JP7046216B2 - Winding method, winding machine, insulator and rotary electric machine - Google Patents

Description

The present invention relates to a winding method, a winding machine, an insulator and a rotary electric machine.

Generally, a stator of a rotary electric machine is configured by arranging a plurality of split stators formed by winding a conducting wire around a laminated iron core via an insulating member in an annular shape and connecting them to each other.

The rotary electric machine is required to be miniaturized. Therefore, in the manufacturing process of the split stator, it is required to tightly wind the conducting wire around the laminated iron core. This is because if the conductor is wound tightly around the laminated iron core, the volume of the winding can be reduced and the volume of the entire split stator can be reduced. If the volume of the split stator is reduced, the volume of the stator is reduced, and as a result, the rotary electric machine is miniaturized.

Due to such circumstances, many inventions of winding methods suitable for increasing the density of windings have been filed. For example, in Patent Document 1, each time the conductor is wound once, the nozzle of the winding machine is swung to separate the newly wound conductor from the already wound conductor, and then the conductor is separated from the already wound conductor. Describes a winding method for re-contacting.

Japanese Unexamined Patent Publication No. 2009-99908

However, in the winding method described in Patent Document 1, each time the conductor is wound once, the nozzle of the winding machine is swung so that the conductor unwound from the nozzle is once separated from the already wound conductor. Then, it is necessary to repeat the operation of re-contacting. Therefore, it takes time to wind the conducting wire, so that the winding method described in Patent Document 1 has a problem that it takes time to manufacture the split stator.

An insulator that electrically insulates the conducting wire and the laminated iron core is attached to the laminated iron core constituting the split stator. Then, the conducting wire is wound around the laminated iron core from above the insulator. Further, in order to form a high-density winding, each time a single-layer winding is formed, the position where the conductor is wound is shifted by the radius of the conductor, and the conductor is bale in the cross-sectional shape of the winding. Need to be stacked. However, at the beginning of winding the winding, the conductor is slippery with respect to the insulator, so that there is a problem that the position of the conductor is not stable. Therefore, at the beginning of winding the winding, there arises a problem that it is difficult to stack the conductors to form a high-density winding. This problem becomes an obstacle to increasing the output and downsizing of the rotary electric machine.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a winding method and a winding machine capable of forming a high-density winding in a short time. Another object of the present invention is to provide an insulator suitable for such a winding method. Further, it is an object of the present invention to provide a rotary electric machine provided with such an insulator.

In order to achieve the above object, the winding method according to the present invention includes an orbiting operation in which a conductor is wound around an object relative to the object and the conductor is wound around the object. This is a winding method for winding a conducting wire around an object by combining an advancing / retreating operation in which the conductor is moved back and forth relative to the object in the direction of the orbiting central axis of the orbiting operation, and has the following first to fourth steps. The first step of winding the conductor around the first section of the cross-sectional shape of the object by stopping the advance / retreat operation and maintaining the position of the conductor relative to the object in the circumferential central axis direction. The conductor is wound around the second section following the first section of the cross-sectional shape of the object by performing a circular motion, and while the conductor is wound around the second section, the conductor is moved back and forth to the outer diameter of the conductor. The second step of moving the conductor relative to the object in the orbiting center axis direction by a corresponding distance, stopping the advancing / retreating operation and maintaining the relative position of the conducting wire in the orbiting center axis direction with respect to the object. , The third step of winding the conductor around the third section following the second section of the cross-sectional shape of the object by performing the orbiting motion, stopping the advancing / retreating motion and relative to the object of the orbiting center axis of the conductor. The fourth step of returning the conductor to the first section by winding the conductor around the fourth section following the third section of the cross-sectional shape of the object while maintaining the position. The object of the winding method according to the present invention is arranged at the corner between the first section and the second section, and the lead wire is wound around the object to form the starting end side of the first layer of the winding. A first step protruding from the end of the winding toward the end of the first layer of the winding , and a corner between the second and third sections of the winding. A second step portion is provided which protrudes from the end end side of the start end side of the first layer toward the end end side of the end end side of the first layer of the winding . Then, in the winding method according to the present invention, at the end of the first section in the first turn of the first layer of the winding , the conducting wire is brought into contact with the first step portion, and the second section of the first turn is made. At the same time as the winding of the conductor in the first turn is started, the advancing / retreating operation is started, and at the same time as the winding of the conducting wire in the second section is completed, the advancing / retreating operation is stopped. It is to be brought into contact with the step portion of .

According to the winding method according to the present invention, in the second step, the conductor is moved relative to the object by a distance corresponding to the outer diameter of the conductor, so that the newly wound conductor is first. The winding density can be increased by bringing it into close contact with the wound conductor. According to the winding method according to the present invention, it is not necessary to swing the conductor every time the conductor is wound once, so that the conductor can be continuously orbited at high speed. Therefore, it is possible to wind the conducting wire at high density in a short time. As a result, according to the present invention, since the high-density winding can be formed in a short time, a miniaturized rotary electric machine can be efficiently manufactured.

Front view of the winding machine according to the embodiment of the present invention. Cross-sectional view of the winding machine cut along the plane shown by the AA'line in FIG. 1A. FIG. 1A is a plan view of a stator of a rotary electric machine configured by combining a split stator mounted on the winding machine and wound with a conducting wire. Perspective view of the stator It is a figure which shows the manufacturing process of the split stator according to FIG. 1A to FIG. 2B in chronological order, and is the perspective view which shows the outer shape of the split laminated iron core. It is a figure which shows the manufacturing process of the split stator according to FIG. 1A to FIG. 2B in chronological order, and is the perspective view which shows the state which attached the insulator to the split laminated iron core. It is a figure which shows the manufacturing process of the split stator according to FIG. 1A-FIG. It is a figure explaining the term used for the description of the winding method which concerns on embodiment of this invention, and the partition stator which is shown in FIGS. Cross section It is a plan view and cross-sectional view of the split stator, and is the figure which shows the process of forming the 1st turn of the winding of the 1st layer by the winding method which concerns on embodiment of this invention. It is a figure which shows the process of forming the 1st turn of the winding of 1st layer, and is the figure which shows the process which follows the process shown in FIG. 5A. It is a figure which shows the process of forming the 1st turn of the winding of 1st layer, and is the figure which shows the process which follows the process shown in FIG. 5B. It is a figure which shows the process of forming the 1st turn of the winding of 1st layer, and is the figure which shows the process which follows the process shown in FIG. 5C. It is a figure which shows the process of forming the 1st turn of the winding of 1st layer, and is the figure which shows the process which follows the process shown in FIG. 5D. It is a figure which shows the process of forming the 1st turn of the winding of 1st layer, and is the figure which shows the process which follows the process shown in FIG. 5E. It is a plan view and the sectional view of the split stator, and is the figure which shows the process of forming the 2nd turn of the winding of the 1st layer by the winding method which concerns on embodiment of this invention. It is a figure which shows the process of forming the 2nd turn of the winding of 1st layer, and is the figure which shows the process which follows the process shown in FIG. 6A. It is a figure which shows the process of forming the 2nd turn of the winding of 1st layer, and is the figure which shows the process which follows the process shown in FIG. 6B. It is a figure which shows the process of forming the 2nd turn of the winding of 1st layer, and is the figure which shows the process which follows the process shown in FIG. 6C. It is a figure which shows the process of forming the 2nd turn of the winding of 1st layer, and is the figure which shows the process which follows the process shown in FIG. 6D. It is a figure which shows the process of forming the 2nd turn of the winding of 1st layer, and is the figure which shows the process which follows the process shown in FIG. 6E. It is a plan view and the sectional view of the split stator, and is the figure which shows the process of forming the 1st turn of the winding of 2nd layer by the winding method which concerns on embodiment of this invention. It is a figure which shows the process of forming the 1st turn of the winding of 2nd layer, and is the figure which shows the process which follows the process shown in FIG. 7A. It is a figure which shows the process of forming the 1st turn of the winding of 2nd layer, and is the figure which shows the process which follows the process shown in FIG. 7B. It is a figure which shows the process of forming the 1st turn of the winding of 2nd layer, and is the figure which shows the process which follows the process shown in FIG. 7C. It is a figure which shows the process of forming the 1st turn of the winding of 2nd layer, and is the figure which shows the process which follows the process shown in FIG. 7D. It is a figure which shows the process of forming the 1st turn of the winding of 2nd layer, and is the figure which shows the process which follows the process shown in FIG. 7E. It is a plan view and the sectional view of the split stator, and is the figure which shows the process of forming the 2nd turn of the winding of the 2nd layer by the winding method which concerns on embodiment of this invention. It is a figure which shows the process of forming the 2nd turn of the winding of 2nd layer, and is the figure which shows the process which follows the process shown in FIG. 8A. It is a figure which shows the process of forming the 2nd turn of the winding of 2nd layer, and is the figure which shows the process which follows the process shown in FIG. 8B. It is a figure which shows the process of forming the 2nd turn of the winding of 2nd layer, and is the figure which shows the process which follows the process shown in FIG. 8C. It is a figure which shows the process of forming the 2nd turn of the winding of 2nd layer, and is the figure which shows the process which follows the process shown in FIG. 8D. It is a figure which shows the process of forming the 2nd turn of the winding of the 2nd layer, and is the figure which shows the process which follows the process shown in FIG. 8E. A graph showing the relationship between the orbital angle around the reference axis of the nozzle, the orbital speed around the reference axis of the nozzle, and the position in the reference axis direction. 1A and 1B are flowcharts showing the processing by the control program installed in the computer provided in the winding machine, and the flowchart of the orbiting speed control program used in the step of forming the winding of the first layer. 1A and 1B are flowcharts showing the processing by the control program installed in the computer provided in the winding machine, and the flowchart of the advance / retreat position control program used in the step of forming the winding of the first layer. 1A and 1B are flowcharts showing the processing by the control program installed in the computer provided in the winding machine, and the flowchart of the orbiting speed control program used in the step of forming the winding of the nth layer. 1A and 1B are flowcharts showing the processing by the control program installed in the computer provided in the winding machine, and the flowchart of the advance / retreat position control program used in the step of forming the winding of the nth layer. Cross-sectional view of the end face insulator and the slot insulator corresponding to the cross-sectional view of FIG. 5A. Arrow view of the end face insulator from the direction indicated by arrow P in FIG. Arrow view of the end face insulator from the direction indicated by arrow Q in FIG. It is a figure which shows the detailed shape of the step part, and is the cross-sectional view obtained by cutting the step part in the plane shown by the line AA'in FIG. The figure which shows the action of a step part Cross-sectional view of the rotary motor Longitudinal section of rotary motor

Hereinafter, the winding method according to the embodiment of the present invention and the winding machine used for carrying out the winding method will be described in detail with reference to the drawings. In each drawing, the same or equivalent parts are designated by the same reference numerals.

(Winding machine)
1A and 1B are diagrams showing the configuration of a winding machine 1 used for carrying out the winding method according to the embodiment of the present invention. 1A is a front view of the winding machine 1, and FIG. 1B is a cross-sectional view of the winding machine 1 cut along a plane shown by the AA'line in FIG. 1A. As shown in FIG. 1A, the winding machine 1 has a core chuck device 3 for gripping a split stator 2 to be wound, and a nozzle 5 for feeding an insulatingly coated conductor wire 4 wound around the split stator 2. The main body 6 is provided. The conductor 4 is fed from a conductor feeder (not shown) arranged on the right side of the main body 6 in FIG. 1A, and is fed out from the tip of the nozzle 5. Further, the core chuck device 3 and the main body 6 are fixed to a common base plate 7, respectively.

The main body 6 is provided with a base 8 fixed to a base 7, and a moving base 9 is supported on the base 8 so as to be able to move forward and backward in the reference axis X direction. The moving table 9 is driven by a driving device 10 arranged between the base 8 and the moving table 9, and freely moves in the reference axis X direction. Further, the shaft support base 11 is fixed to the base 8. A circumferential shaft 12 is rotatably supported around the reference axis X on the moving table 9 and the shaft support table 11. The moving table 9 restrains the relative movement of the orbiting shaft 12 with respect to the moving table 9 in the reference axis X direction, while the shaft support table 11 is relative to the axis support table 11 of the orbiting shaft 12 in the reference axis X direction. Do not restrain movement. That is, the circumferential shaft 12 cannot move in the reference axis X direction with respect to the moving table 9, but can freely move in the reference axis X direction with respect to the shaft support table 11. Therefore, when the moving table 9 is driven by the drive device 10 and moves in the reference axis X direction with respect to the base 8, the circumferential shaft 12 also moves in the reference axis X direction with respect to the base 8.

The circumferential arm 13 is fixed to the end of the circumferential shaft 12 on the core chuck device 3 side. A nozzle 5 is fixed to the tip of the orbiting arm 13. Therefore, when the moving table 9 is driven by the driving device 10 and moves in the reference axis X direction with respect to the base 8, the orbiting arm 13 and the nozzle 5 are moved to the core chuck device 3 and the split stator 2 together with the orbiting shaft 12. On the other hand, move forward and backward. In this way, the moving table 9 and the driving device 10 function as advancing / retreating means for advancing / retreating the nozzle 5 relative to the dividing stator 2 in the reference axis X direction.

As shown in FIG. 1A, the driven pulley 14 is fixed to the end of the circumferential shaft 12 on the side far from the core chuck device 3. Further, the orbiting motor 15 is fixed to the base 8 via a frame (not shown). A drive pulley 16 is fixed to the output shaft of the orbiting motor 15. Further, a timing belt 17 is wound between the drive pulley 16 and the driven pulley 14. Therefore, when the orbiting motor 15 operates, the power of the orbiting motor 15 is transmitted to the orbiting shaft 12 via the drive pulley 16, the timing belt 17, and the driven pulley 14, and the orbiting shaft 12 rotates around the reference axis X. When the circumferential axis 12 rotates around the reference axis X, the orbital arm 13 and the nozzle 5 also rotate around the reference axis X. As a result, the nozzle 5 orbits around the split stator 2. As described above, the mechanism composed of the driven pulley 14, the orbiting motor 15, the drive pulley 16, and the timing belt 17 functions as an orbiting means for orbiting the nozzle 5 around the reference axis X. Further, the reference axis X corresponds to the circumferential central axis of the orbiting means.

As described above, according to the winding machine 1, the nozzle 5 can be moved forward and backward in the reference axis X direction, that is, in the circumferential center axis direction. Further, according to the winding machine 1, the nozzle 5 can be rotated around the reference axis X, that is, around the circumferential center axis.

Further, as shown in FIG. 1A, the winding machine 1 includes a computer 18 and is controlled by the computer 18. The computer 18 includes a CPU 18a for performing arithmetic processing, a storage unit 18b for storing data and programs, and an interface unit 18c for transmitting and receiving control signals between a device outside the computer 18. The winding method described later is executed by the CPU 18a reading a program pre-installed in the storage unit 18b and the CPU 18a executing the process described in the program. The CPU 18a outputs a control signal necessary for executing the process described in the program to the drive device 10 and the orbiting motor 15 via the interface unit 18c. Further, the control signals output by the drive device 10 and the orbiting motor 15 are fed back to the CPU 18a via the interface unit 18c.

(stator)
FIG. 2A is a plan view of a stator 19 of a rotary electric machine (not shown) configured by combining the split stators 2 to be wound, and FIG. 2B is a perspective view of the stator 19. As shown in FIGS. 2A and 2B, the stator 19 is configured by arranging nine split stators 2 in an annular shape. In the actual rotary electric machine, the stator 19 is arranged in a cylindrical casing (not shown), and the split stator 2 is fixed to the casing.

(Split stator)
3A to 3C are perspective views showing the manufacturing process of the split stator 2 in chronological order. FIG. 3A shows the outer shape of the split laminated iron core 21 which is the material of the split stator 2. FIG. 3B shows a state in which an insulator is attached to the split laminated iron core 21, that is, a state immediately before the insulator is attached to a winding machine (not shown). FIG. 3C shows a state in which the conducting wire 4 is wound around the divided laminated iron core 21 shown in FIG. 3B, that is, a state in which the dividing stator 2 is completed.

As shown in FIG. 3A, the divided laminated iron core 21 is configured by laminating a large number of iron core pieces 20. In the state shown in FIGS. 2A and 2B, the portion of the split laminated iron core 21 located on the outer diameter side of the stator 19 is called the back yoke 21a. The portion of the split laminated iron core 21 located on the inner diameter side of the stator 19 is called a shoe 21b. The portion between the back yoke 21a and the shoe 21b that connects the two is called the teeth 21c. The conductor 4 is wound around the teeth 21c.

As shown in FIG. 3B, the end face insulator 22 and the slot insulator 23 are mounted on the divided laminated iron core 21. The end face insulator 22 is an insulating member addressed to the upper end surface and the lower end surface of the divided laminated iron core 21. The slot insulator 23 is an insulating material that is arranged between the two end face insulators 22 mounted on the upper and lower ends of the split laminated iron core 21 and covers the side surfaces of the back yoke 21a, the shoe 21b, and the teeth 21c. The end face insulator 22 is a molded product of a synthetic resin having an insulating property, and the end face insulator 22 is configured by processing a sheet of a synthetic resin having an insulating property.

The split laminated iron core 21 is attached to the winding machine 1 after the end face insulator 22 and the slot insulator 23 are attached, that is, after being brought into the state shown in FIG. 3B, and is attached to the winding machine 1 by the winding method described later. The conductor 4 is wound around to complete the split stator 2 shown in FIG. 3C.

(Explanation of terms)
Prior to the description of the winding method, the terms used in the following description will be described with reference to FIG. Note that FIG. 4 is a schematic cross-sectional view of the split stator 2 before the winding is formed, cut along the plane indicated by the AA'line in FIG. 1A. In FIG. 4, the end face insulator 22 and the slot insulator 23 are not shown. Also in the following description, the existence of the end face insulator 22 and the slot insulator 23 will be ignored, and the description will be continued. That is, in the following description, in the case of "winding the conductor 4 around the teeth 21c", in the actual machine, the end face insulator 22 and the slot insulator 23 are sandwiched between the teeth 21c and the conductor 4. Please note.

As shown in FIG. 4, the cross-sectional shape of the teeth 21c is a quadrilateral. Here, as shown in FIG. 4, each side of the contour of the cross-sectional shape of the teeth 21c is referred to as an upper end side 24a, a left side side 24b, a lower end side 24c, and a right side side 24d. As will be described later, in the present embodiment, since the winding of the conductor 4 is started from the upper end side 24a, the conductor 4 is first wound around the upper end side 24a, and then the left side 24b, the lower end side 24c, and so on. It is sequentially wound around the right side 24d. Then, the conductor 4 returns to the upper end side 24a and is wound around the upper end side 24a again.

The upper end side 24a, the left side side 24b, the lower end side 24c, and the right side side 24d are examples of the first to fourth sections of the present invention, respectively. Further, in the following description, the step of winding the conductor 4 around the teeth 21c once is a step of winding the conductor 4 around the upper end side 24a, a step of winding the lead wire 4 around the left side 24b, a step of winding the lead wire 4 around the lower end side 24c, and the right side. The process of winding around 24d will be described separately. The above four steps are examples of the first to fourth steps of the present invention, respectively.

(Wounding method)
(1st layer, 1st turn)
5A-5F show the process of forming the first turn of the winding of the split stator 2, that is, the first turn of the winding of the first layer in chronological order by the winding method according to the present embodiment. It is a figure which shows along. The states of the split stator 2 at each stage are shown in a plan view and a cross-sectional view in FIGS. 5A to 5F, respectively. It should be noted that each cross-sectional view is a view of the cross section of the teeth 21c viewed from the shoe 21b side. Further, in each cross-sectional view, the circle shown by the two-dot chain line indicates the locus of the reference axis X, that is, the nozzle 5 orbiting around the rotation center of the circumferential shaft 12 (not shown in FIGS. 5A to 5F).

Before starting the winding of the conductor 4, the split stator 2, the conductor 4 and the nozzle 5 are set at the positions shown in FIG. 5A. As shown in the plan view of FIG. 5A, in the present embodiment, the winding of the conductor 4 is started from the state where the conductor 4 is set at the end of the teeth 21c on the back yoke 21a side. As shown in the cross-sectional view of FIG. 5A, in the present embodiment, the conductor 4 is unwound by being unwound from the nozzle 5 in a direction in which the conductor 4 is parallel to the right side 24d of the split stator 2. The conductor 4 is started from the state where it is in contact with the right side 24d. Further, the phase angle of the nozzle 5 at this time is P. In the present specification, the "phase angle" refers to the rotation angle of the orbiting arm 13 (not shown in FIGS. 5A to 5F) around the reference axis X.

When the operator sets the split stator 2, the conductor 4, and the nozzle 5 at the positions shown in FIG. 5A, the winding machine 1 is started to feed the conductor 4 from the nozzle 5, and the circumferential arm 13 (not shown) is used as a reference axis. The nozzle 5 is orbited around X until the phase angle becomes Q, as shown in FIG. 5B. The winding machine 1 is controlled by the computer 18 and operates automatically. As a result, the conducting wire 4 is wound around the upper end side 24a. Further, a step portion 22a is formed in a corner portion between the upper end side 24a and the left side side 24b of the end face insulator 22, and while the conductor 4 is wound around the upper end side 24a, the lead wire 4 is wound on the step portion 22a. Contact with. Therefore, at the end of the winding at the upper end side 24a, the conductor 4 is pushed by the step portion 22a and moves to the shoe 21b side. As a result, as shown in the plan view of FIG. 5B, the conductor 4 is wound diagonally around the upper end side 24a. When the orbiting arm 13 reaches the first orbiting speed, which will be described later, after the orbiting starts, the computer 18 so as to maintain the first orbiting speed while forming the winding of the first layer. Controlled by. That is, while forming the winding of the first layer, the circumferential arm 13 and the nozzle 5 orbit around the reference axis X at a constant speed. The details of controlling the orbiting speed of the orbiting arm 13 and the nozzle 5 will be described later.

The moving table 9 is operated by the computer 18 while the nozzle 5 orbits from the position where the phase angle is P to the position where the phase angle is Q, that is, while the lead wire 4 is wound around the upper end side 24a. It will be stopped. Therefore, during this period, the nozzle 5 does not move in the reference axis X direction. Therefore, during this period, the conductor 4 is wound around the upper end side 24a while maintaining the position shown in the plan view of FIG. 5A in the reference axis X direction. The details of the position control of the moving table 9 and the nozzle 5 in the reference axis X direction will be described later.

Even after the nozzle 5 exceeds the position where the phase angle becomes Q, the computer 18 keeps the orbit around the reference axis X of the nozzle 5 and the extension of the lead wire 4 from the nozzle 5. Therefore, as shown in FIG. 5C, the conductor 4 is wound around the left side 24b. Then, as shown in FIG. 5D, when the nozzle 5 reaches the position where the phase angle is R, the winding of the conducting wire 4 to the left side 24b is completed.

While the nozzle 5 moves from the position where the phase angle is Q to the position where the phase angle is R, that is, while the lead wire 4 is wound around the left side 24b, the computer 18 uses the moving table 9 as a reference axis. By moving the nozzle 5 in parallel with X, the nozzle 5 is moved from the initial position to a position closer to the shoe 21b by a length corresponding to the outer diameter of the lead wire 4. Then, when the nozzle 5 reaches the position where the phase angle becomes R, the computer 18 stops the movement of the moving table 9. As a result, as shown in FIG. 5D, while the conductor 4 is wound around the left side 24b, the conductor 4 moves from the initial position to a position closer to the shoe 21b by a length corresponding to the outer diameter of the conductor 4. Will be done.

Even after the nozzle 5 exceeds the position where the phase angle becomes R, the computer 18 keeps the orbit around the reference axis X of the nozzle 5 and the feeding of the lead wire 4 from the nozzle 5. Therefore, the conducting wire 4 is wound around the lower end side 24c. Then, as shown in FIG. 5E, when the nozzle 5 reaches the position where its phase angle is S, the winding of the conducting wire 4 to the lower end side 24c is completed.

Even after the nozzle 5 exceeds the position where the phase angle becomes S, the computer 18 keeps the orbit around the reference axis X of the nozzle 5 and the feeding of the lead wire 4 from the nozzle 5. Therefore, the conducting wire 4 is wound around the right side 24d. Then, as shown in FIG. 5F, when the nozzle 5 reaches a position where its phase angle is P, the winding of the conducting wire 4 to the right side 24d of the dividing stator 2 is completed. While the nozzle 5 moves from the position where the phase angle is S to the position where the phase angle is P, that is, while the lead wire 4 is wound around the right side 24d of the dividing stator 2, the computer 18 As a result, the moving table 9 is stopped, so that the nozzle 5 does not move in the reference axis X direction. Therefore, the conductor 4 is wound around the right side 24d in the X direction of the reference axis while maintaining the position shown in the plan view of FIG. 5D.

Through the above process, the conducting wire 4 drawn out from the nozzle 5 is wound around the upper end side 24a, the left side side 24b, the lower end side 24c, and the right side side 24d of the dividing stator 2 in this order. As a result, the first turn of the winding of the first layer is completed. Further, while the conductor 4 drawn out from the nozzle 5 is wound around the left side 24b of the dividing stator 2, the shoe 21b is formed by a length corresponding to the outer diameter of the conductor 4 from the initial position in the reference axis X direction. Moved to a position closer to.

(1st layer, 2nd turn)
After the first turn of the winding of the first layer is completed, the winding of the second turn is performed. 6A-6F follow the process of forming the second turn of the windings of the first layer, that is, according to FIGS. 5A-5F, following the process of forming the first turn of the windings of the first layer. It is a figure which shows.

FIG. 6A is the same diagram as FIG. 5F, and is a diagram showing the positions of the split stator 2, the conductor 4, and the nozzle 5 at the timing when the first turn of the winding of the first layer is completed. As shown in the plan view of FIG. 6A, at the timing when the first turn of the winding of the first layer is completed, the conductor 4 corresponds to the outer diameter of the conductor 4 from the end on the back yoke 21a side in the reference axis X direction. It is located closer to the shoe 21b by the length. Further, around the reference axis X, the nozzle 5 is at a position where its phase angle is P.

Also in the second turn, the computer 18 maintains the first orbital speed and orbits the orbiting arm 13 (not shown) around the reference axis X while maintaining the first orbital speed, so that the nozzle 5 has a phase angle thereof. It is circulated from the position where P is to the position where the phase angle is Q. Further, the computer 18 draws out the conducting wire 4 from the nozzle 5 in the meantime. As a result, the conductor 4 is wound around the upper end side 24a. Then, during that time, that is, while the conductor 4 is wound around the upper end side 24a, the moving table 9 is stopped by the computer 18. Therefore, the nozzle 5 does not move in the reference axis X direction. Therefore, during this period, the conductor 4 is wound around the upper end side 24a while maintaining the position shown in the plan view of FIG. 6A in the reference axis X direction.

As in the case of the first turn, in the second turn, even after the nozzle 5 exceeds the position where the phase angle becomes Q, the computer 18 makes an orbit around the reference axis X of the nozzle 5. , Continue feeding the lead wire 4 from the nozzle 5. Therefore, as shown in FIG. 6C, the conductor 4 is wound around the left side 24b. Then, as shown in FIG. 6D, when the nozzle 5 reaches a position where its phase angle is R, the winding of the conducting wire 4 to the left side 24b is completed.

As in the case of the first turn, the computer 18 moves (not shown) while the nozzle 5 orbits from the phase angle Q to the phase angle R, that is, while the lead wire 4 is wound around the left side 24b. The base 9 is moved in parallel with the reference axis X, and the nozzle 5 is moved from the initial position to a position closer to the shoe 21b by a length corresponding to the outer diameter of the lead wire 4. Further, when the nozzle 5 reaches a position where the phase angle becomes R, the computer 18 stops the movement of the moving table 9. As a result, as shown in FIG. 6D, while the conductor 4 is wound around the upper end side 24a, the conductor 4 moves from the initial position to a position closer to the shoe 21b by a length corresponding to the outer diameter of the conductor 4. Will be done.

In this way, while winding the conductor 4 around the left side 24b, the computer 18 moves the conductor 4 parallel to the conductor 4 wound in the first turn by a length corresponding to the outer diameter of the conductor 4. Therefore, the newly wound conductor 4 is wound without a gap with respect to the previously wound conductor 4.

Even after the nozzle 5 exceeds the position where the phase angle becomes R, the computer 18 keeps the orbit around the reference axis X of the nozzle 5 and the feeding of the lead wire 4 from the nozzle 5. Therefore, as shown in FIG. 6E, when the nozzle 5 reaches the position where the phase angle is S, the winding of the conducting wire 4 to the lower end side 24c is completed. The moving table 9 is operated by the computer 18 while the nozzle 5 moves from the position where the phase angle is R to the position where the phase angle is S, that is, while the lead wire 4 is wound around the lower end side 24c. Is stopped, so the nozzle 5 does not move in the reference axis X direction. Therefore, the conductor 4 is wound around the lower end side 24c of the split stator 2 while maintaining the position shown in FIG. 6D in the reference axis X direction.

Even after the nozzle 5 exceeds the position where the phase angle becomes S, the computer 18 keeps the orbit around the reference axis X of the nozzle 5 and the feeding of the lead wire 4 from the nozzle 5. Therefore, as shown in FIG. 6F, when the nozzle 5 reaches the position where its phase angle is P, the winding of the conducting wire 4 to the right side 24d is completed. The moving table 9 is operated by the computer 18 while the nozzle 5 moves from the position where the phase angle is S to the position where the phase angle is P, that is, while the lead wire 4 is wound around the right side 24d. Is stopped, so the nozzle 5 does not move in the reference axis X direction. Therefore, the conductor 4 is wound around the right side 24d while maintaining the position shown in FIG. 6D in the reference axis X direction.

Through the above process, the winding of the second turn is completed. The winding of the second turn is formed at a position closer to the shoe 21b by a length corresponding to the outer diameter of the conducting wire 4 in the reference axis X direction from the winding of the first turn. Further, the winding of the second turn is formed parallel to the winding of the first turn. Therefore, there is no gap between the winding of the second turn and the winding of the first turn.

When the second turn of the winding of the first layer is completed, the same operation as the winding of the second turn is repeated to perform the winding of the third and subsequent turns. Then, when the conductor 4 reaches the end portion of the teeth 21c on the shoe 21b side, that is, when the conductor 4 is wound from the end portion of the teeth 21c on the back yoke 21a side to the end portion on the shoe 21b side, the first conductor is used. One layer of winding is completed. When the winding of the first layer is completed, the conductor 4 is superposed on the winding of the first layer and wound to form the winding of the second layer. Further, the winding of the second layer moves the conducting wire 4 in the direction X of the reference axis in the direction opposite to that of the winding of the first layer, that is, from the end of the teeth 21c on the shoe 21b side to the back yoke 21a side. While moving the conductor 4 toward the end of the wire 4, the conductor 4 is wound around.

(2nd layer, 1st turn)
7A-7F follow the process of forming the first turn of the second layer windings, that is, according to FIGS. 5A-5F. It is a figure which shows.

FIG. 7A is a diagram showing the positions of the split stator 2, the conductor 4, and the nozzle 5 immediately before starting the winding of the conductor 4 in the first turn of the winding of the second layer. That is, FIG. 7A shows the positions of the split stator 2, the conductor 4, and the nozzle 5 at the timing when the final turn of the winding of the first layer is completed.

In the first turn of the second layer winding, the computer 18 orbits the orbiting arm 13 around the reference axis X while maintaining the first orbiting speed, so that the nozzle 5 has a phase angle of P. Orbit from the position to the position where the phase angle is Q. In the meantime, the computer 18 draws out the conductor 4 from the nozzle 5. As a result, the conductor 4 is wound around the upper end side 24a. Then, during that time, that is, while the conductor 4 is wound around the upper end side 24a, the computer 18 stops the moving table 9, so that the nozzle 5 does not move in the reference axis X direction. Therefore, during this period, the conductor 4 is wound around the upper end side 24a while maintaining the position shown in the plan view of FIG. 7A in the reference axis X direction.

As in the case of the first and second turns of the winding of the first layer, in the case of the first turn of the winding of the second layer, even after the phase angle of the nozzle 5 exceeds the position of Q, the computer Reference numeral 18 continues to orbit the nozzle 5 around the reference axis X and to feed the lead wire 4 from the nozzle 5. Therefore, as shown in FIG. 7C, the conductor 4 is wound around the left side 24b. Then, as shown in FIG. 7D, when the nozzle 5 reaches a position where its phase angle is R, the winding of the conducting wire 4 to the left side 24b is completed.

Further, in the first turn of the winding of the second layer, the computer 18 operates the moving table 9 while the nozzle 5 orbits from the position where the phase angle is Q to the position where the phase angle is R. Then, the shoe 21b is moved in the direction toward the shoe 21b, that is, in the same direction as the movement direction of the moving table 9 in each turn of the winding of the first layer, by a length corresponding to the outer diameter of the lead wire 4. As a result, in the state shown in FIG. 7D, the conductor 4 moves from the winding start position of the first turn of the winding of the second layer to the position closer to the shoe 21b by the length corresponding to the outer diameter of the conductor 4. do. Therefore, in the first turn of the winding of the second layer, the conducting wire 4 is in close contact with the shoe 21b, so that the winding density can be increased.

As in the case of the first and second turns of the winding of the first layer, in the case of the first turn of the winding of the second layer, even after the nozzle 5 exceeds the position where the phase angle becomes R. , The computer 18 keeps the orbit around the reference axis X of the nozzle 5 and the feeding of the lead wire 4 from the nozzle 5. Therefore, as shown in FIG. 7E, when the nozzle 5 reaches the position where the phase angle is S, the conducting wire 4 is wound on the winding of the first layer at the lower end side 24c. Further, as shown in FIG. 7F, when the nozzle 5 reaches a position where its phase angle is P, the conducting wire 4 is wound on the winding of the first layer on the right side 24d. Through the above process, the first turn of the winding of the second layer is completed.

(2nd layer, 2nd turn)
When the first turn of the winding of the second layer is completed, the winding of the second turn is performed. 8A-8F follow the process of forming the second turn of the second layer windings, that is, according to FIGS. 5A-5F, following the process of forming the first turn of the first layer windings. It is a figure which shows.

FIG. 8A is the same diagram as FIG. 7F, and is a diagram showing the positions of the split stator 2, the conductor 4, and the nozzle 5 at the timing when the first turn of the winding of the second layer is completed.

At the start of the second turn of the second layer winding, the computer 18 reduces the orbiting speed of the orbiting arm 13 around the reference axis X to a second orbiting speed smaller than the first orbiting speed. Then, after that, the orbiting speed of the orbiting arm 13 is maintained at the second orbiting speed.

Further, while the orbiting arm 13 orbits around the reference axis X, the computer 18 pays out the conducting wire 4 from the nozzle 5. Therefore, when the nozzle 5 orbits from the position where the phase angle is P to the position where the phase angle is Q. As shown in FIG. 8B, the conductor 4 is wound on the winding of the first layer at the upper end side 24a.

In the second turn of the winding of the second layer, while the nozzle 5 moves from the position where the phase angle is P to the position where the phase angle is Q, that is, while the lead wire 4 is wound around the upper end side 24a. In addition, the computer 18 moves the moving table 9 in parallel with the reference axis X, and the nozzle 5 is moved closer to the back yoke 21a by a length corresponding to 1.5 times the outer diameter of the lead wire 4 from the initial position. Move to. As a result, the nozzle 5 of the nozzle 5 in the first turn of the winding of the second layer is a distance corresponding to 1.5 times the outer diameter of the conducting wire 4 from the position at the beginning of the winding of the second turn. It is moved in the opposite direction of the movement direction. Further, as shown in FIG. 8B, while the conductor 4 is wound around the upper end side 24a, the conductor 4 is placed on the back yoke 21a by a length corresponding to 1.5 times the outer diameter of the conductor 4 from the initial position. Moved to a closer position. By moving the conductor 4 significantly in this way, the newly wound conductor 4 can be crossed with the conductor 4 wound in the first layer.

As in the case of the first turn of the winding of the second layer, in the case of the second turn of the winding of the second layer, even after the nozzle 5 exceeds the position where the phase angle becomes Q, the computer 18 Causes the orbit around the reference axis X of the nozzle 5 and the feeding of the lead wire 4 from the nozzle 5 to be continued. Therefore, as shown in FIG. 8C, the conductor 4 is wound on the winding of the first layer on the left side 24b. Then, after passing through the state shown in FIG. 8D, as shown in FIG. 8E, when the nozzle 5 reaches the position where its phase angle is R, the lead wire 4 on the left side 24b onto the winding of the first layer is reached. The winding is completed.

In the second turn of the winding of the second layer, the nozzle 5 winds the lead wire 4 around the left side 24b while the nozzle 5 moves from the position where the phase angle is Q to the position where the phase angle is R. During the rotation, the computer 18 moves the moving table 9 in parallel with the reference axis X to move the nozzle 5 from the initial position to a position closer to the shoe 21b by a length corresponding to the outer diameter of the lead wire 4. As a result, the nozzle 5 is returned to the shoe 21b side by a distance corresponding to the outer diameter of the conducting wire 4 from the position in the direction of the reference axis X when the phase angle is at the position Q. By returning the conductor 4 to the shoe 21b side in this way, the conductor 4 is returned to the regular position, so that the newly wound conductor 4 is brought into close contact with the conductor 4 wound in the first turn. Can be done.

Even after the nozzle 5 exceeds the position where the phase angle becomes R, the computer 18 keeps the orbit around the reference axis X of the nozzle 5 and the feeding of the lead wire 4 from the nozzle 5. Therefore, as shown in FIG. 8F, when the nozzle 5 reaches the position where the phase angle is S, the winding of the conducting wire 4 to the lower end side 24c is completed. The computer 18 moves the moving table 9 while the nozzle 5 moves from the position where the phase angle is R to the position where the phase angle is S, that is, while the lead wire 4 is wound around the lower end side 24c. Since it is stopped, the nozzle 5 does not move in the reference axis X direction.

From the state shown in FIG. 8F, if the orbiting arm 13 and the nozzle 5 are further orbited around the reference axis X and the nozzle 5 is moved to a position where the phase angle thereof is P, the lead wire 4 to the right side 24d The winding is completed. Through the above process, the second turn of the winding of the second layer is completed.

When the second turn of the winding of the second layer is completed, the winding of the winding of the second layer after the third turn is performed. The procedure for winding the windings of the second layer after the third turn is basically the same as the windings of the windings of the first layer after the third turn, but in each turn, the nozzle 5 is used as a reference axis. The direction of movement in the X direction is different. After the third turn of the winding of the first layer, the computer 18 moves the nozzle 5 to the shoe 21b side in each turn, whereas after the third turn of the winding of the second layer, each turn. In, the computer 18 moves the nozzle 5 to the teeth 21c side. Further, in the winding after the third turn of the winding of the second layer, the orbiting speed of the orbiting arm 13 is returned to the first orbiting speed and is made to orbit around the reference axis X.

When the winding of the second layer is completed, the same operation is repeated to sequentially wind the windings of the third layer and subsequent layers on the winding of the second layer. Then, when the windings having a predetermined number of layers are formed, the split stator 2 is completed.

(Nozzle movement and orbital speed)
In the above, the movement of the nozzle 5 in the reference axis X direction and the orbiting speed around the reference axis X in each turn have been described. Hereinafter, the movement of the nozzle 5 in the reference axis X direction and the control of the orbiting speed around the reference axis X will be described.

FIG. 9 is a graph showing the relationship between the orbital angle of the nozzle 5 around the reference axis X, the orbiting speed of the nozzle 5 around the reference axis X, and the position in the reference axis X direction. On the horizontal axis of the graph of FIG. 9, the orbital angle around the reference axis X of the nozzle 5 is displayed as the phase angles P, Q, R, S, the number of turns, and the number of layers. Further, on the vertical axis of the graph of FIG. 9, the orbiting speed around the reference axis X of the nozzle 5 and the amount of movement of the nozzle 5 in the reference axis X direction are displayed.

As shown in FIG. 9, the orbital angle around the reference axis X of the nozzle 5 is monotonically increased by the computer 18 when the winding of the conducting wire 4 is started, and the first turn of the winding of the first layer is performed. The nozzle 5 is controlled to reach the first orbital speed by the time the nozzle 5 reaches the position where the phase angle becomes Q. The nozzle 5 is then controlled by the computer 18 so that the nozzle 5 orbits around the reference axis X at the first orbital speed until the first turn of the second layer winding is completed. .. When the first turn of the second layer winding is completed, the computer 18 controls to reduce the orbital angle of the nozzle 5 around the reference axis X, and in the second turn of the second layer winding, the computer 18 controls the nozzle 5. By the time the phase angle reaches the position where Q, the speed is reduced to the second orbital speed. The second orbital speed is as low as about 40% of the first orbital speed. By reducing the orbital speed of the nozzle 5 to the second orbital speed in the second turn of the winding of the second layer, it is possible to prevent the conductor 4 from slipping and misaligning on the winding of the first layer. .. After that, the nozzle 5 is controlled by the computer 18 to orbit around the reference axis X while maintaining the second orbital speed until the second turn of the winding of the second layer is completed. When the second turn of the second layer winding is completed, the orbital speed of the nozzle 5 is increased again by the computer 18, and the phase angle of the nozzle 5 becomes Q in the third turn of the second layer winding. By the time it reaches the position, it is returned to the first orbital speed. After that, the nozzle 5 is controlled by the computer 18 so as to maintain the first orbital speed and orbit around the reference axis X until the winding of the second layer is completed. When forming the windings of the third and subsequent layers, the computer 18 performs the same speed control as when forming the windings of the second layer.

As shown in FIG. 9, the movement of the nozzle 5 in the reference axis X direction is a position where the phase angle of the nozzle 5 is R from the position where the phase angle is Q in each turn of the winding of the first layer. While rotating to, the nozzle 5 is moved to a position closer to the shoe 21b by a length corresponding to the outer diameter of the lead wire 4. In the first turn of the winding of the second layer, the computer 18 makes the nozzle 5 the outer diameter of the lead wire 4 while orbiting from the position where the phase angle of the nozzle 5 becomes Q to the position where the phase angle becomes R. Move it to a position closer to the shoe 21b by a corresponding length. In the second turn of the second layer winding, the computer 18 orbits the nozzle 5 from the position where the phase angle is P to the position where the phase angle is Q, while the computer 18 moves the nozzle 5 out of the lead wire 4. The nozzle is moved to a position closer to the back yoke 21a by a length corresponding to 1.5 times the diameter, and the nozzle 5 orbits from the position where the phase angle is Q to the position where the phase angle is R. 5 is moved to a position closer to the shoe 21b by a length corresponding to the outer diameter of the lead wire 4. In each turn after the third turn of the winding of the second layer, the computer 18 rotates the nozzle 5 from the position where the phase angle is P to the position where the phase angle is Q. It is moved to a position closer to the back yoke 21a by a length corresponding to the outer diameter of the lead wire 4. Then, when forming the windings of the third and subsequent layers, the computer 18 performs the same position control as when forming the windings of the second layer.

(Control program)
The above winding method is automatically carried out by the winding machine 1. The winding machine 1 controls the winding machine 1 by reading the control program installed in the storage unit 18b of the computer 18 to the CPU 18a and executing the control program, so that the winding machine 1 performs the above winding method. ..

FIG. 10A is a flowchart of a first layer orbiting speed control program that controls the orbiting speed of the orbiting arm 13 in the step of forming the winding of the first layer. The first layer orbital speed control program is started after the split stator 2 is set in the winding machine 1 in response to a switch operation by an operator or an instruction from a higher-level computer (not shown).

As shown in FIG. 10A, when the first layer orbital speed control program is activated, the computer 18 starts the orbiting motor 15 (step 01) and at the same time, the feed operation of the conductor 4 is started (step 02). Then, the computer 18 controls the orbiting motor 15 to maintain the first orbiting speed (step 03). The control for maintaining the orbiting speed of the orbiting motor 15 at the first orbiting speed is continued until the winding of the first layer is completed (step 04: Yes).

FIG. 10B is a flowchart of the first layer advance / retreat position control program that controls the position of the nozzle 5 in the reference axis X direction in the step of forming the winding of the first layer. The first layer advance / retreat position control program is started at the same time as the first layer orbital speed control program.

As shown in FIG. 10B, the computer 18 monitors the phase angle of the nozzle 5, and when the phase angle of the nozzle 5 becomes Q (step 11: Yes), the nozzle 5 corresponds to the outer diameter d of the lead wire 4. Move the shoe 21b closer to the shoe 21b by a distance (step 12). In the following, the movement in the direction approaching the shoe 21b is indicated by a + symbol, and the movement in the direction approaching the back yoke 21a is indicated by a − symbol. After that, the processes of steps 11 to 13 are repeated until the winding of the first layer is completed (step 13: Yes). Therefore, each time the nozzle 5 orbits around the reference axis X and the phase angle of the nozzle 5 becomes Q, the nozzle 5 is moved toward the shoe 21b by a distance corresponding to the outer diameter d of the conducting wire 4.

FIG. 11A is a flowchart of the nth layer orbital speed control program that controls the orbital speed of the orbiting arm 13 in the step of forming the windings of the second and subsequent layers. Although n is an integer of 2 or more, the nth layer orbital speed control program is automatically started after the completion of the first layer orbital speed control program or the n-1st layer orbital speed control program.

As shown in FIG. 11A, when the nth layer orbital speed control program is activated, the computer 18 controls the orbiting motor 15 to maintain the first orbital speed (step 21). Further, the computer 18 monitors the phase angle of the nozzle 5, and when the phase angle of the nozzle 5 becomes P (step 22: Yes), that is, when the first turn of the winding of the nth layer is completed, the computer 18 reduces the speed of the orbiting motor 15 and then controls to maintain the second orbiting speed (step 23). Then, when the phase angle of the nozzle 5 becomes P again (step 24: Yes), that is, when the second turn of the winding of the nth layer is completed, the computer 18 increases the speed of the orbiting motor 15. After that, control is performed so as to maintain the first orbital speed (step 25). The control for maintaining the orbiting speed of the orbiting motor 15 at the first orbiting speed is continued until the winding of the nth layer is completed (step 26: Yes).

FIG. 11B is a flowchart of the nth layer advance / retreat position control program that controls the position of the nozzle 5 in the reference axis X direction in the step of forming the winding of the nth layer. The nth layer advance / retreat position control program is started at the same time as the nth layer orbital speed control program.

As shown in FIG. 11B, when the phase angle of the nozzle 5 becomes Q first (step 31: Yes), that is, when the phase angle of the nozzle 5 becomes Q at the first turn of the winding of the nth layer. , The computer 18 moves the nozzle 5 toward the shoe 21b by a distance corresponding to the outer diameter d of the conducting wire 4 (step 32). Next, when the phase angle of the nozzle 5 becomes P (step 33: Yes), that is, when the first turn of the winding of the nth layer is completed, the computer 18 connects the nozzle 5 to the outer diameter d of the conductor 4. It is moved toward the back yoke 21a by a distance corresponding to 5 times (step 34). Next, when the phase angle of the nozzle 5 becomes Q (step 35: Yes), that is, when the phase angle of the nozzle 5 becomes Q in the second turn of the winding of the nth layer, the computer 18 determines the nozzle. 5 is moved toward the shoe 21b by a distance corresponding to the outer diameter d of the conducting wire 4 (step 36).

Then, when the phase angle of the nozzle 5 becomes Q (step 37: Yes), that is, when the phase angle of the nozzle 5 becomes Q in the third turn of the winding of the nth layer, the computer 18 determines the nozzle. 5 is moved toward the back yoke 21a by a distance corresponding to the outer diameter d of the lead wire 4 (step 38). After that, the processes of steps 37 to 39 are repeated until the winding of the nth layer is completed (step 39: Yes). Therefore, every time the nozzle 5 orbits around the reference axis X and the phase angle of the nozzle 5 becomes Q, the nozzle 5 is moved toward the back yoke 21a by a distance corresponding to the outer diameter d of the conducting wire 4.

The moving direction of the nozzle 5 shown in the above description of the nth layer orbital speed control program is when n is an even number. Note that when n is an odd number, the moving direction of the nozzle 5 is opposite. That is, note that the positive and negative symbols attached in FIG. 11B are reversed depending on whether n is an even number or an odd number. Further, in the description of step 34, the moving amount of the nozzle 5 is 1.5 times the outer diameter d of the conducting wire 4, but the moving amount of the nozzle 5 in this case is not limited to 1.5 times the outer diameter d. .. In this case, the amount of movement of the nozzle 5 may be larger than the outer diameter d.

As described above, according to the winding method and the winding machine according to the above-described embodiment, the newly wound conductor 4 is in close contact with the previously wound conductor 4, so that the winding is performed. Can increase the density of. Further, since the conductor 4 can be continuously wound without stopping the rotation of the nozzle 5, a high-density winding can be formed in a short time.

(Insulator)
Next, with reference to FIGS. 12 to 14, a detailed configuration of the end face insulator 22 and the slot insulator 23 will be described. FIG. 12 is a cross-sectional view of the end face insulator 22 and the slot insulator 23 corresponding to the cross-sectional view of FIG. 5A. 13 is an arrow view of the end face insulator 22 viewed from the direction indicated by the arrow P in FIG. 12, and FIG. 14 is an arrow view of the end face insulator 22 viewed from the direction indicated by the arrow Q in FIG. As shown in FIGS. 12 to 14, the end face insulator 22 includes a corner portion between the upper end side 24a and the left side side 24b of the teeth 21c, a corner portion between the left side side 24b and the lower end side 24c, and a lower end side 24c. A step portion 22a is provided at a corner between the right side 24d. As described above, the end face insulator 22 is provided with stepped portions 22a at three corners except the corner portion between the right side side 24d and the upper end side 24a. Further, as shown in FIGS. 12 and 14, the end face insulator 22 has an introduction groove 22b cut in a corner portion between the lower end side 24c and the right side side 24d. As shown in FIG. 14, the introduction groove 22b is a groove for introducing the conductor 4 from the outer peripheral side of the back yoke 21a to the teeth 21c side when the conductor 4 is wound around the teeth 21c of the divided laminated iron core 21. Therefore, in the state shown in FIG. 5A, the conducting wire 4 is drawn from the outer peripheral side of the back yoke 21a to the teeth 21c side through the introduction groove 22b, and then the winding of the first layer is started.

FIG. 15 is a diagram showing a detailed shape of the step portion 22a, and is a cross-sectional view obtained by cutting the step portion 22a in the plane indicated by the line AA'in FIG. Further, the arc shown by the alternate long and short dash line in FIG. 15 is a cross-sectional shape of the conducting wire 4. In the following, the shape and dimensions of the step portion 22a will be described using the diameter D of the conducting wire 4.

As shown in FIG. 15, the step portion 22a is formed at the end portion of the end face insulator 22 on the side in contact with the back yoke 21a. In the following, the lateral dimension in FIG. 15 of the step portion 22a measured from the outer surface of the portion of the end face insulator 22 in contact with the back yoke 21a will be referred to as “width”. The vertical dimension in FIG. 15 of the step portion 22a measured from the outer surface of the portion of the end face insulator 22 in contact with the teeth 21c is referred to as “height”.

As shown in FIG. 15, the step portion 22a has a two-step stepped cross-sectional shape as a whole. Here, in FIG. 15, among the step portions 22a, a step at a lower position, that is, a step near the teeth 21c is referred to as a lower step portion of the step portion 22a, and a step at a higher position is referred to as an upper step portion of the step portion 22a. To. It should be noted that the "high and low" and "up and down" in the above are those in FIG. It should be noted that the "high and low" and "up and down" of the lower and upper steps of the step 22a change depending on the posture of the end face insulator 22 or the position of the viewpoint of the observer who observes the end face insulator 22.

The lower portion of the step portion 22a protrudes from the upper portion to the left side of the figure, that is, to the shoe 21b side (not shown). Therefore, the width W1 of the lower portion of the step portion 22a is made larger than the width W2 of the upper stage portion. Further, the width W1 and the height H1 of the lower portion of the step portion 22a are equal to the diameter D of the conducting wire 4. The width W2 of the upper portion of the step portion 22a is equal to the radius of the conducting wire 4, that is, 1/2 of the diameter D. Therefore, the difference between the width W1 and the width W2 is equal to the radius of the conductor 4, that is, 1/2 of the diameter D. The height H2 of the upper portion of the step portion 22a is equal to the height when the three conductors 4 are stacked in a bale. That is, the height H2 is equal to √3 * D / 2. Further, the edges of the lower portion and the upper portion of the step portion 22a form an arc having a central angle of 90 °. The radii of curvature R1 and R2 of the arc are equal to the radius of the lead wire 4, that is, 1/2 of the diameter D.

FIG. 16 is a diagram showing the action of the step portion 22a. As shown in FIG. 16, in the first turn of the winding of the first layer, the conductor 4a abuts on the lower portion of the step portion 22a and is wound. After that, the conductor 4 is wound while sequentially moving to the left side, that is, in the direction indicated by the arrow P, so as to be in contact with the left side surface of the previously wound conductor 4a. When the winding of the first layer reaches the end on the shoe 21b side (not shown), the winding of the second layer is started. In the winding of the second layer, the conductor 4 is wound while sequentially moving to the right side, that is, in the direction indicated by the arrow Q, so as to be in contact with the right side surface of the previously wound conductor 4. At this time, the conductor 4 is stacked on the conductor 4 constituting the winding of the first layer. Then, the conducting wire 4b constituting the final turn of the winding of the second layer is wound in contact with the upper portion of the step portion 22a. The conductor 4c constituting the first turn of the winding of the third layer is wound in contact with the conductor 4 constituting the final turn of the winding of the second layer and the upper portion of the step portion 22a. In the winding of the third layer, the conductor 4 is wound while sequentially moving to the left side, that is, in the direction indicated by the arrow R, so as to be in contact with the right side surface of the previously wound conductor 4.

As described above, in the present embodiment, the step portion 22a is formed at the end portion of the end face insulator 22 on the side in contact with the back yoke 21a. Then, the conducting wire 4 constituting the start end of the first layer and the end of the second layer of the winding abuts on the step portion 22a. Therefore, at the beginning of winding of the conductor 4, that is, when the first layer and the second layer of the winding are formed, the conductor 4 is stably held by the end face insulator 22. Therefore, it becomes easy to stack the conductors 4 constituting the first layer and the second layer of the winding. As a result, it becomes easy to obtain a high-density winding in a short time.

(Rotating electric machine)
FIG. 17 is a cross-sectional view of the rotary motor 30, and FIG. 18 is a vertical cross-sectional view of the rotary motor 30. The rotary motor 30 is a specific example of the rotary electric machine according to the present invention.

As shown in FIGS. 17 and 18, the rotary motor 30 includes a casing 31 constituting the outer shell of the rotary motor 30, a rotor 33 rotatably supported by the casing 31 via a bracket 32, and a rotor 33. The stator 34 is provided on the outer periphery of the casing 31 and fixed to the casing 31. An air gap of about 0.3 to 1.0 mm is formed between the rotor 33 and the stator 34.

As shown in FIG. 17, the rotor 33 has a cylindrical rotor core 35, a permanent magnet 36 embedded in the rotor core 35, and a shaft 37 fixed to the central portion of the rotor core 35. .. Further, as shown in FIG. 18, the rotor core 35 is configured by laminating iron core pieces 38 made of electromagnetic steel sheets in the axial direction and integrating them by caulking. As shown in FIG. 17, the rotor core 35 is formed with 12 magnet insertion holes 39 penetrating the rotor core 35. The permanent magnet 36 is inserted into the magnet insertion hole 39 and fixed to the rotor core 35. Further, as shown in FIG. 17, two magnet insertion holes 39 are arranged in a V shape to form a set of magnet insertion holes 39. The rotor 33 includes a set of 6 sets of magnet insertion holes 39. Two permanent magnets 36, which are inserted and fixed to each of the sets of magnet insertion holes 39, form one magnetic pole. Therefore, the rotor 33 according to this embodiment has six magnetic poles.

The permanent magnet 36 is a flat plate-shaped member long in the axial direction of the rotor core 35. In FIG. 17, the permanent magnet 36 has a width in the circumferential direction and a thickness in the radial direction of the rotor core 35. In the present embodiment, the thickness of the permanent magnet 36 is 2 mm. The permanent magnet 36 is composed of a rare earth magnet containing neodymium (Nd), iron (Fe) and boron (B) as main components, and is magnetized in the thickness direction.

As shown in FIG. 17, a flux barrier (leakage flux suppressing hole) 40 is formed at the end of the magnet insertion hole 39 located at both ends of each magnetic pole. Since the flux barrier 40 is provided, the wall thickness of the iron core between the flux barrier 40 and the outer periphery of the rotor core 35 becomes thin. Therefore, a short circuit of magnetic flux between adjacent magnetic poles is suppressed. As a result, the generation of leakage flux between adjacent magnetic poles is suppressed. It is desirable that the thickness of the thin portion between the flux barrier 40 and the outer periphery of the rotor core 35 is the same as the thickness of the iron core piece 38 (not shown in FIG. 17) of the rotor core 35.

As shown in FIG. 17, the stator 34 is configured by combining eight split stators 41 arranged in an annular shape. As shown in FIG. 18, the split stator 41 is configured by laminating iron core pieces 42 made of electrical steel sheets in the axial direction and integrating them by caulking. As shown in FIG. 17, an insulator 43 is attached to the split stator 41. A conducting wire 44 is wound around the insulator 43. The insulator 43 includes the above-mentioned step portion 22a (not shown in FIGS. 17 and 18). Therefore, in the split stator 41, the winding of the conductor 44 is unlikely to be disturbed. As a result, the split stator 41 can obtain a high-density winding in a short time. As described above, in the rotary motor 30, since it is easy to apply high-density winding to the stator 34, it is easy to reduce the size and increase the output.

In the above embodiment, the example in which the rotor 33 has six magnetic poles is shown, but the number of magnetic poles included in the rotor 33 is not limited to six. The rotor 33 may be provided with two or more magnetic poles. Further, in the above, an example in which two permanent magnets 36 arranged in a V shape form one magnetic pole is illustrated, but the rotary motor 30 is not limited to those having such a configuration. In the rotary motor 30, one permanent magnet 36 may form one magnetic pole. In the rotor 33, when one permanent magnet 36 constitutes one magnetic pole, the permanent magnet 36 is arranged so that the width direction thereof is orthogonal to the radius of the rotor 33.

The technical scope of the present invention is not limited to the above embodiments. The present invention can be freely modified, modified or improved within the scope of the technical idea shown in the claims.

In the above embodiment, the winding of the conductor 4 is started from the upper end side 24a, the conductor 4 is wound in the order of the left side 24b, the lower end side 24c, and the right side 24d, and the conductor 4 is returned to the upper end side 24a. Illustrate. However, the portion where the winding of the conducting wire 4 starts is not limited to the upper end side 24a. The winding of the conductor 4 may be started from the left side 24b, the lower end side 24c, or the right side 24d. The order or direction in which the conductor 4 is wound is also not limited to those exemplified. That is, the conductor 4 may be wound in the order of the upper end side 24a, the right side side 24d, the lower end side 24c, and the left side side 24b. Further, also in this case, the portion where the winding of the conducting wire 4 is started is not limited to the upper end side 24a.

In the above embodiment, an example is shown in which the first turn of the winding of the first layer is performed at the end of the teeth 21c on the back yoke 21a side. That is, in the first layer, an example is shown in which the conducting wire 4 is wound from the end of the teeth 21c on the back yoke 21a side toward the end of the shoe 21b. However, in the first layer, the direction in which the conductor 4 is wound is not limited to the illustrated one. In the first layer, the teeth 21c may be wound from the end on the shoe 21b side toward the end of the back yoke 21a.

In the above embodiment, an example in which the conductor 4 is wound around the split laminated core 21 to manufacture the split stator 2 is shown, but the object of the winding method according to the present invention is the split laminated core 21. Not limited. The product manufactured by the winding method according to the present invention is not limited to the split stator 2. The winding method according to the present invention can be widely applied when the conducting wire 4 is wound around a member generally called a bobbin.

In the above embodiment, as a specific example of the object around which the conducting wire 4 is wound, a split laminated iron core 21 to which the insulator 22 for the end face and the insulator 23 for the slot are mounted is exemplified. However, the shape and mechanical configuration of the object around which the conductor 4 is wound are not limited to those exemplified.

The mechanical configuration of the winding machine 1 shown in the above embodiment is an example, and the mechanical configuration of the winding machine 1 is not limited to the exemplified one. In particular, since it is sufficient that the nozzle 5 is configured to be able to orbit and advance and retreat relative to the split stator 2, the orbiting means and the advancing and retreating means are not limited to those exemplified. For example, the core chuck device 3 may be provided with a device for rotating the split stator 2 around the reference axis X, and the nozzle 5 may be fixed to the moving table 9. Alternatively, the moving table 9 may be fixed to the table 7 by providing a device for advancing and retreating the core chuck device 3 with respect to the base 7 in the reference axis X direction.

In the above embodiment, the rotary electric machine 30 is exemplified as a specific example of the rotary electric machine according to the present invention, but the rotary electric machine according to the present invention is not limited to the electric motor. The rotary electric machine according to the present invention may be a generator. Further, in the above embodiment, the inner rotor type rotary motor 30 is exemplified, but the rotary motor 30 is not limited to the inner rotor type. The rotary motor 30 may be an outer rotor type. Further, in the above embodiment, an example in which the insulator 43 is attached to the stator 34 of the rotary motor 30 and the conducting wire 44 is wound around the insulator 43 to form a winding is shown, but the insulator 43 and the winding are shown. The armature provided with the wire is not limited to the stator 34. The rotary motor 30 may include an insulator 43 and a winding on the rotor 33.

It is sufficient that the insulator 43 included in the rotary motor 30 includes the step portion 22a, and the shape and mechanical configuration of the insulator 43 are not limited in other respects. In particular, the insulator 43 is not limited to the one configured by combining the end face insulator 22 and the slot insulator 23 shown in FIG. 3B. The shape and mechanical configuration of the insulator 43 can be changed as needed.

In the above embodiment, an example is shown in which the winding of the winding of the first layer is started from the end portion of the insulator 43 on the back yoke 21a side. Therefore, in the above embodiment, the step portion 22a is formed at the end portion of the end face insulator 22 on the back yoke 21a side. However, the starting end of the winding of the first layer is not limited to the end portion of the insulator 43 on the back yoke 21a side. The winding of the winding of the first layer may be started from the end portion of the insulator 43 on the shoe 21b side. In this case, the step portion 22a is formed at the end portion of the end face insulator 22 on the shoe 21b side.

In the above embodiment, the height and width dimensions of the step portion 22a have been described with reference to the diameter D of the conducting wire 44, but these dimensions are merely design dimensions. It should be noted that in a real product, some error is acceptable.

The present invention allows for various embodiments and modifications without departing from the broad spirit and scope of the invention. Further, the above-described embodiments are for explaining the present invention, and do not limit the scope of the present invention. That is, the scope of the present invention is shown not by the embodiment but by the claims. And various modifications made within the scope of the claims and within the equivalent meaning of the invention are considered to be within the scope of the present invention.

This application is based on Japanese Patent Application No. 2018-184004 filed on September 28, 2018. The specification, claims, and drawings of Japanese Patent Application No. 2018-184004 are incorporated herein by reference.

The present invention can be suitably used as a winding method, a winding machine, an insulator and a rotary electric machine.

1 Winder, 2 Split Stator, 3 Core Chuck Device, 4,4a, 4b, 4c Lead Wire, 5 Nozzle, 6 Main Body, 7 Base, 8 Base, 9 Mobile Base, 10 Drive Device, 11 Axis Support, 12 orbital shaft, 13 orbital arm, 14 driven pulley, 15 orbiting motor, 16 drive pulley, 17 timing belt, 18 computer, 18a CPU, 18b storage unit, 18c interface unit, 19 stator, 20 core pieces, 21 split laminated core , 21a back yoke, 21b shoe, 21c teeth, 22 end face insulator, 22a step, 22b introduction groove, 23 slot insulator, 24a upper end side, 24b left side, 24c lower end side, 24d right side, 30 rotary motor, 31 Casing, 32 brackets, 33 rotors, 34 stators, 35 rotor cores, 36 permanent magnets, 37 shafts, 38 core pieces, 39 magnet insertion holes, 40 flux barriers, 41 dividers, 42 core pieces, 43 insulators, 44 lead wire

Claims (12)

An orbiting motion in which a conductor is orbited around an object relative to the object and the conductor is wound around the object, and the conductor is wound around the object in the direction of the orbiting central axis of the orbiting motion. It is a winding method in which the conducting wire is wound around the object by combining the moving forward / backward movements relative to each other.
While stopping the advancing / retreating operation and maintaining the relative position of the conducting wire in the circumferential central axis direction with respect to the object, the orbiting operation is performed, and the conducting wire is formed in the first section of the cross-sectional shape of the object. The first step of winding and
The orbiting operation is performed to wind the conducting wire around the second section following the first section of the cross-sectional shape of the object, and while the conducting wire is wound around the second section, the advancing / retreating operation is performed. A second step of moving the conductor relative to the object in the circumferential central axis direction by a distance corresponding to the outer diameter of the conductor.
While stopping the advancing / retreating operation and maintaining the relative position of the conducting wire in the circumferential central axis direction with respect to the object, the orbiting operation is performed to continue to the second section of the cross-sectional shape of the object. The third step of winding the conductor around the third section and
While stopping the advancing / retreating operation and maintaining the relative position of the conducting wire in the circumferential central axis direction with respect to the object, the orbiting operation is performed to continue to the third section of the cross-sectional shape of the object. It has a fourth step of winding the conductor around the fourth section and returning the conductor to the first section.
The object is arranged in a corner between the first section and the second section, and the lead wire is wound around the object to form a winding end on the starting end side of the first layer. The windings are arranged in the first step portion protruding in the direction toward the end side of the first layer of the winding and the corner portion between the second section and the third section. A second step that projects from the start end of the first layer of the winding toward the end of the first layer of the winding .
At the end of the first section in the first turn of the first layer of the winding, the conductor is brought into contact with the first step and the winding of the conductor in the second section of the first turn. The advancing / retreating operation is started at the same time as the turning is started, the advancing / retreating operation is stopped at the same time as the winding of the conducting wire in the second section is completed, and the conducting wire is stopped at the end of the second section in the first turn. Is in contact with the second step portion,
Winding method. The first to fourth steps are repeated in order to apply windings extending from one end to the other end of the object.
The winding method according to claim 1. After winding is applied from one end of the object to the other end, the first to fourth steps are repeated in order, and the winding is placed on the previously applied winding. Winding from the other end of the object to the one end is applied to form a multi-layered winding.
The winding method according to claim 2. An orbiting motion in which a conductor is orbited around an object relative to the object and the conductor is wound around the object, and the conductor is wound around the object in the direction of the orbiting central axis of the orbiting motion. It is a winding method in which the conducting wire is wound around the object by combining the moving forward / backward movements relative to each other.
While stopping the advancing / retreating operation and maintaining the relative position of the conducting wire in the circumferential central axis direction with respect to the object, the orbiting operation is performed, and the conducting wire is formed in the first section of the cross-sectional shape of the object. The first step of winding and
The orbiting operation is performed to wind the conducting wire around the second section following the first section of the cross-sectional shape of the object, and while the conducting wire is wound around the second section, the advancing / retreating operation is performed. A second step of moving the conductor relative to the object in the circumferential central axis direction by a distance corresponding to the outer diameter of the conductor.
While stopping the advancing / retreating operation and maintaining the relative position of the conducting wire in the circumferential central axis direction with respect to the object, the orbiting operation is performed to continue to the second section of the cross-sectional shape of the object. The third step of winding the conductor around the third section and
While stopping the advancing / retreating operation and maintaining the relative position of the conducting wire in the circumferential central axis direction with respect to the object, the orbiting operation is performed to continue to the third section of the cross-sectional shape of the object. It has a fourth step of winding the conductor around the fourth section and returning the conductor to the first section.
The first to fourth steps are repeated in order to apply windings extending from one end of the object to the other end, and at the same time.
After winding is applied from one end of the object to the other end, the first to fourth steps are repeated in order, and the winding is placed on the previously applied winding. A winding method for forming a plurality of layers of windings by applying windings extending from the other end of the object to the one end.
In the step of forming the winding of the first layer, the orbiting operation is performed at the first speed, and the winding operation is performed.
In the first turn of the process of forming the windings after the second layer, the orbiting operation is performed while maintaining the first speed.
In the second turn of the process of forming the windings after the second layer, the orbiting operation is performed at a second speed lower than the first speed.
In the third turn of the process of forming the windings of the second layer and subsequent layers, the orbiting operation is performed at the first speed.
Hereinafter, in the step of forming the windings of the second layer and subsequent layers, the orbiting operation is performed while maintaining the first speed.
Winding method. An orbiting motion in which a conductor is orbited around an object relative to the object and the conductor is wound around the object, and the conductor is wound around the object in the direction of the orbiting central axis of the orbiting motion. It is a winding method in which the conducting wire is wound around the object by combining the moving forward / backward movements relative to each other.
While stopping the advancing / retreating operation and maintaining the relative position of the conducting wire in the circumferential central axis direction with respect to the object, the orbiting operation is performed, and the conducting wire is formed in the first section of the cross-sectional shape of the object. The first step of winding and
The orbiting operation is performed to wind the conducting wire around the second section following the first section of the cross-sectional shape of the object, and while the conducting wire is wound around the second section, the advancing / retreating operation is performed. A second step of moving the conductor relative to the object in the circumferential central axis direction by a distance corresponding to the outer diameter of the conductor.
While stopping the advancing / retreating operation and maintaining the relative position of the conducting wire in the circumferential central axis direction with respect to the object, the orbiting operation is performed to continue to the second section of the cross-sectional shape of the object. The third step of winding the conductor around the third section and
While stopping the advancing / retreating operation and maintaining the relative position of the conducting wire in the circumferential central axis direction with respect to the object, the orbiting operation is performed to continue to the third section of the cross-sectional shape of the object. It has a fourth step of winding the conductor around the fourth section and returning the conductor to the first section.
The first to fourth steps are repeated in order to apply windings extending from one end of the object to the other end, and at the same time.
After winding is applied from one end of the object to the other end, the first to fourth steps are repeated in order, and the winding is placed on the previously applied winding. A winding method for forming a plurality of layers of windings by applying windings extending from the other end of the object to the one end.
In the second step of the first turn of the step of forming the windings of the second layer and subsequent layers, the advancing / retreating operation is performed while the conductor is wound around the second section, and the conductor is subjected to the outer diameter of the conductor. Move the conductor in the same direction as the moving direction of the lead wire in the second step of the previous turn by a distance corresponding to.
In the first step of the second turn of the step of forming the windings of the second layer and thereafter, the advancing / retreating operation is performed while the conducting wire is wound around the first section, and the conducting wire is made of the conducting wire. It is larger than the distance corresponding to the outer diameter and is moved in the direction opposite to the moving direction of the conducting wire in the second step of the first turn.
In the second step of the second turn of the step of forming the windings of the second layer and thereafter, the advancing / retreating operation is performed while the conducting wire is wound around the first section, and the conducting wire is made of the conducting wire. The conductor is moved in the same direction as the conductor in the second step of the first turn by a distance corresponding to the outer diameter.
Winding method. An orbiting means for orbiting the nozzle that sends out the conductor around the object and relative to the object.
An advancing / retreating means for advancing / retreating the nozzle relative to the object in the direction of the orbiting central axis of the orbiting means.
A computer for controlling the lap means and the advance / retreat means is provided.
The winding method according to any one of claims 1 to 5 is executed.
A winding machine that winds the object. An insulator that is attached to an armature core having a rectangular cross-sectional shape and electrically insulates between a conducting wire that is wound around the armature core to form a winding and the armature core.
A step portion of the insulator that protrudes from the end of the first layer of the winding on the start end side toward the end of the first layer of the winding on the end side, and is the first step of the winding. The stepped portions to which the conductors constituting the first turn of the layer abut are provided at three of the four corners appearing in the cross-sectional shape of the insulator perpendicular to the radial axis of the armature core.
Insulator. In the cross-sectional shape, the first side on which the conductor forming the first turn of the first layer of the winding is wound first and the second side on which the conductor is wound next. The step portion is provided in the three corner portions excluding the corner portion in between.
The insulator according to claim 7. An insulator that is attached to an armature core having a rectangular cross-sectional shape and electrically insulates between a conducting wire that is wound around the armature core to form a winding and the armature core.
A step portion of the insulator that projects from the end on the start end side of the first layer of the winding toward the end on the end side of the first layer of the winding, and is the first step of the winding. It is provided with a stepped portion to which the conductors constituting the first turn of the layer abut, and also
The step portion is
The lower part with which the conductors constituting the first turn of the first layer of the winding come into contact with each other.
It comprises an upper portion with which the conductors that make up the last turn of the second layer of the winding come into contact.
Insulator. The lower portion protrudes toward the end side of the first layer of the winding from the upper portion, and the difference in the amount of protrusion between the two is equal to the radius of the cross-sectional shape of the conductor.
The insulator according to claim 9. The amount of protrusion of the upper portion measured from the end of the first layer of the winding of the insulator on the starting end side is equal to the radius of the cross-sectional shape of the conductor.
The insulator according to claim 10. An armature iron core equipped with the insulator according to any one of claims 7 to 11.
A conducting wire wound around the armature core from above the insulator, and
Have an armature equipped with,
Rotating electric machine.

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