JP7710544B2 - Manufacturing apparatus and manufacturing method - Google Patents

Description

The present invention relates to motor manufacturing technology.

Assemblies having multiple conductor segments are known as stator coils that are attached to the stator core of a motor. These assemblies are inserted into slots in the stator core. Patent documents 1 to 4 disclose manufacturing techniques for assembling assemblies from multiple conductor segments. In these manufacturing techniques, the individual conductor segments are arranged and aligned in a ring shape using a jig.

JP 2004-72839 A Patent No. 4214469 Patent No. 3118837 Patent No. 3199068

To improve the manufacturing efficiency of assemblies, it is necessary to assemble more assemblies continuously. Conventional technologies have room for improvement in terms of manufacturing efficiency.

The object of the present invention is to improve the manufacturing efficiency of assemblies of multiple conductor segments.

According to the present invention,
A manufacturing apparatus for manufacturing an assembly in which a plurality of conductor segments are arranged in an annular manner and which is to be attached to a stator core of a motor, comprising:
a jig unit including a plurality of jigs for assembling the assembly in stages and a support on which the plurality of jigs are mounted;
A conveying device that conveys the jig unit;
a plurality of working devices disposed along a transport path of the jig unit by the transport device,
The plurality of working devices are
At least one feeder device for feeding a plurality of conductor segments to a fixture to be worked on;
at least one driving device that causes the jig to perform an assembly operation, the jig being the work target to which the plurality of conductor segments are supplied by the at least one supplying device;
At least one transfer device that transfers the intermediate assembly assembled by the jig to a next stage jig,

Each of the plurality of conductor segments comprises:
a pair of legs to be inserted into different slots of the stator core; and a connection portion connecting ends of the pair of legs,
The assembling operation includes an operation of moving the legs of a plurality of conductor segments to align the pair of legs,
The plurality of jigs include
a leading fixture on which the first stage intermediate assembly is assembled;
At least one subsequent fixture;
The leading jig includes a first inner jig and a first outer jig surrounding the first inner jig, and the first inner jig and the first outer jig are provided so as to be capable of relative rotation around a first rotation center line;
the first inner jig has a plurality of first inner holding portions that are arranged in an annular shape around the first rotation center line and that hold one of the pair of legs;
the first outer jig has a plurality of first outer holding portions that are arranged in an annular shape around the first rotation center line and that hold the other of the pair of legs so as to be displaceable in a radial direction;
The at least one subsequent jig includes a second inner jig and a second outer jig surrounding the second inner jig, and the second inner jig and the second outer jig are provided so as to be capable of relative rotation around a second rotation center line;
the second inner jig has a plurality of second inner holding portions that are arranged in an annular shape around the second rotation center line and that hold the previous stage assembly and one of the pair of legs;
the second outer jig has a plurality of second outer holding portions that are arranged in an annular shape around the second rotation center line and that hold the other of the pair of legs so as to be displaceable in a radial direction;
the at least one driving device is a device for relatively rotating the first inner jig and the first outer jig, and relatively rotating the second inner jig and the second outer jig;
The at least one transfer device is a device that transfers the intermediate assembly to the second inner holding portions of the at least one subsequent jig of a next stage.
A manufacturing apparatus is provided.

The present invention makes it possible to improve the manufacturing efficiency of assemblies of multiple conductor segments.

Layout diagram of the manufacturing system. FIG. 2 is a side view of a manufacturing apparatus constituting the manufacturing system of FIG. 1 . FIG. Partially enlarged views of each jig. FIG. 3 is an explanatory diagram of the operation of the manufacturing apparatus of FIG. 2 . FIG. 3 is an explanatory diagram of the operation of the manufacturing apparatus of FIG. 2 . FIG. 3 is an explanatory diagram of the operation of the manufacturing apparatus of FIG. 2 . FIG. 3 is an explanatory diagram of the operation of the manufacturing apparatus of FIG. 2 . FIG. 3 is an explanatory diagram of the operation of the manufacturing apparatus of FIG. 2 . FIG. 3 is an explanatory diagram of the operation of the manufacturing apparatus of FIG. 2 . FIG. 3 is an explanatory diagram of the operation of the manufacturing apparatus of FIG. 2 . FIG. 11 is a layout diagram of a manufacturing apparatus according to another example. FIG. 13 is a perspective view of a jig unit according to another example. 14A to 14C are diagrams showing a manufacturing example using the jig unit of FIG. 13 . 14A to 14C are diagrams showing a manufacturing example using the jig unit of FIG. 13 . 14A to 14C are diagrams showing a manufacturing example using the jig unit of FIG. 13 . 13A and 13B are perspective views of several alternative examples of jig units.

The embodiments are described in detail below with reference to the attached drawings. Note that the following embodiments do not limit the invention according to the claims, and not all combinations of features described in the embodiments are necessarily essential to the invention. Two or more of the features described in the embodiments may be combined in any desired manner. In addition, the same reference numbers are used for identical or similar configurations, and duplicate descriptions are omitted.

First Embodiment
<Manufacturing System>
FIG. 1 is a layout diagram showing a manufacturing system 100 for manufacturing a stator of a three-phase AC motor. In each drawing, arrows X and Y indicate horizontal directions perpendicular to each other, and arrow Z indicates an up-down direction. The manufacturing system 100 includes a cutting device 110, a processing device 120, a conveying device 130, a manufacturing device 1, a supplying device 140, an attachment device 150, and a processing device 160. To summarize the operation of the manufacturing system 100, the cutting device 110, the processing device 120, the conveying device 130, and the manufacturing device 1 manufacture the stator coil assembly 10, and the supplying device 140 supplies the stator core 141. The attachment device 150 attaches the assembly 10 to the slot 142 of the stator core 141, and the processing device 160 performs processing of the end of the assembly 10 attached to the stator core 141.

The cutting device 110 is equipped with a reel 111 around which wire material for the stator coil is wound. The wire is, for example, a metal wire (e.g., copper wire) having a rectangular cross section, and its surface is coated with an insulating film. The wire pulled out from the reel 111 is formed into a straight shape by a shape correction device 112, and then cut to a predetermined length by a cutting device 113 to produce a rod-shaped conductor wire 114. The insulating film on the surface of both ends of the conductor wire 114 is peeled off by a peeling device (not shown).

The conductor wire 114 is supplied to the processing device 120. The processing device 120 includes a bending device 121. The bending process is performed in two stages. In the first stage, the bending device 121 bends the conductor wire 114 into an approximately U-shape on the same plane. In the second stage, the bending process is performed in a direction intersecting the same plane, and the connection portion C described below is curved. This produces a conductor segment CS. The conductor segment CS is integrally provided with a pair of legs F that are inserted into the slots 142 of the stator core 141, and a connection portion C that connects the ends of the pair of legs F. The pair of legs F extend linearly parallel to each other. The connection portion C has a roof shape or a mountain shape. The curved connection portion C makes it easier for the pair of legs F to be inserted into the slots 142, and a ring-shaped assembly can be obtained by assembling a plurality of conductor segments CS in a manner described below.

The conveying device 130 is a device that supplies the conductor segments CS manufactured by the processing device 120 to the manufacturing device 1. The conveying device 130 is equipped with, for example, a chute that sequentially flows the conductor segments CS into the stocker 7 of the manufacturing device 1.

In this embodiment, two sets of cutting device 110, processing device 120 and conveying device 130 are provided, one set on each side of the manufacturing line (X-direction line) of manufacturing device 1. Manufacturing device 1 is a device for manufacturing assembly 10 in which multiple conductor segments CS are arranged in a ring shape. Details will be described later.

The supply device 140 sequentially supplies the stator cores 141 to the mounting device 150. The stator core 141 has a cylindrical shape as a whole, and a plurality of slots 142 that open onto its inner circumferential surface are formed radially. The mounting device 150 mounts the assembly 10 to the stator core 141 by inserting the legs F of each conductor segment CS of the assembly 10 into the slots 142 of the stator core 141. A pair of legs F of each conductor segment CS are inserted into different slots 142. The processing device 160 performs bending processing to bend each leg F protruding outward from the stator core 141, welding adjacent legs F together, and the like.

<Manufacturing equipment>
The configuration of the manufacturing apparatus 1 will be described with reference to Figures 1 to 3. Figure 2 is a side view of the manufacturing apparatus 1, and Figure 3 is a perspective view of a jig unit 2 used in assembling an assembly 10. The manufacturing apparatus 1 includes a plurality of jig units 2, a transport device 3 that transports the jig units 2 in a cyclical manner, a plurality of work devices 4 to 6 that are arranged along a transport path of the jig units 2 by the transport device 3, and a plurality of stockers 7.

The conveying device 3 includes an upper conveyor 30 and a lower conveyor 31 arranged in two stages, one above the other. The conveyor 30 forms the outgoing path of the conveying path of the jig unit 2, and the conveyor 31 forms the return path of the conveying path of the jig unit 2.

Conveyors 30 and 31 are roller conveyors that extend in the X direction and have two rows of rollers RL spaced apart in the Y direction. As shown by the arrows in Figure 2, conveyor 30 transports the jig unit 2 placed on the rollers RL in one direction in the X direction, and conveyor 31 transports the jig unit 2 placed on the rollers RL in the opposite direction to the X direction.

A movable conveyor 32 is disposed at each end in the X direction of the conveyors 30 and 31. The movable conveyor 32 is a roller conveyor in which a number of rollers RL are arranged in two rows spaced apart in the Y direction, and has a length sufficient to accommodate one jig unit 2. The movable conveyor 32 is raised and lowered by a lifting device 33 between a position continuous with the conveyor 30 (position indicated by a solid line in FIG. 2) and a position continuous with the conveyor 31 (position indicated by a dashed line in FIG. 2).

The jig unit 2 is transported from one end of the conveyor 30 in the X direction to the other end, and then lowered by the moving conveyor 32 and transferred to the conveyor 31. The jig unit 2 is then transported from the other end of the conveyor 31 in the X direction to the other end, and then raised by the moving conveyor 32 and transferred to the conveyor 30. In this way, the jig unit 2 is transported in a circular manner by the transport device 3.

The jig unit 2 has a plurality of jigs 22 and 23 that assemble the assembly 10 in stages, and a support 20 on which the jigs 22 and 23 are mounted. One assembly 10 can be manufactured by one jig unit 2. In this embodiment, the support 20 has a plate-shaped main body and a plurality of support parts 21. The jigs 22 and 23 are supported by the support parts 21. The jigs 22 and 23 are arranged side by side in the X direction, and the jig 22 is the leading jig when viewed in the conveying direction by the conveying device 30, and the jig 23 is the trailing jig. In this embodiment, the jigs 22 and 23 are mounted on the support 20 in the assembly order of the assembly 10 in the conveying direction of the jig unit 2 by the conveyor 30. The arrangement of the jigs 22 and 23 is not limited to the assembly order, but according to the arrangement of this embodiment, the jigs to be worked on progress in order in the conveying direction, making it easier to understand the progress of the assembly, and facilitating the management of the assembly process and the layout of the working devices 4 to 6.

The jig 22 has an inner jig 221 and an outer jig 222 surrounding the inner jig 221. In this embodiment, the inner jig 221 and the outer jig 222 both have a cylindrical shape, and the outer surface of the inner jig 221 is in contact with the inner surface of the outer jig 222. The inner jig 221 and the outer jig 222 are relatively rotatable around a rotation center line 22a in the Z direction. In this embodiment, the inner jig 221 is fixed to the support portion 21, and the outer jig 222 is rotatably supported by the support portion 21. However, the inner jig 221 may be rotatably supported and the outer jig 222 may be fixed.

In this embodiment, the outer jig 222 has a pressed portion 223 that protrudes radially from its outer circumferential surface, and rotates when an external force in the Y direction acts on the pressed portion 223. However, the rotation mechanism of the outer jig 222 is not limited to this, and may be configured to rotate the outer jig 222 by a drive source mounted on the support body 20 or the support portion 21, for example.

The jig 23 has a structure similar to that of the jig 22. The jig 23 has an inner jig 231 and an outer jig 232 surrounding the inner jig 231. In this embodiment, the inner jig 231 and the outer jig 232 both have a cylindrical shape, and the outer surface of the inner jig 231 is in contact with the inner surface of the outer jig 232. The inner jig 231 and the outer jig 232 are relatively rotatable around the rotation center line 23a in the Z direction. In this embodiment, the inner jig 231 is fixed to the support part 21, and the outer jig 232 is rotatably supported by the support part 21. However, the inner jig 231 may be rotatably supported and the outer jig 232 may be fixed.

The jigs 22 and 23 each have a holding portion formed therein for holding the leg portion F of the conductor segment CS. Figure 4 is a partially enlarged view of the jigs 22 and 23, and a plan view showing a portion of the jigs 22 and 23.

The inner jig 221 of the jig 22 has a plurality of inner holding portions 224 formed thereon, and the outer jig 222 has a plurality of outer holding portions 225 formed thereon. In this embodiment, the inner holding portion 224 is a hole having a depth in the Z direction, which penetrates the inner jig 221 in the Z direction. When viewed in cross section in the X-Y plane, the inner holding portion 224 is large enough to insert one leg F. The multiple inner holding portions 224 are arranged in a ring shape centered on the rotation center line 22a, at equal pitch in the circumferential direction.

The outer holding portion 225 has a depth in the Z direction and is a groove that opens into the inner surface of the outer jig 222. In this embodiment, it is a groove that penetrates the outer jig 222 in the Z direction. When viewed in cross section in the X-Y plane, the outer holding portion 225 has a width that allows one leg F to be inserted, and extends radially so that the leg F can be displaced radially. The multiple outer holding portions 225 are arranged in a ring shape centered on the rotation center line 22a, with equal circumferential pitch. The number of inner holding portions 224 and outer holding portions 225 is the same, and the circumferential pitch is also the same.

The inner jig 231 of the jig 23 has a plurality of inner holding parts 234 formed thereon, and the outer jig 232 has a plurality of outer holding parts 235 formed thereon. In this embodiment, the inner holding part 234 is a hole having a depth in the Z direction, which penetrates the inner jig 231 in the Z direction. When viewed in cross section in the X-Y plane, the inner holding part 234 has a width sufficient to insert one leg F, and a length sufficient to insert multiple legs F arranged radially. The multiple inner holding parts 234 are arranged in a ring shape centered on the rotation center line 23a, at equal pitch in the circumferential direction.

The outer holding portion 235 has a depth in the Z direction and is a groove that opens into the inner surface of the outer jig 232; in this embodiment, it is a groove that penetrates the outer jig 232 in the Z direction. When viewed in cross section in the X-Y plane, the outer holding portion 235 has a width that allows one leg F to be inserted, and extends radially so that the leg F can be displaced radially. The multiple outer holding portions 235 are arranged in a ring shape centered on the rotation center line 23a, at equal pitches in the circumferential direction. The number of inner holding portions 234 and outer holding portions 235 is the same, and the circumferential pitch is also the same.

The working devices 4 to 6 will be described with reference to Figures 1 and 2. The working devices 4 to 6 are arranged to the side of the transport device 3, and there are four working devices 4, two working devices 5, and one working device 6 that perform various operations on the jig unit 2 transported by the conveyor 30, but the number and arrangement of each working device can be designed as appropriate.

The working device 4 is a multi-axis robot that moves the working head 4a in each of the X, Y, and Z directions, and supplies the conductor segments CS one by one from the stocker 7 to the jig 22 or jig 23 that is the work target. In the case of this embodiment, the working device 4 is a vertical multi-joint type robot, and a gripping part 4b capable of gripping the conductor segment CS is provided at the tip of the working device 4. Although the working device 4 is a vertical multi-joint type, a horizontal multi-joint type robot or other well-known industrial robots can also be used.

The working device 5 is a drive device that causes the jig 22 or jig 23 to perform an assembly operation. In this embodiment, the working device 5 is a pusher that reciprocates the pressing portion 5a in the Y direction, and presses the pressed portion 223 of the outer jig 222 or the pressed portion 233 of the outer jig 232 to rotate the outer jig 222 or the outer jig 232. The pusher in this embodiment is an air actuator that expands and contracts the pressing portion 5a in the Y direction.

The working device 6 is a transfer device that transfers the intermediate assembly assembled in the jig 22 to the jig 23. The working device 6 has a holding head 6a that holds the intermediate assembly, a lifting unit 6b that raises and lowers the holding head 6a, and a moving unit 6c that moves the lifting unit 6b in the X direction. The holding head 6a holds the intermediate assembly in the jig 22, the lifting unit 6b lifts the intermediate assembly from the jig 22, the moving unit 6c moves the holding unit 6a and the lifting unit 6b to the jig 23, and the lifting unit 6b lowers the holding unit 6a to transfer the intermediate assembly to the jig 23.

In this embodiment, multiple working devices 4 and 5 are provided, spaced apart in the transport direction of the jig unit 2 by the conveyor 30. Specifically, four working devices 4 and two working devices 5 are provided. Work can be performed on multiple jig units 2 simultaneously, improving manufacturing efficiency. In this embodiment, there is one working device 6, but multiple working devices 6 may also be provided, spaced apart in the transport direction of the jig unit 2.

<Manufacturing method>
Each manufacturing process of the assembly 10 will be described with reference to Figures 1 and 5 to 11. In manufacturing the assembly 10, the jig unit 2 is transported and stopped by the transport device 3. While the transport of the jig unit 2 is stopped, work is performed on the jig unit 2 by the working devices 4 to 6. Thereafter, the transport and stopping of the jig unit 2 and the work on the jig unit 2 are repeated.

The following describes the work carried out on the jig unit 2. The assembly 10 is manufactured by carrying out work on the jig 22 using two work devices 4 and one work device 5 located upstream (on the left side in FIG. 1) in the transport direction of the jig unit 2 on the transport device 30, and then transferring the intermediate assembly from the jig 22 to the jig 23 using the work device 6. Furthermore, the work devices 4 and 5 located downstream (on the right side in FIG. 1) in the transport direction of the jig unit 2 on the transport device 30 carry out work on the jig 23, and the assembly 10 is obtained.

A more detailed explanation will be given. First, for example, the process starts with the operation of supplying a plurality of conductor segments CS to the jig 22 indicated by the symbol G in FIG. 1 using the working device 4. FIG. 5 is a schematic diagram showing this process. The working device 4 takes out the conductor segments CS one by one from the stocker 7 using the gripping portion 4b and inserts them into the jig 22. When inserting, one of the pair of legs F of the conductor segment CS is inserted into the inner holding portion 224, and the other leg F is inserted into the outer holding portion 225. In this way, the conductor segment CS is inserted between the inner jig 221 and the outer jig 222 so as to straddle them. The working device 4 repeats this operation of supplying the conductor segments CS, so that a plurality of conductor segments CS are arranged in a circular shape around the jig 22. As shown in the cross-sectional view of line A-A in Figure 5, one leg F of the conductor segment CS is inserted into the inner holding portion 224, and the other leg F is inserted into the outer holding portion 225 which is located at a different circumferential position from the inner holding portion 224 into which the one leg F is inserted.

Next, the jig unit 2 is transported downstream in the transport direction by the conveyor 30, and the jig 22, which is at position G in Figure 1, is transported to position H and stopped. After the jig 22 is stopped at position H, the working device 5 is driven to cause the jig 22 to perform an assembly operation. Figure 6 is an explanatory diagram. The pressed portion 223 of the jig 22, after the insertion operation of the multiple conductor segments CS has been completed, is pressed by the pressing portion 5a of the working device 5, and the outer jig 222 is rotated in the direction of the arrow. This produces the intermediate assembly 11. Figure 7 shows the assembly operation in more detail than Figure 6.

As the outer jig 222 rotates, the legs F inserted into the outer holding portion 225 are displaced circumferentially around the outer jig 222 and radially inward, causing the connection portions C of the adjacent conductor segments CS to be aligned in a ring shape. Finally, the legs F held by the outer holding portion 225 are displaced to a position adjacent to the legs F of another conductor segment CS held by the inner holding portion 224, completing the intermediate assembly 11 in which a pair of legs F are aligned. The intermediate assembly 11 has two layers (two rows) of legs F arranged in a ring shape in the radial direction.

Regarding the configuration for reversing the outer jig 222 to its original position after rotation, for example, a drive source (not shown) for reversing may be provided on the support 20 or the support portion 21. Alternatively, the outer jig 222 may be reversed by a working device 5 different from the working device 5 that rotated the outer jig 222. Or, the outer jig 222 may be reversed by a working device (not shown) during the process of transporting the jig unit 2 by the conveyor 21.

Next, the working device 6 is driven to transfer the intermediate assembly 11 assembled in the jig 22 at the position indicated by the symbol H in Fig. 1 to the next stage jig 23 at the position indicated by the symbol I. Fig. 8 is a schematic diagram showing this process.

The working device 6 holds the intermediate assembly 11 of the jig 22 with the holding head 6a. The tip of the holding head 6a has a plurality of pins 6d that can be inserted radially into the intermediate assembly 11 and detached, and holds the intermediate assembly 11 by engaging the plurality of pins 6d with each connection part C of the intermediate assembly 11. A large number of pins 6d may be provided in the circumferential direction of the intermediate assembly 11. After the pins 6d are inserted radially from below each connection part C, the holding head 6a begins to rise by the lifting part 6b, and the intermediate assembly 11 also rises and is lifted up from the jig 22. After lifting the intermediate assembly 11 from the jig 22, the moving part 6c moves the holding head 6a and the lifting part 6b to the jig 23 located at the position of the symbol I in FIG. 1, and the holding head 6a is positioned on the jig 23. Next, the holding head 6a is lowered by the lifting part 6b, and the leg F of the intermediate assembly 11 is inserted into the hole of the inner holding part 234 of the jig 23. After the insertion, the pin 6d is released, and the transfer of the intermediate assembly 11 to the jig 23 is completed.

The legs F of the intermediate assembly 11 are inserted into the holes of the inner holding portion 234 of the inner jig 231. As shown in the partially enlarged cross-sectional view of Figure 8, two layers (two legs) of legs F are inserted into one hole of the inner holding portion 234.

Next, the jig unit 2 is transported downstream in the transport direction by the conveyor 30, and the jig 23, which is at position I, is transported to position J in Figure 1 and stopped there. After the jig 23 is stopped at position J, the working device 4 supplies multiple conductor segments CS to the jig 23. Figure 9 is a schematic diagram showing this process. The working device 4 uses the gripper 4b to take out the conductor segments CS one by one from the stocker 7 and insert them into the jig 23. During insertion, of the pair of legs F of the conductor segment CS, one leg F is inserted into the inner holding portion 234, and the other leg F is inserted into the outer holding portion 235. The leg F inserted into the inner holding portion 234 is inserted outside the intermediate assembly 11 that has already been inserted.

In this way, the conductor segment CS is inserted between the inner jig 231 and the outer jig 232 so as to straddle them. The working device 4 repeats this supplying operation of the conductor segment CS, so that a plurality of conductor segments CS are arranged in a ring shape around the jig 23, surrounding the intermediate assembly 11. In Figure 9, as shown in the cross-sectional view of line B-B, etc., one leg F of the conductor segment CS is inserted into the inner holding portion 234, and the other leg F is inserted into the outer holding portion 235 which is located at a different circumferential position from the inner holding portion 234 into which the one leg F is inserted.

Figure 10 is a partially enlarged cross-sectional view showing the conductor segment CS inserted into the jig 23. Two layers of legs F of the intermediate assembly 11 and one leg F of the conductor segment CS are inserted into each inner holding portion 234 of the inner jig 231. The other leg F of the conductor segment CS is inserted into each outer holding portion 235 of the outer jig 232.

Next, the jig unit 2 is transported downstream in the transport direction by the conveyor 30, and the jig 23, which is at position J in Figure 1, is transported to position K and stopped. After the jig 23 is stopped at position K, the working device 5 is driven to cause the jig 23 to perform an assembly operation. Figure 11 is an explanatory diagram. The pressed portion 233 of the jig 23, which has completed the insertion operation of the intermediate assembly 11 and the multiple conductor segments CS, is pressed by the pressing portion 5a of the working device 5, and the outer jig 232 is rotated. This produces the assembly 10, which is the final assembly.

As in the case of the jig 22 described with reference to FIG. 7, as the outer jig 232 rotates, the leg F inserted in the outer holding portion 235 is displaced in the circumferential direction of the outer jig 232 while being displaced radially inward, and the connection portions C of the adjacent conductor segments CS are aligned in a ring shape. Finally, the leg F held by the outer holding portion 235 is displaced to a position adjacent to the leg F of another conductor segment CS held by the inner holding portion 234, and the pair of legs F are aligned. The assembly 10 has two layers (two rows) of legs F arranged in a ring shape on the outside of the intermediate assembly 11 in the radial direction, and has a structure having four layers of legs F in the radial direction as a whole. After that, the jig unit 2 is transported downstream in the transport direction by the conveyor 30, and the jig 23 at the position of symbol K in FIG. 1 is transported to the position of symbol L on the moving conveyor 32 and stopped. After the jig 23 is stopped at the position indicated by the symbol L, the assembly 10 is transferred to the mounting device 150 by a working device (not shown) or a worker.

Regarding the configuration for reversing the outer jig 232 to its original position after rotation, for example, a drive source (not shown) for reversing may be provided on the support body 20 or the support portion 21. Alternatively, the outer jig 232 may be reversed by a working device 5 different from the working device 5 that rotated the outer jig 232. Or, the outer jig 232 may be reversed by a working device (not shown) during the process of transporting the jig unit 2 by the conveyor 21.

The jig unit 2 from which the assembly 10 has been removed is lowered by the lifting device 33 from a position continuous with the conveyor 30 to a position continuous with the conveyor 31. Next, the jig unit 2 is transported from the other end (the right end in FIG. 1) of the conveyor 31 in the X direction to one end (the left end in FIG. 1), and then raised by the moving conveyor 32 to a position continuous with the conveyor 30 and transferred to the conveyor 30. In this way, the jig unit 2 is transported in a circular manner by the transport device 3, and the assembly work of the assembly 10 is continuously and repeatedly performed by the working devices 4 to 6.

As described above, in this embodiment, the assembly 10 is assembled by the working devices 4 to 6 while the jig unit 2 is transported intermittently in the X direction. This enables on-line production of the assembly 10, improving the manufacturing efficiency of the assembly 10. Because the jig unit 2 is transported in a cyclical manner, the assembly 10 can be manufactured continuously without delay, further improving its manufacturing efficiency. In addition, there is no need to lift or lower the jigs 22 and 23 during the assembly manufacturing process, and there is no need to transfer the jigs 22 and 23 from another storage location to the assembly position, eliminating the need for complicated management and storage of the jigs.

In this embodiment, the intermediate assembly 11 is transferred to the jig 23 and then the conductor segment CS is supplied, but conversely, the intermediate assembly 11 may be transferred to the jig 23 after the conductor segment CS is supplied.

Second Embodiment
When the assembly 10 is used as a stator coil of a three-phase AC motor, electrical interlayer connection work needs to be performed for each of the three phases (U-phase, V-phase, and W-phase) between the 1-2 layer coil and the 3-4 layer coil. In the first embodiment, it is assumed that the wiring work is performed after the assembly 10 is manufactured, but a conductor segment that is the same as the conductor segment CS may be used and incorporated into the assembly as a conductor segment for interlayer connection. The conductor segment for interlayer connection may be different from the conductor segment CS. For example, the distance between a pair of legs F may be different, or the shape of the connection portion C may be different, such as a roof-shaped or mountain-shaped one.

Figure 12 is a layout diagram of manufacturing apparatus 1A in this embodiment. Manufacturing apparatus 1A manufactures assembly 10A incorporating conductor segments for connection as a final assembly. The basic configuration of manufacturing apparatus 1A is the same as that of manufacturing apparatus 1, but differs in the number and arrangement of jig units and working devices 4 to 6.

Figure 13 is an oblique view of the jig unit 2A used in this embodiment. The basic configuration of the jig unit 2A is the same as that of the jig unit 2, but the number of jigs is different. The jig unit 2A has a number of jigs 22-24 that assemble the assembly 10 in stages, and a support 20 on which the jigs 22-24 are mounted. One assembly 10 can be manufactured using one jig unit 2. In this embodiment, the support 20 has a plate-shaped main body and a number of support portions 21. The jigs 22-24 are each supported by the support portions 21.

The jigs 22 to 24 are arranged in the X direction, and when viewed from the upstream side (left side in FIG. 12) of the conveying direction by the conveying device 30, the jig 22 is the leading jig, and the jigs 24 and 23 are the following jigs. The jig 23 is the rearmost jig, and the jig 24 is an intermediate jig between the jig 22 and the jig 23. In this embodiment, the jigs 22, 24, and 23 are mounted on the support 20 in the assembly order of the assembly 10 in the conveying direction of the jig unit 2 by the conveyor 30. That is, the assembly 10 is assembled in the order of the work using the jig 22, the work using the jig 24, and the work using the jig 23. The arrangement of the jigs 22, 24, and 23 is not limited to the assembly order, but according to the arrangement of this embodiment, the progress of the assembly with the assembly 10 is easy to understand, and the management of the assembly process and the layout of the work devices 4 to 6 are facilitated.

The configurations of the jigs 22 and 23 are the same as those of the jigs 22 and 23 described in the first embodiment. The configuration of the jig 24 is the same as that of the jig 23 except for the size, and has an inner jig 241, an outer jig 242, and a pressed portion 243, and the outer jig 242 is rotatable around the rotation center line 24a. The inner jig 241 and the outer jig 242 are formed with an inner holding portion 244 and an outer holding portion 245 similar to the inner holding portion 234 and the outer holding portion 235 of the jig 23 (see FIG. 14).

Each manufacturing process of the assembly 10A will be described. First, in the same procedure as in the first embodiment, a conductor segment CS is supplied by the working device 4 to the jig 22 located at the position indicated by the symbol M in Fig. 12. In parallel with this, or after the conductor segment CS is supplied to the jig 22, as shown in Fig. 14, a connection segment DS is supplied by the working device 4 to the jig 24 located at the position indicated by the symbol N in Fig. 12. The connection segment DS is the same segment as the conductor segment CS.

The working device 4 uses the gripper 4b to take out the connection segments DS (conductor segments CS) one by one from the stocker 7 and insert them into the jig 24. When inserting, one of the pair of legs F of the connection segment DS is inserted into the inner holding part 244, and the other leg F is inserted into the outer holding part 245. In this way, the connection segment DS is inserted between the inner jig 241 and the outer jig 242 so as to straddle them. By repeating this supply operation of the connection segments DS by the working device 4, multiple connection segments DS are arranged in a fan shape on the jig 24. In this embodiment, the number of layers is 2 for the 1-2 layer coil and the 3-4 layer coil, and the number of phases is 3 (U phase, V phase, W phase), so 2 x 3 = 6 connection segments DS are supplied to the jig 24.

In this embodiment, a portion (six pieces) of the leg group F in the second layer and a portion (six pieces) of the leg group F in the third layer are formed by the leg F of the connection segment DS. Therefore, the conductor segments CS are supplied to the jig 22 thinned out by the amount of the connection segments DS.

Next, the conveyor 30 transports the jig unit 2A downstream in the transport direction, and transports the jigs 22 and 24, which are at positions M and N in Figure 12, to positions P and Q, where they are stopped. After the jigs 22 and 24 have been stopped at positions P and Q, the working device 5 is driven to cause the jig 22 to perform an assembly operation.

Next, the conveyor 30 transports the jig unit 2A downstream in the transport direction, and transports the jigs 22 and 24, which are at positions P and Q in Figure 12, to positions R and S, where they are stopped.

12, the jig 22 and the jig 24 are stopped at positions R and S, respectively, and then the intermediate assembly 11 is transferred by the working device 6 from the jig 22 at position R to the jig 24 at position S. The intermediate assembly 11 is inserted into the inner jig 241 of the jig 24.

Figure 15 is a partially enlarged cross-sectional view showing the intermediate assembly 11 transferred to the jig 24. In the illustrated example, the leg F of the conductor segment CS constituting the intermediate assembly 11 is indicated by the reference symbol 11, and the leg F of the connection segment DS is indicated by the reference symbol DS. In the six inner holding parts 244, the leg F of the conductor segment CS and the leg F of the connection segment DS form two layers (two rows) of leg F. In the inner holding part 244 into which one leg F of the connection segment DS is inserted, one layer (one leg) of the intermediate assembly 11 is inserted inside the leg F of the connection segment DS. In the remaining inner holding parts 244 (inner holding parts 244 into which the leg F of the connection segment DS is not inserted), only two layers (two legs) of the intermediate assembly 11 are inserted.

Next, the working device 5 is driven to cause the jig 24, located at the position indicated by the symbol S in Figure 12, to perform an assembly operation. Figure 16 is an explanatory diagram. After the insertion of the six connection segments DS and the intermediate assembly 11 has been completed, the pressed portion 243 of the jig 24 is pressed by the pressing portion 5a of the working device 5, and the outer jig 242 is rotated. An intermediate assembly 12 is manufactured in which six connection segments DS are added to the intermediate assembly 11. The third layer of legs F of the intermediate assembly 12 are partially formed by the six legs F of the connection segments DS.

Next, the working device 6 transfers the intermediate assembly 12 from the jig 24 at position S in Figure 12 to the jig 23 at position T. The intermediate assembly 12 is inserted into the inner jig 231 of the jig 23. Two layers (two pieces) of legs F and one leg F of the connection segment DS are inserted into the six inner holding parts 234. Only two layers (two pieces) of legs F are inserted into the remaining inner holding parts 234.

Next, the jig unit 2A is transported downstream in the transport direction by the conveyor 30, and the jig 23 at position T is transported to position U and stopped. After the jig 23 is stopped at position U, the working device 4 supplies multiple conductor segments CS to the jig 23, as in the first embodiment. The working device 4 uses the gripper 4b to take out the conductor segments CS one by one from the stocker 7 and inserts them into the jig 23. When inserting, one of the pair of legs F of the conductor segment CS is inserted into the inner holding part 234, and the other leg F is inserted into the outer holding part 235. The leg F inserted into the inner holding part 234 is inserted outside the intermediate assembly 12 that has already been inserted, but the leg F of the conductor segment CS is not inserted into the inner holding part 234 into which the leg F of the connection segment DS is inserted. Multiple conductor segments CS are arranged in a ring shape around the jig 23 so as to surround the intermediate assembly 12.

Next, the jig unit 2A is transported downstream in the transport direction by the conveyor 30, and the jig 23 at position U is transported to position V and stopped. After the jig 23 is stopped at position V, the working device 5 is driven in the same manner as in the first embodiment to cause the jig 23 to perform an assembly operation, completing the assembly 10A. The assembly 10A has two radial layers (two rows) of annularly arranged legs F on the outside of the intermediate assembly 12, with radially inner 1-2 layers of coils and outer 3-4 layers of coils. The second and third layers of coils contain legs F of the connection segments DS. The assembly 10A has a structure in which the legs F of the conductor segments CS are arranged in four radial layers as a whole.

In this way, the manufacturing apparatus 1A can relatively easily obtain assemblies with different structures by changing the jig unit 2 (adding the jig 24) and changing the layout of the work devices 4 to 6 in the manufacturing apparatus 1. Note that in this embodiment, the connection segment DS is supplied to the jig 24 and then the intermediate assembly 11 is transferred thereto, but conversely, the connection segment DS may be supplied to the jig 24 and then the intermediate assembly 11 is transferred thereto.

In addition, in this embodiment, the procedure is such that the intermediate assembly 12 is transferred to the jig 23 and then the conductor segment CS is supplied, but conversely, the intermediate assembly 12 may be transferred after the conductor segment CS is supplied to the jig 23.

Third Embodiment
The manufacturing apparatus 1 can obtain further different assemblies by changing the jig unit 2 and changing the layout of the working devices 4 to 6. Below, examples of the configuration of the jig unit and examples of the structure of an assembly obtained from the jig unit will be described.

17 includes jig 22, jig 23A, and jig 23B. Jig 23A and jig 23B each have the same configuration as jig 23 of the first embodiment, and include inner jigs 231A and 231B corresponding to inner jig 231, and outer jigs 232A and 232B corresponding to outer jig 232.

A six-layered assembly can be obtained by using jig unit 2B. In general, an intermediate assembly similar to intermediate assembly 11 of the first embodiment can be obtained by using jig 22, and this intermediate assembly can be transferred to jig 23A, and conductor segments CS can be supplied to jig 23A for assembly to obtain a four-layered intermediate assembly similar to final assembly 10 of the first embodiment. This intermediate assembly can be transferred to jig 23B, and conductor segments CS can be supplied to jig 23B for assembly to obtain a six-layered final assembly.

17 includes jig 22 and jigs 23A to 23C. Each of jigs 23A to 23C has the same configuration as jig 23 in the first embodiment, and includes inner jigs 231A, 231B, and 231C corresponding to inner jig 231, and outer jigs 232A, 232B, and 232C corresponding to outer jig 232.

An eight-layered assembly can be obtained by using the jig unit 2C. In general, an intermediate assembly similar to the intermediate assembly 11 of the first embodiment can be obtained by using the jig 22, and a four-layered intermediate assembly similar to the final assembly 10 of the first embodiment can be obtained by transferring this intermediate assembly to the jig 23A, supplying the conductor segments CS to the jig 23A, and performing an assembly operation. A six-layered intermediate assembly can be obtained by transferring this intermediate assembly to the jig 23B, supplying the conductor segments CS to the jig 23B, and performing an assembly operation. A final eight-layered assembly can be obtained by transferring this intermediate assembly to the jig 23C, supplying the conductor segments CS to the jig 23C, and performing an assembly operation.

17 includes jig 22, jig 24A, jig 23A, jig 24B, and jig 23B. Jig 23A and jig 23B each have the same configuration as jig 23 of the first embodiment, and include inner jigs 231A and 231B corresponding to inner jig 231, and outer jigs 232A and 232B corresponding to outer jig 232. Jig 24A and jig 24B each have the same configuration as jig 24 of the second embodiment, and include inner jigs 241A and 241B corresponding to inner jig 241, and outer jigs 242A and 242B corresponding to outer jig 242.

The jig unit 2D can provide an assembly with a six-layer structure incorporating interlayer connection conductor segments (connection segments DS) that connect between the coils of the 1-2 layer and the coils of the 3-4 layer, and between the coils of the 3-4 layer and the coils of the 5-6 layer. In general terms, the jig 22 can provide an intermediate assembly similar to the intermediate assembly 11 of the first embodiment. An intermediate assembly similar to the intermediate assembly 12 of the second embodiment can be obtained by supplying the connection segments DS to the jig 24A, transferring the intermediate assembly to the jig 24A, and then assembling the jig 24A. This intermediate assembly can be transferred to the jig 23A, and the conductor segments CS can be supplied to the jig 23A for assembly, resulting in an intermediate assembly similar to the final assembly 10A of the second embodiment.

By supplying the connection segments DS to the jig 24B and transferring the intermediate assembly to the jig 24B, and then assembling the jig 24B, an intermediate assembly in which the connection segments DS are arranged is obtained in the final assembly 10A of the second embodiment. This intermediate assembly is transferred to the jig 23B, and the conductor segments CS are further supplied to the jig 23B and assembled to obtain the final assembly. This final assembly has a six-layer structure, and the legs F of the connection segments DS are mixed in with the leg groups F of the second, third, fourth, and fifth layers. In other words, this final assembly is an assembly incorporating connection segments DS that connect between the coils of the 1-2 layer and the coils of the 3-4 layer, and between the coils of the 3-4 layer and the coils of the 5-6 layer.

Considering each of the above embodiments, the number of jigs constituting the jig unit, N, is N = (number of layers in the final assembly) / 2 when no connection segments for interlayer connection are incorporated. Also, the number of jigs when connection segments for interlayer connection are incorporated is N = (number of layers in the final assembly) - 1.

The above describes an embodiment of the invention, but the invention is not limited to the above embodiment, and various modifications and variations are possible within the scope of the gist of the invention.

Claims (9)

A manufacturing apparatus for manufacturing an assembly in which a plurality of conductor segments are arranged in an annular manner and which is to be attached to a stator core of a motor, comprising:
a jig unit including a plurality of jigs for assembling the assembly in stages and a support on which the plurality of jigs are mounted;
A conveying device that conveys the jig unit;
a plurality of working devices disposed along a transport path of the jig unit by the transport device,
The plurality of working devices are
At least one feeder device for feeding a plurality of conductor segments to a fixture to be worked on;
at least one driving device that causes the jig to perform an assembly operation, the jig being the work target to which the plurality of conductor segments are supplied by the at least one supplying device;
At least one transfer device that transfers the intermediate assembly assembled by the jig to a next stage jig,
Each of the plurality of conductor segments comprises:
a pair of legs to be inserted into different slots of the stator core; and a connection portion connecting ends of the pair of legs,
The assembling operation includes an operation of moving the legs of a plurality of conductor segments to align the pair of legs,
The plurality of jigs include
a leading fixture on which the first stage intermediate assembly is assembled;
At least one subsequent fixture;
The leading jig includes a first inner jig and a first outer jig surrounding the first inner jig, and the first inner jig and the first outer jig are provided so as to be capable of relative rotation around a first rotation center line;
the first inner jig has a plurality of first inner holding portions that are arranged in an annular shape around the first rotation center line and that hold one of the pair of legs;
the first outer jig has a plurality of first outer holding portions that are arranged in an annular shape around the first rotation center line and that hold the other of the pair of legs so as to be displaceable in a radial direction;
The at least one subsequent jig includes a second inner jig and a second outer jig surrounding the second inner jig, and the second inner jig and the second outer jig are provided so as to be capable of relative rotation around a second rotation center line;
the second inner jig has a plurality of second inner holding portions that are arranged in an annular shape around the second rotation center line and that hold the previous stage assembly and one of the pair of legs;
the second outer jig has a plurality of second outer holding portions that are arranged in an annular shape around the second rotation center line and that hold the other of the pair of legs so as to be displaceable in a radial direction;
the at least one driving device is a device for relatively rotating the first inner jig and the first outer jig, and relatively rotating the second inner jig and the second outer jig;
The at least one transfer device is a device that transfers the intermediate assembly to the second inner holding portions of the at least one subsequent jig of a next stage.
A manufacturing apparatus comprising: The manufacturing apparatus according to claim 1 ,
The conveying device is
Circulating the jig unit;
The transport path includes an outbound path along which work is performed by the plurality of work devices, and a return path.
A manufacturing apparatus comprising: The manufacturing apparatus according to claim 1 ,
One of the at least one subsequent jig is provided,
The leg portion is assembled in a radial direction to form a two-layer intermediate assembly by the leading jig,
The second inner jig of the subsequent jig holds the two-layer intermediate assembly,
The subsequent jig assembles the legs in the radial direction to form a four-layer final assembly.
A manufacturing apparatus comprising: The manufacturing apparatus according to claim 1 ,
the plurality of conductor segments include a plurality of connection segments for interlayer connection;
The at least one subsequent jig includes a jig in which the plurality of connection segments are held by the second inner jig and the second outer jig.
A manufacturing apparatus comprising: The manufacturing apparatus according to claim 1 ,
The at least one subsequent jig includes a first subsequent jig and a second subsequent jig;
the plurality of conductor segments include a plurality of connection segments for interlayer connection;
The leg portion is assembled in a radial direction to form a two-layer intermediate assembly by the leading jig,
The second inner fixture of the first subsequent fixture holds the two-layer intermediate assembly;
The second inner jig and the second outer jig of the first subsequent jig hold the plurality of connection segments;
an intermediate assembly having the plurality of connection segments in two radial layers of the leg portion is assembled by the first subsequent jig;
an intermediate assembly having the plurality of connection segments is held in the second inner fixture of the second subsequent fixture;
A final assembly having the plurality of connection segments and four layers of the legs in the radial direction is assembled by the second subsequent jig.
A manufacturing apparatus comprising: The manufacturing apparatus according to claim 1 ,
The plurality of jigs are mounted on the support in an assembly order of the assembly in a conveying direction of the jig unit.
A manufacturing apparatus comprising: The manufacturing apparatus according to claim 1 ,
The at least one supply device and the at least one drive device are each provided in plurality.
A manufacturing apparatus comprising: A method for manufacturing an assembly in which a plurality of conductor segments are arranged in an annular manner and which is attached to a stator core of a motor, comprising the steps of:
a conveying step of conveying the jig unit;
a working step of performing a work on the jig unit transported by the transporting step,
The jig unit includes a plurality of jigs for assembling the assembly in stages, and a support on which the plurality of jigs are mounted,
The working process includes:
a supply step of supplying a plurality of conductor segments to a jig to be worked on;
a driving step of causing the jig to perform an assembly operation, the jig having the plurality of conductor segments supplied thereto by the supplying step;
A transfer process of transferring the intermediate assembly assembled by the jig to a next-stage jig,
Each of the plurality of conductor segments comprises:
a pair of legs to be inserted into different slots of the stator core; and a connection portion connecting ends of the pair of legs,
The assembling operation includes an operation of moving the legs of a plurality of conductor segments to align the pair of legs,
The plurality of jigs include
a leading fixture on which the first stage intermediate assembly is assembled;
At least one subsequent fixture;
The leading jig includes a first inner jig and a first outer jig surrounding the first inner jig, and the first inner jig and the first outer jig are provided so as to be capable of relative rotation around a first rotation center line;
the first inner jig has a plurality of first inner holding portions that are arranged in an annular shape around the first rotation center line and that hold one of the pair of legs;
the first outer jig has a plurality of first outer holding portions that are arranged in an annular shape around the first rotation center line and that hold the other of the pair of legs so as to be displaceable in a radial direction;
The at least one subsequent jig includes a second inner jig and a second outer jig surrounding the second inner jig, and the second inner jig and the second outer jig are provided so as to be capable of relative rotation around a second rotation center line;
the second inner jig has a plurality of second inner holding portions that are arranged in an annular shape around the second rotation center line and that hold the previous stage assembly and one of the pair of legs;
the second outer jig has a plurality of second outer holding portions that are arranged in an annular shape around the second rotation center line and that hold the other of the pair of legs so as to be displaceable in a radial direction;
In the driving step, the first inner jig and the first outer jig are rotated relative to each other, or the second inner jig and the second outer jig are rotated relative to each other,
In the transfer step, the intermediate assembly is transferred to the second inner holding portions of the at least one subsequent jig of a next stage.
A manufacturing method comprising the steps of: The method according to claim 8 , further comprising the steps of:
In the conveying step, the jig unit is conveyed cyclically in an outward direction and a return direction,
The working process is performed on the jig unit transported along the outgoing path.
A manufacturing method comprising the steps of: