaneously moves the holding parts 123 of the first and second holding units 120A and 120B (see Figure 6) forward and backward between the pair of clamping parts 41.

[0054] As shown in Figure 1, the controller 150 controls the operation of each device 10, 20, 70, and 80 of the winding device 1, such as the nozzle moving device 10, as well as the transport device 90 and the lifting device 100. The controller 150 is composed of a microcomputer equipped with a CPU (Central Processing Unit), ROM (Read-Only Memory), RAM (Random Access Memory), and an I / O interface (Input / Output Interface). The RAM stores data from the CPU's processing, and the ROM stores the CPU's control program and the like in advance. The I / O interface is used for inputting and outputting information with each device 10, 20, 70, 80, 90, and 100 connected to the controller 150.

[0055] Next, a method for manufacturing the stator 220 according to this embodiment will be described. The method for manufacturing the stator 220 is used in the winding device 1, and the operation of the winding device 1 is automatically controlled by the controller 150.

[0056] The method for manufacturing the stator 220 involves holding a stator core 30 (see Figure 2), in which a slot 33 is formed with an opening 31 whose width W1 is narrower than the width W2 of the opposing bottom 32, on the axis of a spindle 22 (see Figure 1) which serves as the axis of rotation, and guiding the wire 2 fed out from the nozzle 3 into the slot 33 to wind it onto the bottom 32. This method comprises a main guide preparation step and a sub-guide preparation step shown in Figure 7, and a winding step shown in Figures 8 to 10.

[0057] The manufacturing method of the stator 220 further includes a clamping step as shown in Figure 7(a), in which the stator core 30, supplied by the first holding unit 120A (see Figure 6) before winding, is clamped by a pair of clamping parts 41, thereby holding the stator core 30 on the axis of the spindle 22 (see Figure 1).

[0058] In the main guide preparation step shown in Figure 7(b), a pair of main guides 51 are positioned opposite each other with a first guide gap CL1 between them, with respect to the stator core 30 which is held on the axis of the spindle 22, to guide the wire 2 into the opening 31.

[0059] The main guide 51 is driven by an actuator (not shown) and is positioned to guide the wire 2 into the opening 31, and the first guide gap CL1 is formed between the pair of tip guide portions 51a of the pair of main guides 51.

[0060] As shown by the dashed line in Figure 2, the first guide gap CL1 formed by the pair of main guides 51 is larger than the outer diameter of the wire 2 and narrower than the width W1 of the opening 31. This prevents the insulating coating of the wire 2, which is guided into the opening 31 by the pair of main guides 51, from being damaged by the edges of the flanges 34 and 35.

[0061] In the sub-guide preparation step shown in Figure 7(c), a pair of sub-guides 61 (here, a pair of sub-guides 61 of sub-guide mechanisms 60A and 60B, and a pair of sub-guides 61 of sub-guide mechanisms 60C and 60D) are positioned opposite each other with a second guide gap CL2 between them, with the stator core 30 held on the axis of the spindle 22 at a position offset from the opening 31 in the rotational direction of the spindle 22.

[0062] The sub-guide 61 is driven by the actuator unit 24 (see Figure 1) and is positioned to guide the wire 2 into the slot 33 (see Figure 2) of the stator core 30. The second guide gap CL2 is formed between the pair of guide claws 61b of the pair of sub-guides 61 and is set to the same size as the first guide gap CL1.

[0063] The main guide preparation process and the sub-guide preparation process may be performed simultaneously, or the sub-guide preparation process may be performed before the main guide preparation process.

[0064] In the winding process shown in Figures 8 to 10, the position of the first guide gap CL1 of the main guide 51 and the position of the second guide gap CL2 of the sub-guide 61 are moved relative to each other along the axial direction AX of the spindle 22. This adjusts the winding position of the wire 2 inserted into the slot 33 (see Figure 2) through the first and second guide gaps CL1 and CL2, while winding it onto the bottom 32. In Figures 8 to 10, the rotation direction of the stator core 30 is clockwise when viewed from the left side of the figure. In the winding process shown in Figures 8 to 10, the center position of the nozzle 3 in the axial direction AX of the spindle 22 is aligned with the center position L1 of the opening 31 of the stator core 30. In other words, the center position L1 of the opening 31 of the stator core 30 is the center position of the bottom 32 of the stator core 30. As shown in Figures 8 to 10, the pair of subguides 61 that form the second guide gap CL2 are provided at a distance of 180 degrees from each other in the rotational direction of the spindle 22.

[0065] Figure 8 shows the arrangement of the main guide 51 and sub-guide 61 when the wire 2 is wound around the bottom 32 of the stator core 30 at a winding position L2 that is to the left of the center position L1 of the opening 31 in the axial direction AX of the spindle 22.

[0066] A pair of main guides 51 that guide the wire 2 into the opening 31 are positioned relative to the opening 31 with a first guide gap CL1, and in the axial direction AX of the spindle 22, the center position of the first guide gap CL1 is aligned with the center position L1 of the opening 31. The pair of main guides 51 are fixedly positioned relative to the opening 31 of the stator core 30 during winding.

[0067] The pair of sub-guides 61 are aligned to the winding position L2 while having a second guide gap CL2, and in the axial direction AX of the spindle 22, the center position of the second guide gap CL2 is aligned to the winding position L2. The pair of sub-guides 61 are aligned to the winding position L2 while maintaining the second guide gap CL2.

[0068] In the guide arrangement shown in Figure 8, for example, compared to the state shown in Figure 7(c), the position of the second guide gap CL2 of the sub-guide 61 is moved relative to the position of the first guide gap CL1 of the main guide 51 to the left in the figure.

[0069] In this state, when the spindle 22 (see Figure 1) rotates as shown by the arrow in Figure 8, the stator core 30, which is held in place by the clamping portion 41, rotates together with the main guide 51 and sub-guide 61 around the spindle 22, which acts as the axis of rotation. In other words, the stator core 30, the main guide 51, and the sub-guide 61 rotate relative to the nozzle 3. As the stator core 30 rotates, the wire 2 is fed out from the nozzle 3 and wound around the bottom portion 32 of the stator core 30. The operation of the main guide 51 and sub-guide 61 during winding will be described below.

[0070] The wire 2 fed out from the nozzle 3 is guided by the main guide 51 and inserted into the slot 33 through the opening 31 via the first guide gap CL1 (wire 2 shown as a solid line in Figure 8). Furthermore, as the stator core 30 rotates, the wire 2 fed out from the nozzle 3 is sequentially guided by sub-guides 61 provided at 180-degree intervals, thereby adjusting the winding position of the wire 2 within the slot 33 to the winding position L2 shown as a dashed line in Figure 8. In Figure 8, as the stator core 30 rotates approximately one full turn, the winding position of the wire 2 fed out from the nozzle 3 and inserted into the slot 33 is adjusted from the position shown as a solid line to the position shown as a dashed line. Specifically, as shown in Figure 8, the wire 2 fed out from the nozzle 3 contacts the guide surface 61a of the sub-guide 61, changing its direction of travel, and as the sub-guide 61 rotates, it slides along the guide surface 61a and is guided into the second guide gap CL2 between the guide claws 61b. The guide surface 61a is formed as a three-dimensional outer surface that guides the contacting wire 2 toward the second guide gap CL2 while it rotates. Note that in Figure 8, only the wire 2 whose winding position within the slot 33 has been adjusted is shown, and the other wires 2 are not shown.

[0071] As described above, in the axial direction AX of the spindle 22, the winding position of the wire 2 inserted into the slot 33 through the opening 31 is adjusted to the winding position L2 as shown by the dashed line in Figure 8. Furthermore, by adjusting the winding position in this way, the rotational speed of the spindle 22 does not need to be reduced when winding in the corners of the slot 33 (see Figure 2), thus enabling faster winding. In this way, by adjusting the two second guide gaps CL2 of the pair of upper and lower subguides 61 in Figure 8 to the left in Figure 8 relative to the first guide gap CL1, the wire 2 can be positioned at the winding position "S" in Figure 11.

[0072] Furthermore, when winding on the back side of the stator core 30, that is, on the side of the opening 39 (see Figure 2), since the slot 38 (see Figure 2) is rectangular, it is not necessary to guide the wire 2 with a guide similar to the main guide 51. When winding on the back side of the stator core 30, the position of the nozzle 3 in the axial direction AX of the spindle 22 may be adjusted to the winding position L2, in which case the pair of sub-guides 61 of the sub-guide mechanisms 60C and 60D on the lower side of Figure 8 can be omitted.

[0073] Figure 9 shows the arrangement of the main guide 51 and sub-guides 61 when the wire 2 is wound around the bottom 32 of the stator core 30 at a winding position L3 to the right of the center position L1 of the opening 31 in the axial direction AX of the spindle 22. In this case, the pair of sub-guides 61 are aligned with the winding position L3, and first and second guide gaps CL1 and CL2 are formed between the pair of main guides 51 and between the pair of sub-guides 61, similar to the case in Figure 8.

[0074] In this case, compared to the state shown in Figure 7(c), for example, the position of the second guide gap CL2 of the subguide 61 is moved relative to the position of the first guide gap CL1 of the main guide 51 to the right in the figure, and the winding position of the wire 2 in the slot 33 in the axial direction AX of the spindle 22 is adjusted in the same way as in Figure 8, to the winding position L3 as shown by the dashed line. In Figure 9, as the stator core 30 rotates approximately one full turn, the winding position of the wire 2 fed out from the nozzle 3 and inserted into the slot 33 is adjusted from the position shown by the solid line to the position shown by the dashed line. Note that in Figure 9, only the wire 2 whose winding position in the slot 33 has been adjusted is shown, and the other wires 2 are not shown. In this way, by adjusting the two second guide gaps CL2 of the pair of subguides 61, one above and one below in Figure 9, to the right in Figure 9 with respect to the first guide gap CL1, the wire 2 can be positioned at the winding position "5" in Figure 11.

[0075] Figure 10 shows the arrangement of the main guide 51 and sub-guide 61 when winding the wire 2 around the center position L1 of the opening 31 in the axial direction AX of the spindle 22, relative to the bottom 32 of the stator core 30. In this case, since the center position L1 of the opening 31 is the winding position, the pair of sub-guides 61 are aligned with the center position L1 of the opening 31 in the axial direction AX of the spindle 22.

[0076] In this case, for example, compared to the state shown in Figure 8, the position of the second guide gap CL2 of the sub-guide 61 is moved to the right in the figure, causing the main guide 51 and the sub-guide 61 to move relative to each other.

[0077] In this case, when the stator core 30 rotates, the wire 2 fed out from the nozzle 3 is wound around the bottom 32 at the center position L1 of the opening 31 in the axial direction AX of the spindle 22, and the winding position of the wire 2 within the slot 33 is not particularly adjusted by the subguide 61. However, even in this case, the winding position of the wire 2 within the slot 33 is adjusted by the relative movement of the main guide 51 and the subguide 61, compared to the state shown in Figure 8, for example.

[0078] Thus, in the winding process, with the first guide gap CL1 fixed to the opening 31 of the stator core 30, the second guide gap CL2 is moved along the axial direction AX of the spindle 22 relative to the first guide gap CL1, thereby adjusting the winding position of the wire 2 inserted into the slot 33 through the first and second guide gaps CL1 and CL2 within the slot 33.

[0079] Figure 11 is an explanatory diagram of aligned winding, which is performed by adjusting the winding position within the slot 33. In Figure 11, the winding order of aligned winding is indicated by labeling the wire material 2 wound around the bottom 32 of the stator core 30 with "S" to indicate the start of winding, "2 to 13" to indicate the intermediate winding sequence, and "F" to indicate the end of winding.

[0080] For example, the starting winding position of wire 2 in winding order "S" is in a corner of the slot 33 and is covered by the flange 34 from the opening 31 side. Therefore, by winding with the guide arrangement shown in Figure 8, the winding position of wire 2 inserted into the slot 33 is adjusted, and wire 2 is positioned in a corner of the slot 33.

[0081] In this example, the wires 2 with winding orders "S", "2", "8", "9", "10", and "F" are wound using the guide arrangement shown in Figure 8, the wires 2 with winding orders "4", "5", "6", "7", "12", and "13" are wound using the guide arrangement shown in Figure 9, and the wires 2 with winding orders "3" and "11" are wound using the guide arrangement shown in Figure 10.

[0082] In the winding process, the wire 2 is wound around the bottom 32 of the stator core 30, which rotates around the spindle 22 (see Figure 1) as the axis of rotation. This forms a layer 130 in which the wire 2 is aligned in the axial direction AX of the spindle 22. In addition, multiple layers 130 are formed by stacking the next layer 130 on top of the formed layer 130.

[0083] When forming each layer 130, the position of the sub-guide 61 is shifted by one pitch, equivalent to the outer diameter of the wire 2, in the axial direction AX of the spindle 22, each time the wire 2 is wound. This adjusts the winding position of the wire 2 within the slot 33, thereby aligning the wires 2 in the axial direction AX of the spindle 22.

[0084] When forming the next layer 130 on top of the formed layer 130, the position of the sub-guide 61 is shifted by half a pitch in the axial direction AX of the spindle 22, thereby adjusting the winding position of the wire 2 within the slot 33 to an intermediate position between the two wires 2 in the already formed layer 130.

[0085] In this example, a total of four layers 130, from the first layer 131 to the fourth layer 134, are formed by stacking them. The number of turns of the wire 2 forming each layer 130 is less on the opening 31 side than on the bottom 32 side, corresponding to the width of the slot 33, where the opening 31 side is narrower than the bottom 32 side.

[0086] If the position of the wire 2 at the start of winding sequence "S" is misaligned, the positions of subsequent wire 2 will also be misaligned. Furthermore, depending on how the wire 2 at the end of winding sequence "F" is wound, winding collapse may occur in the alignedly wound wire 2. For this reason, in the winding device 1, the rotational speed of the stator core 30 (in other words, the rotational speed of the spindle 22) during aligned winding is set as follows.

[0087] Figures 12 and 13 show examples of setting the rotational speed of the stator core 30 during aligned winding. As shown in Figures 12 and 13, the rotational speed of the stator core 30 is lower during the winding at the beginning and end of winding the wire 2 across the entire set of layers 130 (periods "S" and "F" in winding order) than during the winding between the beginning and end of winding (periods "2" to "13" in winding order).

[0088] In the first setting example shown in Figure 12, the rotational speed of the stator core 30 is gradually increased during the initial winding of winding sequence "S". The rotational speed of the stator core 30 is gradually increased from zero towards the rotational speed during the intermediate windings "2 to 13". The rotational speed during the intermediate windings is considered to be the steady-state rotational speed. The rotational speed during the intermediate windings does not have to be constant.

[0089] In the first example setting, the rotational speed of the stator core 30 gradually decreases when winding the final winding of winding sequence "F". The rotational speed of the stator core 30 gradually decreases from the rotational speed during the intermediate winding towards zero.

[0090] Therefore, in the first setting example, the rotational speed of the stator core 30 is transiently increased or decreased relative to the rotational speed during intermediate winding (for example, during winding sequence "2", i.e., the winding immediately following the start of winding, or during winding sequence "13", i.e., the winding immediately preceding the end of winding) when winding the first and last windings are being made.

[0091] In the second setting example shown in Figure 13, the rotational speed of the stator core 30 is increased in steps during the initial winding of winding sequence "S". The rotational speed of the stator core 30 is increased in steps from zero to a rotational speed lower than the rotational speed during the intermediate winding. The rotational speed during the intermediate winding is increased in steps from the rotational speed during the initial winding of winding sequence "S".

[0092] In the second setting example, the rotational speed of the stator core 30 is gradually reduced when winding the final winding of winding sequence "F". The rotational speed of the stator core 30 is gradually reduced from the rotational speed during the intermediate winding to a rotational speed higher than zero, and then gradually reduced to zero at the end of the winding.

[0093] Therefore, in the second setting example, when winding the beginning and end of winding order "S" and "F", the rotational speed of the stator core 30 is increased or decreased in a stepwise manner compared to the rotational speed during intermediate winding (for example, when winding order "2" or when winding order "13").

[0094] In both the first setting example shown in Figure 12 and the second setting example shown in Figure 13, the wire 2 is wound more slowly at the beginning of winding sequence "S" than at the intermediate winding, making it easier to wind the wire 2 more accurately to the starting winding position of winding sequence "S". Also, the wire 2 is wound more slowly at the end of winding sequence "F" than at the intermediate winding, making it less likely for the winding to collapse due to the wire 2 wound at the end of winding sequence "F".

[0095] After the winding of the winding sequence "F" is completed, the wire 2 is cut by a cutter (not shown) between the nozzle 3 and the stator core 30 (see Figure 1), thereby forming the end portion of the wire 2 wound around the stator core 30. The end portion of the wire 2 needs to have its insulating coating removed because it will be connected to terminals, etc., when the stator core 30 is mounted.

[0096] Therefore, in the winding device 1, the insulating coating stripping process is incorporated into the winding process in such a way that it interrupts the winding, and the rotational speed of the stator core 30 during winding is set as follows.

[0097] Figures 14 and 15 show examples of setting the rotational speed of the stator core 30 during the winding process, which incorporates a stripping process. The first setting example shown in Figure 14 corresponds to the first setting example in Figure 12, and the second setting example shown in Figure 15 corresponds to the second setting example in Figure 13.

[0098] In these examples, the rotation of the stator core 30 is stopped before the end of the winding of the wire 2 across the entire number of layers 130, and the insulating coating of the wire 2 is stripped off in the portion including the end position of the wire 2 corresponding to the remaining winding length of the wire 2.

[0099] In this embodiment, when the wire 2 in winding order "9" is finished winding, the end position of the wire 2, corresponding to the remaining winding length of the wire 2, reaches a position where the insulating coating of the wire 2 can be peeled off by the stripping device 70 (see Figure 1). Therefore, in these setting examples, when the wire 2 in winding order "9" is finished winding, the timing for stopping the rotation of the stator core 30 to peel off the insulating coating of the end portion of the wire 2 arrives, and the rotation of the stator core 30 is stopped.

[0100] The timing for stopping the rotation of the stator core 30 can be determined in advance by knowing the length of the wire 2 between the stator core 30 and the stripping device 70, and the remaining length of the wire 2 to the end position according to the number of turns on the stator core 30. Furthermore, when stopping the rotation of the stator core 30 for the stripping process, in the first setting example shown in Figure 14, the rotation speed of the stator core 30 is transiently reduced, and in the second setting example shown in Figure 15, the rotation speed of the stator core 30 is reduced in steps.

[0101] In the stripping process, the insulating coating of the wire 2, including the end position, is stripped by the stripping device 70 (see Figure 1). Once the stripping process is complete, the interrupted winding process resumes, and winding from winding sequence "10" onwards is carried out. After all winding is complete, the wire 2 is cut by a cutter (not shown), and the end portion of the wire 2 is formed with the insulating coating stripped and the conductor exposed.

[0102] By removing the insulating coating in this way, it is not necessary to remove the insulating coating during mounting the stator core 30, and the mounting procedure for the stator core 30 is simplified. When resuming winding, in the first setting example shown in Figure 14, the rotational speed of the stator core 30 is increased transiently, and in the second setting example shown in Figure 15, the rotational speed of the stator core 30 is increased in steps.

[0103] As shown in Figure 1, the winding process is performed by a winding device 1 which is rotated around a spindle 22 as a rotation axis and has a pair of clamping parts 41 that are provided on both sides of the axial direction AX of the spindle 22 and face each other, and clamp the stator core 30.

[0104] Furthermore, the manufacturing method of the stator 220 further includes a stator core loading and unloading step in which the stator core 30 is loaded into and unloaded from the winding device 1 by transporting a pallet 110, which has holding parts 123 of first and second holding units 120A and 120B (see Figure 6) that serve as first and second holding parts for holding the stator core 30 before and after winding, respectively, in a transport direction that crosses between a pair of clamping parts 41. The pallet 110 is transported using a transport device 90.

[0105] Figure 16 is an explanatory diagram of the stator core loading and unloading process. In Figure 16, the rotating device 20A and pallet 110 are shown with the horizontal direction in the figure being the transport direction, and the state of the pair of clamping parts 41 of the rotating devices 20A and 20B and the stator core 30 as seen from the transport direction is also shown.

[0106] In the stator core loading and unloading process, the pallet 110 is first transported into the winding device 1 with the stator core 30, before winding, held in the holding portion 123 (first holding portion) of the first holding unit 120A, and the holding portion 123 (second holding portion) of the second holding unit 120B is positioned between a pair of clamping portions 41 in the transport direction (arrow P1). At this time, the stator core 30, after winding, is clamped between the pair of clamping portions 41.

[0107] Next, the holding portions 123 of the first and second holding units 120A and 120B are moved in the direction of entry (upward in Figure 16) relative to the pair of clamping portions 41, so that the wound stator core 30, which is clamped between the pair of clamping portions 41, is held by the holding portion 123 of the second holding unit 120B (arrow P2).

[0108] Next, the pair of clamping parts 41 are retracted to release the clamping of the stator core 30 after winding (arrow P3), thereby placing the stator core 30 after winding on the holding part 123 of the second holding unit 120B.

[0109] Next, the pair of clamping parts 41 perform an operation to replace the stator core 30, which is clamped by the pair of clamping parts 41, with the stator core 30 before winding (arrows P4 to P6).

[0110] Next, with the stator core 30 after winding held in the holding section 123 of the second holding unit 120B, the pallet 110 is transported outside the winding device 1 (arrow P7), and the stator core 30 after winding is sent to the next process by the pallet 110.

[0111] With this stator core loading and unloading process, as shown in Figure 1, the transport device 90 can be positioned opposite the nozzle 3 with the axis of the spindle 22 in between, so that the stator core 30 can be loaded and unloaded while avoiding interference with the nozzle 3, the nozzle moving device 10, and a cutter (not shown) that cuts the wire 2 at its end position.

[0112] Figure 17 is a flowchart showing the manufacturing method of the motor 200 (see Figure 3). The manufacturing method of the motor 200 includes a first step 141 in which the stator core 30 before winding is brought into the winding device 1 and winding is performed; a second step 142 in which the stator core 30 after winding is removed from the winding device 1; a third step 143 in which the stator 220 is assembled by housing the stator core 30 after winding in the holder 221 (see Figure 3); and a fourth step 144 in which the motor 200 is assembled by incorporating the rotor 210 and stator 220 into the housing 240.

[0113] In the first step 141, winding is performed using the manufacturing method of the stator 220 described above, and steps 141 to 343 correspond to the manufacturing method of the stator 220.

[0114] According to this method of manufacturing the motor 200, since the motor 200 is manufactured using the same manufacturing method as the stator 220, it is possible to increase the manufacturing capacity of the motor 200 and reduce manufacturing costs by increasing the winding speed.

[0115] In this embodiment, the motor 200 has been described as having a stator 220 composed of multiple stator cores 30 as segmented cores, but the motor 200 may be, for example, a shaded-pole motor. A shaded-pole motor also has an iron core (stator core) with a bottom portion where the stator coils are wound, and a space (slot) formed in which the width of the opening is narrower than the width of the opposing bottom portions.

[0116] The main effects and advantages of the manufacturing methods for the stator 220 and motor 200 according to the present invention will be summarized below.

[0117] A method for manufacturing a stator 220 involves holding a stator core 30, in which a slot 33 is formed with an opening 31 whose width W1 is narrower than the width W2 of the opposing bottom 32, on the axis of a spindle 22 which serves as a rotation axis, and guiding the wire 2 fed out from a nozzle 3 into the slot 33 and winding it onto the bottom 32, comprising a main guide preparation step of arranging a pair of main guides 51 opposite the stator core 30, which is held on the axis of the spindle 22, with a first guide gap CL1 between them, and a main guide preparation step of arranging a pair of main guides 51 for guiding the wire 2 into the opening 31, opposite each other with a first guide gap CL1 between them, and a main guide preparation step of arranging a stator core 30, which is held on the axis of the spindle 22 The system includes a sub-guide preparation step of arranging a pair of sub-guides 61 opposite each other with a second guide gap CL2 between them, at a position offset from the opening 31 in the rotational direction of the spindle 22, to guide the wire 2 to the stator core 30 in its current state, and a winding step of winding the wire 2 to the bottom 32 while adjusting the winding position of the wire 2 inserted into the slot 33 through the first and second guide gaps CL1 and CL2, by relatively moving the position of the first guide gap CL1 of the main guide 51 and the position of the second guide gap CL2 of the sub-guides 61 along the axial direction AX of the spindle 22.

[0118] According to this method, the winding position of the wire 2 inserted into the slot 33 through the pair of main guides 51 is adjusted according to the relative position of the first guide gap CL1 and the second guide gap CL2. Therefore, when winding at the corner of the bottom 32 of the slot 33, where the width W1 of the opening 31 is narrower than the width W2 of the opposite bottom 32, the winding speed does not need to be reduced, and the winding speed can be increased.

[0119] In the winding process, with the first guide gap CL1 fixed to the opening 31 of the stator core 30, the second guide gap CL2 is moved along the axial direction AX of the spindle 22 relative to the first guide gap CL1, thereby adjusting the winding position of the wire 2 inserted into the slot 33 through the first and second guide gaps CL1 and CL2.

[0120] According to this method, the winding position within the slot 33 of the wire 2 can be adjusted simply by adjusting the position of the sub-guide 61 in the axial direction AX of the spindle 22, making it easier to speed up winding in aligned winding.

[0121] In the winding process, the wire 2 is wound around the bottom 32 of the stator core 30, which rotates around the spindle 22, thereby forming layers 130 aligned in the axial direction AX of the spindle 22. In addition, multiple layers 130 are formed by stacking the next layer 130 on top of the formed layer 130. At the beginning and end of the winding of the wire 2 across the multiple layers 130, the rotational speed of the stator core 30 is reduced compared to the winding between the beginning and end, i.e., during intermediate winding.

[0122] According to this method, the wire 2 is wound more slowly at the beginning of the winding compared to the intermediate winding, making it easier to wind the wire 2 more accurately relative to the starting winding position. Also, because the wire 2 is wound more slowly at the end of the winding compared to the intermediate winding, it becomes less likely for the winding to collapse due to the wire 2 wound at the end of the winding.

[0123] In the winding process, the wire 2 is wound around the bottom 32 of the stator core 30, which rotates around the spindle 22, thereby forming layers 130 aligned in the axial direction AX of the spindle 22. Multiple layers 130 are then formed by stacking the next layer 130 on top of the formed layer 130. Before the winding of the wire 2 is completed across all of the multiple layers 130, the rotation of the stator core 30 is stopped, and the insulating coating of the wire 2 is stripped from the portion of the wire 2 that includes the end position of the wire 2, corresponding to the remaining winding length of the wire 2.

[0124] This method eliminates the need to remove the insulating coating during mounting of the stator core 30, thus simplifying the mounting procedure for the stator core 30.

[0125] The winding process is performed by a winding device 1 that rotates around a spindle 22 and has a pair of clamping parts 41 that are positioned opposite each other on both sides of the axial direction AX of the spindle 22 and clamp the stator core 30. The manufacturing method of the stator 220 further includes a stator core loading and unloading process in which the stator core 30 is loaded into and unloaded from the winding device 1 by transporting a pallet 110, which has holding parts 123 of first and second holding units 120A and 120B, respectively, as first and second holding parts that hold the stator core 30 before and after winding, in a transport direction that crosses between the pair of clamping parts 41. In the stator core loading and unloading process, the pallet 110 is transported into the winding device 1 with the stator core 30 before winding held in the holding part 123 of the first holding unit 120A, which serves as the first holding part, and the holding part 123 of the second holding unit 120B, which serves as the second holding part, is positioned between a pair of clamping parts 41 in the transport direction, and the holding parts 123 of the first and second holding units 120A and 120B are moved in the direction of entry between the pair of clamping parts 41 so that they are clamped by the pair of clamping parts 41. The following operations are performed: holding the wound stator core 30 in the holding portion 123 of the second holding unit 120B; retracting the pair of clamping portions 41 to release the clamping of the wound stator core 30; replacing the wound stator core 30 with the unwound stator core 30 held by the pair of clamping portions 41; and transporting the pallet 110 outside the winding device 1 while the wound stator core 30 is held in place by the holding portion 123 of the second holding unit 120B.

[0126] This method allows the transport device 90 to be positioned opposite the nozzle 3 with the axis of the spindle 22 in between, thus enabling the stator core 30 to be loaded and unloaded while avoiding interference with the nozzle 3, the nozzle moving device 10, and a cutter (not shown) that cuts the wire 2 at its end position.

[0127] In the method for manufacturing a motor 200 having a stator 220, the stator 220 is manufactured using the method for manufacturing the stator 220 described above.

[0128] This method allows for increased manufacturing capacity and reduced manufacturing costs for the motor 200 through faster winding of the stator 220 manufacturing method.

[0129] Although embodiments of the present invention have been described above, these embodiments are merely examples of how the present invention can be applied, and are not intended to limit the technical scope of the present invention to the specific configurations of the above embodiments.

[0130] This application claims priority under Japanese Patent Application No. 2025-4220, filed with the Japan Patent Office on 10 January 2025, and all contents of that application are incorporated herein by reference.

Claims

1. A method for manufacturing a stator, comprising: holding a stator core on the axis of a rotating shaft, in which a slot is formed having an opening width narrower than the width of an opposing bottom, and guiding a wire unwound from a nozzle into the slot and winding it onto the bottom, the method comprising: a main guide preparation step of arranging a pair of main guides for guiding the wire into the opening opposite the stator core, which is held on the axis of the rotating shaft, with a first guide gap between them; a sub-guide preparation step of arranging a pair of sub-guides for guiding the wire at a position offset from the opening in the rotational direction of the rotating shaft, with a second guide gap between them; and a winding step of winding the wire onto the bottom while adjusting the winding position of the wire inserted into the slot through the first guide gap and the second guide gap by relatively moving the positions of the first guide gap and the second guide gap along the axial direction of the rotating shaft.

2. A method for manufacturing a stator according to claim 1, wherein in the winding step, the first guide gap is fixed with respect to the opening of the stator core, and the second guide gap is moved with respect to the first guide gap along the axial direction of the rotation shaft, thereby adjusting the winding position of the wire inserted into the slot through the first guide gap and the second guide gap within the slot.

3. A method for manufacturing a stator according to claim 1 or 2, wherein in the winding step, the wire is wound around the bottom of the stator core which is rotated around the rotation axis to form a layer in which the wire is aligned in the axial direction of the rotation axis, and a plurality of layers are formed by stacking the next layer on top of the formed layer, and the rotation speed of the stator core is reduced at the beginning and end of winding of the wire in the plurality of layers compared to the winding between the beginning and end of winding.

4. A method for manufacturing a stator according to any one of claims 1 to 3, wherein in the winding step, the wire is wound around the bottom of the stator core which is rotated around the rotation axis to form a layer in which the wire is aligned in the axial direction of the rotation axis, and a plurality of layers are formed by stacking the next layer on top of the formed layer, and the rotation of the stator core is stopped before the end of winding the wire in the plurality of layers, and the insulating coating of the wire is peeled off in the portion including the end position of the wire corresponding to the remaining winding length of the wire.

5. A method for manufacturing a stator according to any one of claims 1 to 4, wherein the winding step is performed by a winding device having a pair of clamping parts that are rotated about the rotation axis and are provided on both sides of the rotation axis facing each other and clamping the stator core, and further comprises a stator core loading / unloading step for loading and unloading the stator core to the winding device by transporting a pallet having first and second holding parts that each hold the stator core before winding and after winding in a transport direction that crosses between the pair of clamping parts, the stator core loading / unloading step is to transport the pallet into the winding device with the stator core before winding held in the first holding part, positioning the second holding part between the pair of clamping parts in the transport direction, moving the first and second holding parts in an approach direction relative to the pair of clamping parts, so that the stator core after winding that is clamped between the pair of clamping parts is held by the second holding part, and retracting the pair of clamping parts to release the clamping of the stator core after winding A method for manufacturing a stator, comprising: replacing the stator core held by the pair of clamping portions with the stator core before winding from the stator core after winding, and transporting the pallet outside the winding device while the stator core after winding is held by the second holding portion.

6. A method for manufacturing a motor having a stator, wherein the stator is manufactured using the method for manufacturing a stator described in any one of claims 1 to 5.

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