METHOD OF MANUFACTURING STATOR AND COIL INSERTION APPARATUS

• US 20130153702A1
• Filed: 12/10/2012
• Published: 06/20/2013
• Est. Priority Date: 12/15/2011
• Status: Active Grant

• Current Assignee: Aisin AW Company Limited (Aisin Corp.)
• Original Assignee: Shigeki Sato, Yasuo Yamaguchi
• Inventors: YAMAGUCHI, Yasuo, HAYASHI, Katsuyuki, SATO, Shigeki
• Granted Patent: US 8,936,211 B2
• Time in Patent Office: Days
• US Class Current: 242/432
• CPC Class Codes: H01F 41/06 Coil winding
• CPC Class Codes: H02K 15/0037 Shaping or compacting winding heads H02K15/005, H02K15/0087 and H02K15/0428 take precedence
• CPC Class Codes: H02K 15/068 Strippers
• CPC Class Codes: Y10T 29/5146 Common reciprocating support for spaced tools

Abstract

A method of manufacturing a stator includes a first winding step of, with annular conductors of a first coil portion being placed in a coil holding unit, inserting the annular conductors into the respective slots by a coil pushing-out unit; and a second winding step of, after the first coil winding step, with annular conductors of a second coil portion placed in the coil holding unit, moving a positioning unit in an axial direction at least from one end of the stator core to the other end of the stator core in the axial direction, and inserting the annular conductors into the respective slots by the coil pushing-out unit while a part of the first coil portion, which is located in the slots, is pressed in a direction from the opening of the slot toward an inside of the slot by the radial end faces of the projecting teeth.

Claims

1. A method of manufacturing a stator by winding a coil on a stator core by using a coil insertion apparatus, wherein

the coil has a first coil portion and a second coil portion that are placed so as to adjoin each other in a radial direction when mounted on the stator core,

the coil insertion apparatus includes a coil holding unit that has blades arranged along a circumferential direction and extending in an axial direction so as to face teeth of the stator core, respectively, a positioning unit that is fitted on the blades to adjust a positional relation between the blades, and a coil pushing-out unit that pushes out the coil held in the coil holding unit toward slots of the stator core, and

the positioning unit has projecting teeth each extending between adjoining ones of the blades and protruding toward the stator core along a radial direction, and is formed such that a radial end face of each of the projecting teeth is located at a position in the slot, which is located inward of an opening of the slot, the method of manufacturing a stator comprising:

a first coil winding step of, with annular conductors of the first coil portion being placed in the coil holding unit, inserting the annular conductors into the respective slots by the coil pushing-out unit; and

a second coil winding step of, after the first coil winding step, with annular conductors of the second coil portion being placed in the coil holding unit, moving the positioning unit in the axial direction at least from one end of the stator core in the axial direction to the other end of the stator core in the axial direction, and inserting the annular conductors into the respective slots by the coil pushing-out unit while a part of the first coil portion, which is located in the slots, is pressed in a direction from the opening of the slot toward an inside of the slot by the radial end faces of the projecting teeth.

2. The method of manufacturing a stator according to claim 1, wherein

each of coil end portions of the first coil portion and the second coil portion, which protrudes from the stator core in the axial direction of the stator core, includes link portions connecting different ones of the slots of the stator core and extending in the circumferential direction of the stator core,

each of the link portions is placed such that one end of the link portion in the circumferential direction is located inward, in the radial direction, of any other of the link portions which is located at the same position as the link portion in the circumferential direction, and such that the other end in the circumferential direction is located outward, in the radial direction, of any other of the link portions which is located at the same position as the link portion in the circumferential direction, and

each of the first coil winding step and the second coil winding step has

a coil placement step of placing the annular conductors in the coil holding unit, in which the annular conductors are placed such that a first portion of each of the annular conductors is inserted into a first hanging gap formed between the blades, a second portion thereof is inserted into a second hanging gap located a predetermined pitch away from the first hanging gap, and a joint portion connecting the first portion and the second portion of each of the annular conductors extends on one side, in the axial direction, with respect to the first portion of any other of the annular conductors which is positioned to overlap the joint portion as viewed in the axial direction,

a coil deformation step of, after the coil placement step, with a position of the positioning unit being fixed with respect to the coil holding unit, moving the coil pushing-out unit in the axial direction along the blades to a set position where an axial interval between the positioning unit and the coil pushing-out unit is shorter than an overall length of the annular conductors in the axial direction before deformation, thereby deforming the joint portions of the annular conductors, and

a coil insertion step of after the coil deformation step, further moving the coil pushing-out unit in the axial direction to insert the first portions and the second portions of the annular conductors into the slots.

3. The method of manufacturing a stator according to claim 2, wherein

an end of the coil holding unit on an axial first direction side, which is one side of the coil holding unit in the axial direction, corresponds to open ends of the blades, and the coil holding unit has a holding portion that integrally holds the blades on an axial second direction side, which is the other side of the coil holding unit in the axial direction, with respect to the open ends,

the coil placement step in the second coil winding step is performed after the first coil winding step with the positioning unit being located on the axial first direction side with respect to the coil holding unit, and

between the coil placement step of the second coil winding step and the coil deformation step of the second coil winding step, the positioning unit is moved in the axial direction toward the axial second direction side from a position on the axial first direction side with respect to the coil holding unit to a position where an end of the positioning unit on the axial second direction side is aligned with the end of the stator core on the axial second direction side, or to a position located on the axial second direction side with respect to the position where the end of the positioning unit on the axial second direction side is aligned with the end of the stator core on the axial second direction side, and in the coil insertion step of the second coil winding step, the positioning unit is moved in the axial direction toward the axial first direction side.

4. A coil insertion apparatus for winding a coil on a stator core, comprising:

a coil holding unit that has blades arranged along a circumferential direction and extending in an axial direction so as to face teeth of the stator core, respectively;

a positioning unit that is fitted on the blades to adjust a positional relation between the blades;

and a coil pushing-out unit that pushes out the coil held in the coil holding unit toward slots of the stator core, wherein

the positioning unit has projecting teeth each extending between adjoining ones of the blades and protruding toward the stator core along a radial direction, and

the positioning unit is formed such that, with the positioning unit being placed at the same position in the axial direction as the stator core, a radial end face of each of the projecting teeth is located at a position in the slot, which is located inward of an opening of the slot.

5. The coil insertion apparatus according to claim 4, wherein

the radial end face has a width in the circumferential direction which corresponds to a width of the slot in the circumferential direction, and the radial end face is placed at a position in the radial direction, which divides an area of a cross section perpendicular to the axial direction of the slot into two equal parts.

6. The coil insertion apparatus according to claim claim 4, wherein

the projecting tooth has a tilted surface that extends in the radial direction from the opening of the slot toward an inside of the slot as the tilted surface extends from an end of the projecting tooth in the axial direction toward a central portion of the projecting tooth in the axial direction.

7. The coil insertion apparatus according to claim 5, wherein

the projecting tooth has a tilted surface that extends in the radial direction from the opening of the slot toward an inside of the slot as the tilted surface extends from an end of the projecting tooth in the axial direction toward a central portion of the projecting tooth in the axial direction.