Method for manufacturing armature

Patent metadata

Field	Value
Publication number	US-10693337-B2
Application number	US-201615576512-A
Country	US
Kind code	B2
Filing date	Aug 24, 2016
Priority date	Aug 28, 2015
Publication date	Jun 23, 2020
Grant date	Jun 23, 2020

Abstract

An annular conductor retaining device has a retention guide portion formed by blades arranged in a cylindrical shape with gaps therebetween. An annular conductor is inserted into two of the gaps across a plurality of the blades. The next annular conductor is inserted into the gaps to partially overlap the previously arranged annular conductor. This step is repeated so that the annular conductors are arranged in a spiral shape in the retention guide portion. The retention guide portion and the inner circumferential part of the core are fitted to each other, and the gaps and the slots of the core are made to coincide with each other. A pusher is inserted into the inner circumferential part of the retention guide portion so that the annular conductors are caught on the pusher, to move them in the axial direction into the slots of the core, and thus become the coils.

First claim

The invention claimed is:

1. A method for manufacturing an armature including a core having a plurality of slots provided at a cylindrical inner circumferential part, and coils inserted into the slots, the method being performed by using an annular conductor inserting device, the annular conductor inserting device including:
a retention guide portion having support members and a fixation member, the support members being arranged in a cylindrical shape with gaps therebetween in a circumferential direction and one end of each support member being fixed to the fixation member, thus forming a cylindrical part, the cylindrical part configured to be fitted to the inner circumferential part of the core and configured such that positions in the circumferential direction of the gaps coincide with positions of the slots of the core; and
an engagement portion configured to be movable, inside the cylindrical part, in an axial direction of the cylindrical part, the method comprising:
an arrangement step of arranging a necessary number of annular conductors each formed by winding a conductive wire in an annular shape, in the retention guide portion, by combination of: a simple arrangement step of inserting, across a plurality of the support members, a plurality of the annular conductors into the gaps in which the annular conductors have not been inserted yet, thereby arranging the plurality of annular conductors in the retention guide portion; and an overlap arrangement step of inserting another of the annular conductors into others of the gaps across a plurality of the support members so as to partially overlap the previously inserted annular conductor in the axial direction, thereby arranging the other annular conductor in the retention guide portion;
a fitting step of fitting the retention guide portion and the inner circumferential part of the core to each other and causing the positions in the circumferential direction of the gaps to coincide with the positions of the slots; and
an insertion step of moving the engagement portion in the axial direction of the retention guide portion and engaging the engagement portion with the annular conductors arranged in the retention guide portion, to insert the annular conductors into the slots, thereby forming the coils,
wherein the arrangement step includes:
a first-round arrangement step of arranging the annular conductors in the retention guide portion over an entire circumference of the retention guide portion by combination of the simple arrangement step and the overlap arrangement step; and
a second-round arrangement step of, after the annular conductors are arranged in the first-round arrangement step, further arranging the annular conductors in the retention guide portion over the entire circumference of the retention guide portion by combination of the simple arrangement step and the overlap arrangement step, such that, in the simple arrangement step in the second-round arrangement step, another of the annular conductors is inserted into others of the gaps, at a position shifted in the circumferential direction of the retention guide portion so as not to overlap, in the axial direction of the retention guide portion, the annular conductor arranged in the simple arrangement step in the first-round arrangement step, whereby the other annular conductor is arranged in the retention guide portion.

2. The method for manufacturing the armature according to claim 1 , wherein
in the simple arrangement step, the plurality of annular conductors are inserted into the gaps and arranged in the retention guide portion such that the plurality of annular conductors are dispersed in the circumferential direction of the retention guide portion so as not to overlap each other in the axial direction.

3. The method for manufacturing the armature according to claim 2 , wherein
each coil has slot accommodation portions accommodated in the corresponding slots, and coil ends connecting the slot accommodation portions,
the method comprising, prior to the simple arrangement step and the overlap arrangement step, an insulator arrangement step of inserting an insulator into the gaps across a plurality of the support members so as to be located at the same position as each annular conductor to be arranged later, thereby arranging the insulator in the retention guide portion, the insulator having first members with a predetermined gap therebetween, and second members connecting the first members, and
in the insertion step, the engagement portion is moved in the axial direction of the retention guide portion and engaged with the insulators and the annular conductors arranged in the retention guide portion, to insert the insulators and the annular conductors into the slots, so that each insulator becomes an insulating member having: insulating portions each covering one side, of the corresponding coil end, in a radial direction of the inner circumferential part of the core; and linkage portions located inside the slots and connecting the insulating portions, while the first members become the insulating portions and the second members become the linkage portions, and the annular conductors become the coils having the slot accommodation portions and the coil ends.

4. The method for manufacturing the armature according to claim 3 , wherein
the linkage portions of the insulating members are located inside the slots and serve also as wedge portions preventing the coils from protruding out of the slots.

5. The method for manufacturing the armature according to claim 4 , wherein
the second members of the insulators have narrow width portions,
the narrow width portions have such dimensions that allow the narrow width portions to be inserted into the gaps of the support members, and
when the insulators are arranged in the support members, the narrow width portions are inserted into the gaps of the support members and thus arranged in the retention guide portion.

6. The method for manufacturing the armature according to claim 1 , wherein
each coil has slot accommodation portions accommodated in the corresponding slots, and coil ends connecting the slot accommodation portions,
the method comprising, prior to the simple arrangement step and the overlap arrangement step, an insulator arrangement step of inserting an insulator into the gaps across a plurality of the support members so as to be located at the same position as each annular conductor to be arranged later, thereby arranging the insulator in the retention guide portion, the insulator having first members with a predetermined gap therebetween, and second members connecting the first members, and
in the insertion step, the engagement portion is moved in the axial direction of the retention guide portion and engaged with the insulators and the annular conductors arranged in the retention guide portion, to insert the insulators and the annular conductors into the slots, so that each insulator becomes an insulating member having: insulating portions each covering one side, of the corresponding coil end, in a radial direction of the inner circumferential part of the core; and linkage portions located inside the slots and connecting the insulating portions, while the first members become the insulating portions and the second members become the linkage portions, and the annular conductors become the coils having the slot accommodation portions and the coil ends.

7. The method for manufacturing the armature according to claim 6 , wherein
the linkage portions of the insulating members are located inside the slots and serve also as wedge portions preventing the coils from protruding out of the slots.

8. The method for manufacturing the armature according to claim 7 , wherein
the second members of t

Assignees

• Mitsubishi Electric Corp

Inventors

• Tsuiki Hironori
• Hashimoto Akira

Classifications

• H02K3/12

  arranged in slots · CPC title

• H02K15/10

  Applying solid insulation to windings, stators or rotors, e.g. applying insulating tapes · CPC title

• H02K3/345 Primary

  between conductor and core, e.g. slot insulation · CPC title

• H02K3/04

  Windings characterised by the conductor shape, form or construction, e.g. with bar conductors · CPC title

• H02K15/06

  Embedding prefabricated windings in the machines · CPC title