Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02670849 2009-06-30
STATOR MANUFACTURING APPARATUS
BACKGROUND OF THE INVENTION
Field of the Invention:
The present invention relates to a stator manufacturing
apparatus for joining a plurality of separate cores, each
carrying a coil wound thereon, into an annular stator.
Description of the Related Art:
Heretofore, there has been known a stator for electric
rotary machines, which comprises a plurality of
interconnected separate cores. Each of the separate cores
comprises an arcuate yoke, a pole extending radially inward
from the yoke, and a coil wound around the pole.
The yoke for each of the separate cores has a recess
defined in a portion thereof, and a tooth provided on
another portion thereof. The recess of the yoke of one of
the separate cores receives therein the tooth of the yoke of
an adjacent right-hand separate core, and also receives the
tooth of the yoke of one of the separate cores that is
fitted into the recess of the yoke of an adjacent left-hand
separate core. The yokes are thus interconnected by an
interfitting engagement of recesses and teeth, thereby
combining the separate cores into an annular stator.
For the purpose of improving performance of electric
rotary machines having such a stator, attempts have been
made in the art to increase the number of windings of the
coil on each separate core, so as to increase the space
factor of slots between the poles. For example, Japanese
Laid-Open Patent Publication No. 11-341748 discloses a
stator assembling method, whereby the coil wound around a
- 1 -
CA 02670849 2009-06-30
pole is compressed to reduce the occupied volume of the coil
and thereby increase the space factor.
Specifically, a winding is wound a plurality of times
around the pole to form a coil, which is greater in size
than the coil storage space that accommodates the coil. In
this manner, a plurality of separate cores are produced.
Then, the separate cores are arranged in an annular pattern
with insulators inserted between adjacent coils of the
separate cores.
The annularly arranged separate cores are then
compressed and displaced radially inward. The coils of
adjacent separate cores, with the insulators interposed
therebetween, are pressed together. Also, windings that are
positioned outside of the coil storage spaces are pressed
into the coil storage spaces.
With the windings pressed into the coil storage spaces,
the separate cores are joined together into an annular
stator.
Therefore, it has been known in the art to arrange a
plurality of separate cores in an annular pattern, and
thereafter displace the separate cores simultaneously
radially inward to compress the coils. However, Japanese
Laid-Open Patent Publication No. 11-341748 discloses nothing
concerning structural apparatus details for carrying out the
above method.
SUMMARY OF THE INVENTION
It is a general object of the present invention to
provide a stator manufacturing apparatus, which is capable
of compressing coils into a given shape when separate cores
- 2 -
CA 02670849 2009-06-30
with the coils wound therearound are joined together into an
annular stator.
A major object of the present invention is to provide a
stator manufacturing apparatus, which can increase the space
factor of windings.
Another object of the present invention is to provide a
stator manufacturing apparatus, which is capable of
assembling a stator efficiently.
According to an aspect of the present invention, there
is provided a stator manufacturing apparatus for joining a
plurality of separate cores, each carrying a coil wound
thereon, into an annular stator, comprising a base plate, a
plurality of radially inward displacing jigs disposed
radially in an annular pattern on the base plate and which
are radially displaceable toward and away from each other, a
plurality of core holding jigs disposed radially inward of
the radially inward displacing jigs and which are radially
displaceable toward and away from each other, a movable
plate disposed vertically upward of the base plate and which
is vertically movable toward and away from the base plate, a
cam disposed on the movable plate for displacing the
radially inward displacing jigs radially toward each other
when the movable plate is lowered, and a spacer holding jig
for holding spacers that are inserted between adjacent ones
of the separate cores, wherein when the cam is lowered in
unison with the movable plate, the cam presses the radially
inward displacing jigs to displace the radially inward
displacing jigs radially toward each other for thereby
compressing the coils radially, and wherein the core holding
jigs are displaced radially toward each other in unison with
- 3 -
CA 02670849 2009-06-30
the radially inward displacing jigs for thereby joining the
separate cores held by the core holding jigs into a stator.
With the above arrangement, the separate cores can be
joined annularly into a stator simply by lowering the cam,
so as to press the radially inward displacing jigs and the
core holding jigs radially inward, for thereby displacing
the radially inward displacing jigs and the core holding
jigs radially inward toward each other, thus reducing the
diameters of their respective annular patterns.
At the same time that the stator is produced, the side
surfaces of the coils are compressed. Since the stator can
be assembled and the coils can be compressed simply by
lowering the cam, the stator can be fabricated highly
efficiently.
Further, since the coils are compressed, the space
factor of the stator is increased.
The stator manufacturing apparatus according to the
present invention is thus capable of joining separate cores
into an annular stator while compressing the side surfaces
of the coils in a single process. Therefore, the stator can
be fabricated highly efficiently, and the space factor of
the stator is increased.
Preferably, the radially inward displacing jigs include
respective lower surface pressing members for pressing
respective lower surfaces of the coils, and the core holding
jigs include respective upper surface pressing members for
pressing respective upper surfaces of the coils. The
movable plate may include a pressing means, which is
vertically movably mounted thereon.
After the coils have been compressed radially, the
- 4 -
CA 02670849 2009-06-30
pressing means is lowered vertically downward from the
movable plate, thus causing the lower surface pressing
members and the upper surface pressing members to compress
the lower and upper surfaces, respectively, of the coils.
Since not only the side surfaces of the coils, but also the
upper and lower surfaces of the coils can be compressed, the
efficiency with which the stator is fabricated, as well as
the space factor of the stator, is further increased.
The mechanism for compressing the side surfaces of the
coils and the mechanism for compressing the upper and lower
surfaces of the coils may be incorporated in one piece of
equipment. Therefore, equipment costs for the stator
manufacturing apparatus can be reduced, and the stator
manufacturing apparatus can be simplified in structure and
reduced in size.
Preferably, the core holding jigs include respective
core upper surface holders for holding respective upper
surfaces of the separate cores vertically downward, and the
radially inward displacing jigs include respective core
urging means for urging respective lower surfaces of the
separate cores vertically upward. The separate cores, which
are urged by the core urging means, are held against the
core upper surface holders, respectively.
With the above arrangement, the separate cores have
equal heights respectively, and hence the separate cores
within the produced stator also have heights that are equal
to each other. Therefore, connectors at the ends of the
coils, and silicone resin inlets on upper surfaces of the
separator cores, are positioned accurately.
The stator manufacturing apparatus may further include
- 5 -
CA 02670849 2009-06-30
a holder for holding the core holding jigs in an annular
pattern. The holder may be gripped by a gripping means to
make it highly easy to set the core holding jigs and the
separate cores on the radially inward displacing jigs.
The stator manufacturing apparatus may also include an
engaging member positioned centrally in the annular pattern
made up of the radially inward displacing jigs, and the
holder may include a columnar member positioned centrally in
the annular pattern made up of the core holding jigs. When
the engaging member engages within an insertion opening
defined in a lower end of the columnar member, the holder
becomes positioned and fixed, so as to bring the annular
pattern made up of the radially inward displacing jigs and
the annular pattern made up of the core holding jigs into
coaxial alignment with each other.
Since the center of the annular pattern made up of the
radially inward displacing jigs and the center of the
annular pattern made up of the core holding jigs are aligned
with each other, the core holding jigs are displaced
accurately toward the center while the radially inward
displacing jigs are displaced radially inward. Since the
separate cores are prevented from being shifted out of
position, the stator can be assembled with ease.
The stator manufacturing apparatus preferably includes
a spacer moving means for moving the spacer holding jig
vertically downward. The spacers provide clearances between
the adjacent coils when the stator is assembled. After the
coils have been compressed radially, the spacer moving means
moves the spacer holding jig vertically downward so as to
release the spacers from between the adjacent separate
- 6 -
CA 02670849 2009-06-30
cores. Clearances between the adjacent coils thus are
maintained, thereby preventing the adjacent coils from
becoming short-circuited.
The above and other objects, features, and advantages
of the present invention will become more apparent from the
following description when taken in conjunction with the
accompanying drawings in which a preferred embodiment of the
present invention is shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view, partially in cross
section, of a station including a stator manufacturing
apparatus according to an embodiment of the present
invention, the view showing a casing positioned below a
vertical moving device;
FIG. 2 is a front elevational view, partially in cross
section, of the station, the view showing radially inward
displacing jigs positioned below the vertical moving device;
FIG. 3 is a vertical cross-sectional view of a base
plate and radially inward displacing jigs of the stator
manufacturing apparatus;
FIG. 4 is a plan view showing a positional relationship
between a plurality of spacer holding jigs, a pressing
plate, and a fixing jig;
FIG. 5 is a cross-sectional view taken along line V-V
of FIG. 4;
FIG. 6 is a vertical cross-sectional view of a holder,
which holds a plurality of core holding jigs with separate
cores mounted thereon;
FIG. 7 is a plan view of the holder;
- 7 -
CA 02670849 2009-06-30
FIG. 8 is a vertical cross-sectional view showing a
holder, which is fitted over a protrusive cylindrical member
of a flange member;
FIG. 9 is a plan view of the station, showing the
holder positioned below the vertical moving device;
FIG. 10 is a vertical cross-sectional view of the
station, showing a movable plate that is lowered;
FIG. 11 is a vertical cross-sectional view of the
station, showing the manner in which the movable plate is
further lowered from the position shown in FIG. 10, so as to
displace the radially inward displacing jigs and the core
holding jigs;
FIG. 12 is a vertical cross-sectional view of the
holder, showing the core holding jigs that are displaced;
FIG. 13 is a plan view of the holder shown in FIG. 12;
and
FIG. 14 is a vertical cross-sectional view showing the
manner in which the stator and the holder are inserted into
the casing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A stator manufacturing apparatus according to a
preferred embodiment of the present invention will be
described in detail below with reference to the accompanying
drawings.
FIG. 1 is a front elevational view, partially in cross
section, of a station 12 including a stator manufacturing
apparatus 10 according to an embodiment of the present
invention. The station 12 doubles as a manufacturing
station for producing a stator, and an accommodating station
- 8 -
CA 02670849 2009-06-30
for placing the produced stator inside a casing 14.
Specifically, the station 12 includes a base 18 with a
pair of guide rails 16a, 16b mounted on an upper surface
thereof. The stator manufacturing apparatus 10 includes a
base plate 20 slidably mounted on the guide rails 16a, 16b.
The casing 14 is positioned on and fixed to a table 22,
which is slidably mounted on the guide rails 16a, 16b. The
base plate 20 and the table 22 are connected to each other
by a connector 24. The base plate 20 has a lower surface
coupled by a joint 26 to a first rod 30 of a working base
moving cylinder 28, which is mounted on a lower surface of
the base 18. When the first rod 30 is extended and
retracted, the base plate 20 is displaced along the guide
rails 16a, 16b in the directions indicated by the arrow X.
The table 22 also is displaced along the guide rails 16a,
16b in the directions indicated by the arrow X.
A first limit switch 32 and a second limit switch 34
are mounted on the base 18 respectively, at opposite left
and right ends of the guide rails 16a, 16b. When the first
rod 30 is fully extended, as shown in FIG. 1, the base plate
20 engages with the first limit switch 32 at the left end of
the guide rails 16a, 16b, and the table 22 with the casing
14 mounted thereon is positioned below a vertical moving
device 36. At this time, the station 12 serves as an
accommodating station.
When the first rod 30 is fully retracted, as shown in
FIG. 2, the table 22 engages with the second limit switch 34
at the right end of the guide rails 16a, 16b, and the base
plate 20 is positioned below the vertical moving device 36.
At this time, the station 12 serves as a manufacturing
- 9 -
CA 02670849 2009-06-30
station.
The vertical moving device 36 includes a movable plate
38 connected to a second rod 41 of a vertically moving
cylinder 40. With the casing 14 being in the position shown
in FIG. 1, the movable plate 38 is vertically movable toward
and away from the casing 14 when the second rod 41 is
extended and retracted. With the base plate 20 in the
position shown in FIG. 2, the movable plate 38 is vertically
movable toward and away from the base plate 20 when the
second rod 41 is extended and retracted.
The station 12, which serves as a manufacturing
station, includes the stator manufacturing apparatus 10
according to the present embodiment. The stator
manufacturing apparatus 10 comprises a plurality of radially
inward displacing jigs 42 displaceably mounted on the base
plate 20, a plurality of spacer holding jigs 46 for holding
spacers 44, which are made of an insulating material, a
plurality of core holding jigs 50 for holding respective
separate cores 48, and a holder 52 for holding the core
holding jigs 50. In FIG. 1, the spacer holding jigs 46 are
shown separately from the radially inward displacing jigs
42.
Each of the separate cores 48 comprises an arcuate
yoke, a pole extending radially inward from the yoke, and a
coil 54 wound around the pole. The structure of the
separate cores 48 is well known by those skilled in the art,
and will not be described in detail below.
The base plate 20 is substantially circular in shape.
As shown in FIG. 3, the base plate 20 includes a central
thin portion 56 and a thick portion 58 surrounding the
- 10 -
CA 02670849 2009-06-30
central thin portion 56. The central thin portion 56
includes a through hole 60 defined substantially centrally
therethrough.
A sleeve 62, which extends vertically through the base
18, has an annular flange 64 disposed on an upper end
thereof and projecting radially outward. A cylindrical
member 66 is inserted through the sleeve 62. A flange
member (engaging member) 70, having a protrusive cylindrical
member 68 and a disk 72, is fitted over the upper distal end
of the cylindrical member 66. A first helical spring 74 is
interposed between the disk 72 and the flange 64, and is
disposed around the cylindrical member 66. The flange
member 70, and hence the cylindrical member 66, are normally
urged resiliently so as to be moved vertically upward in
FIG. 3 by means of the first helical spring 74.
The sleeve 62 has an upper end portion thereof
surrounded by a fixing jig 76, which partially projects from
the base 18. The fixing jig 76 holds a bracket 80 that
supports a spacer moving cylinder 78, which acts as a spacer
moving means.
A coupling plate 84 is connected to a third rod 82 of
the spacer moving cylinder 78, and is slidably fitted over
the sleeve 62 for vertical movement therealong. The
coupling plate 84 includes an outer edge held slidably
against the bracket 80. When the third rod 82 is extended
and retracted, the coupling plate 84 is vertically displaced
along the sleeve 62 and the bracket 80.
A plurality of elongate rods 86 extend vertically and
have respective lower ends attached to the coupling plate
84. The rods 86 extend through respective through holes 88
- 11 -
CA 02670849 2009-06-30
defined in the fixing jig 76, and through a through hole 60
defined in the central thin portion 56 of the base plate 20,
to respective positions near the radially inward displacing
jigs 42.
The rods 86 have respective upper distal ends coupled
to a circular pressing plate 90. When the third rod 82 is
retracted, the circular pressing plate 90 is lowered to move
the spacer holding jigs 46 vertically downward.
The thick portion 58 of the base plate 20 has a step 92
defined in an upper surface thereof. On the step 92, a
sliding plate member 94 is disposed, having a low
coefficient of friction for assisting in displacing the
radially inward displacing jigs 42. An upstanding support
plate 96 is mounted on the upper end of the thick portion 58
radially outward of the sliding plate member 94.
Each of the radially inward displacing jigs 42 on the
sliding plate member 94 comprises a base 98, and a cam 100
that extends substantially vertically from the base 98. The
cam 100 is slightly narrower than the base 98. The base 98
includes a horizontally extending tie rod hole 102 defined
therein. A tie rod 104 is inserted through the tie rod hole
102. The tie rod 104 has an outer distal end retained by
the support plate 96, and an inner head engaged by a second
helical spring 108 that is seated on a wider step 106 in the
end of the tie rod hole 102, which is positioned remotely
from the support plate 96. The tie rod 104 is thus normally
urged resiliently so as to be moved radially inward by means
of the second helical spring 108. The base 98 supports a
coil lower surface pressing member 110, mounted vertically
thereon at a position facing an inner vertical wall of the
- 12 -
CA 02670849 2009-06-30
cam 100. The coil lower surface pressing member 110 serves
to press the lower surface of the coil 54 of a corresponding
separate core 48.
The cam 100 includes a finger 112 extending toward the
pressing plate 90 from an inner vertical wall thereof
substantially parallel to the tie rod 104. A core lower
surface pressing member 114 for pressing the lower surface
of a corresponding separate core 48 is attached to the
finger 112 by a connecting rod 116. The core lower surface
pressing member 114 is normally urged resiliently to move
vertically upward by a third helical spring (core urging
means) 118 disposed around the connecting rod 116.
The cam 100 has an outer wall surface including a first
tapered surface 120, which is slanted progressively downward
in a radially outward direction.
As shown in FIG. 4, the spacer holding jigs 46 are
arranged in an annular pattern and loosely held on the
pressing plate 90, such that the spacer holding jigs 46 are
displaceable in radial directions of the pressing plate 90.
To each of the spacer holding jigs 46, there are
connected two support members 122, which support respective
spacers 44, each in the form of a rectangular plate, in an
upright orientation. In other words, each of the spacer
holding jigs 46 holds two spacers 44. As shown in FIG. 5,
each of the support members 122 has an insertion slot 124
defined therein, with the corresponding spacer 44 being
removably inserted inside the insertion slot 124.
The support members 122 are loosely fastened by screws,
not shown, to shims 126, which are mounted on the lower
surface of the pressing plate 90. Therefore, the support
- 13 -
CA 02670849 2009-06-30
members 122 are swingable circumferentially along the
pressing plate 90.
As shown in FIGS. 6 and 7, the holder 52 holds the core
holding jigs 50 together collectively in an annular pattern.
In FIG. 7, for illustrative purposes, the spacers 44 are
shown as being interposed between adjacent coils 54.
Structural details of the holder 52 will be described
below with reference to FIG. 6. The holder 52 includes a
columnar member 134 having a large flange 130 and a small
flange 132 formed respectively on a lower end and an upper
end thereof. The columnar member 134 has a large-diameter
portion 136 and a small-diameter portion 138 located between
the large flange 130 and the small flange 132. The large-
diameter portion 136 is contiguous to the large flange 130,
and the small-diameter portion 138 is contiguous to the
small flange 132. The columnar member 134 includes a hollow
space, which extends from the large flange 130 to a
substantially central portion of the large-diameter portion
136, and another hollow space, which extends from the small
flange 132 to a substantially central portion of the small-
diameter portion 138. A first bearing 140 and a second
bearing 142 are fitted respectively into the hollow spaces.
A slide assistance member 144 having a low coefficient
of friction for assisting in displacing the core holding
jigs 50 is disposed on an upper surface of the large flange
130. A presser member 148 is coupled to an upper surface of
the large-diameter portion 136 by bolts 146. The core
holding jigs 50 are sandwiched slidably by the slide
assistance member 144 and the presser member 148.
The core holding jigs 50 have respective bolt insertion
- 14 -
CA 02670849 2009-06-30
holes 150 defined therethrough. The large-diameter portion
136 of the columnar member 134 includes internally threaded
holes 152 defined in a substantially central portion
thereof. Bolts 154, which are inserted through the
respective bolt insertion holes 150, have externally
threaded distal end portions 156 that are threaded in the
internally threaded holes 152, respectively.
The bolt insertion holes 150 include respective steps
158 on which ends of fourth helical springs 160 are seated,
whereas opposite ends of the fourth helical springs 160 are
held against an outer wall surface of the large-diameter
portion 136. The core holding jigs 50 normally are urged
resiliently by the fourth helical springs 160 so as to move
radially outward away from the columnar member 134.
The core holding jigs 50 have respective arms 162
pivotally mounted on upper portions thereof by respective
hinge mechanisms. Each of the arms 162 has a first coil
upper surface pressing member 164, formed on an inner
surface thereof, which faces a corresponding separate core
48, for pressing the upper surface of the coil 54 of the
separate core 48. The first coil upper surface pressing
member 164 is positioned on and fixed to the arm 162 by two
coupling pins 166, which are covered by a cover member 168.
If any clearance exists between the cover member 168 and the
arm 162, then when the cover member 168 is pressed toward
the upper surface of the arm 162, the coupling pin 166 is
displaced so as to project from the lower surface of the arm
162, thereby pushing the first coil upper surface pressing
member 164 away from the lower surface of the arm 162.
Each of the arms 162 includes a tooth 172 projecting
- 15 -
CA 02670849 2009-06-30
from the lower surface thereof, which is inserted into a
recess 170 defined in the yoke of the corresponding separate
core 48. As described later, when the tooth 172 is inserted
into the recess 170, the tooth 172 holds the upper surface
of the separate core 48 vertically downward. The tooth 172
thus serves as a core upper surface holder.
Each of the core holding jigs 50 has a cavity 174
defined in an upper surface thereof near the arm 162. As
shown in FIG. 7, each of the core holding jigs 50 also has a
key cavity 175 defined in a portion thereof where the spacer
44 is placed.
As shown in FIGS. 1 and 2, the vertical moving device
36 for vertically moving the holder 52 comprises a pair of
post members 176a, 176b vertically mounted on the base 18,
and a bridge member 178 that extends horizontally between
the post members 176a, 176b. The post members 176a, 176b
and the bridge member 178 jointly provide a gate-like
structure. The bridge member 178 supports the vertically
moving cylinder 40 thereon.
The movable plate 38 is supported on a pair of bearing
members 180a, 180b, which are slidably fitted over the
respective post members 176a, 176b. The second rod 41 of
the vertically moving cylinder 40 is inserted into a rod
bearing 182, which is mounted substantially centrally on the
movable plate 38. A washer 184 is fitted over the second
rod 41 for locking the second rod 41 and preventing removal
of the second rod 41 from the rod bearing 182.
Cams 186, which are the same in number as the radially
inward displacing jigs 42, hang from the lower surface of
the movable plate 38. The cams 186 have respective end
- 16 -
CA 02670849 2009-06-30
surfaces that face toward a chuck (gripping means) 188
mounted centrally on the lower surface of the movable plate
38. The end surfaces of the cams 186 include respective
second tapered surfaces 190, which are slanted progressively
downward in an outward radial direction.
A second coil upper surface pressing member 194 is
positioned by a guide pin 192 on the movable plate 38,
radially inward of each of the cams 186. The guide pin 192
is slidably movable with respect to the movable plate 38,
and has an upper end thereof retained in a retaining hole
195 defined in the movable plate 38. A fifth helical spring
198 is inserted into an insertion hole 196, which is defined
in the second coil upper surface pressing member 194 and the
movable plate 38. The second coil upper surface pressing
member 194 is normally urged resiliently, so as to be moved
vertically downward by the fifth helical spring 198. The
second coil upper surface pressing member 194 is vertically
displaceable along the guide pin 192 while the fifth helical
spring 198 is compressed and expanded.
Pressing cylinders (pressing means) 200 are supported
on the movable plate 38 and disposed between the second coil
upper surface pressing members 194 and the chuck 188. The
pressing cylinders 200 have respective fourth rods 202,
which are vertically movable, i.e., the fourth rods 202 can
be vertically extended and retracted.
The chuck 188 has a first arm 204 and a second arm 206,
which have respective horizontal hands for holding the lower
surface of the small flange 132 of the columnar member 134
of the holder 52. An engaging shaft 208, which is mounted
on and hangs from the movable plate 38, extends vertically
- 17 -
CA 02670849 2009-06-30
between the horizontal hands of the first arm 204 and the
second arm 206.
A coupling sleeve 210 is coupled to the engaging shaft
208. An engaging sleeve 212 is fitted movably over the
coupling sleeve 210 for vertical movement with respect to an
outer wall surface of the coupling sleeve 210. When the
engaging sleeve 212 is lowered, the lower distal end thereof
ultimately engages within the cavities 174 of the core
holding jigs 50.
The station 12 that incorporates the stator
manufacturing apparatus 10 according to the present
embodiment basically is constructed as described above.
Operations and advantages of the station 12 will be
described below.
The separate cores 48 are assembled into an annular
stator in the following manner. First, the separate cores
48, each comprising a coil 54 wound around a pole, are
mounted on the core holding jigs 50 (see FIG. 6).
Then, as shown in FIG. 8, the arms 162 are lowered to
insert the teeth 172 provided on lower surfaces of the arms
162 into corresponding recesses 170 provided in the yokes of
the separate cores 48. The first coil upper surface
pressing members 164 on the arms 162 are thus positioned
closely to or in abutment against the coils 54.
Then, the first bearing 140, which is fitted into the
corresponding hollow space in the columnar member 134 of the
holder 52, is fitted over the protrusive cylindrical member
68 of the flange 70, which is fitted over the upper distal
end of the cylindrical member 66. The first helical spring
74 is slightly compressed under the weight of the holder 52
- 18 -
CA 02670849 2009-06-30
and the separate cores 48. At this time, the base plate 20
is positioned in engagement with the first limit switch 32,
as shown in FIG. 1.
Then, the working base moving cylinder 28 is actuated
in order to retract the first rod 30 to the right, as shown
in FIG. 1. The base plate 20 and the table 22 are displaced
to the right along the guide rails 16a, 16b until the table
22 ultimately engages with the second limit switch 34,
whereupon the base plate 20 and the table 22 stop moving.
The holder 52 is thus positioned below the vertical moving
device 36, as shown in FIG. 9.
Then, the vertically moving cylinder 40 is actuated in
order to extend the second rod 41 vertically downward. As
shown in FIG. 10, the movable plate 38 is lowered so as to
insert the engaging shaft 208 into the second bearing 142,
in the corresponding hollow space in the columnar member 134
of the holder 52.
Continued descent of the movable plate 38 causes the
engaging shaft 208 to press the holder 52. The pressing
force with which the engaging shaft 208 presses the holder
52 is greater than the resilient force of the first helical
spring 74, such that the first helical spring 74 is
compressed and the cylindrical member 66 starts to be
lowered. As shown in FIG. 7, the spacers 44 are inserted
between the adjacent coils 54 of the separate cores 48.
Since the support members 122 are swingable along the
circumferential direction of the pressing plate 90, as the
cylindrical member 66 descends, the support members 122 are
swung until the spacers 44 reach respective appropriate
positions.
- 19 -
CA 02670849 2009-06-30
As shown in FIG. 10, the second coil upper surface
pressing members 194, which are coupled to the movable plate
38, press against upper surfaces of the arms 162, thereby
holding the upper surfaces of the separate cores 48. At
this time, the fifth helical springs 198 are compressed,
thus pushing the guide pins 192 out of the retaining holes
195.
The second tapered surfaces 190 of the cams 186 engage
with the first tapered surfaces 120 of the cams 100 of the
radially inward displacing jigs 42. The descending cams 186
apply pressing forces to the first tapered surfaces 120 of
the cams 100 via the second tapered surfaces 190 thereof.
As a result, as shown in FIG. 11, all of the radially inward
displacing jigs 42 begin to be displaced radially inward,
while being guided by the tie rods 104, thereby compressing
the second helical springs 108.
The core holding jigs 50 are pressed by the radially
inward displacing jigs 42. As a result, as shown in FIG.
12, the core holding jigs 50 start being displaced radially
inward while being guided by the bolts 154, thereby
compressing the fourth helical springs 160. The sliding
plate member 94 disposed beneath the bases 98 of the
radially inward displacing jigs 42, and the slide assistance
member 144 disposed on the upper surface of the large flange
130, allow the radially inward displacing jigs 42 and the
core holding jigs 50 to be smoothly displaced radially
inward.
At the same time, the spacers 44 engage within the
respective key cavities 175 (see FIG. 7) defined in the core
holding jigs 50, whereupon the spacers 44 are displaced in
- 20 -
CA 02670849 2009-06-30
unison with the core holding jigs 50, owing to the fact that
the spacer holding jigs 46 are displaceable in radial
directions of the pressing plate 90.
When the movable plate 38 is fully lowered, the first
helical spring 74, the second helical springs 108, the third
helical springs 118, the fourth helical springs 160, and the
fifth helical springs 198 are fully compressed. As shown in
FIGS. 11 and 12, at this time, the radially inward
displacing jigs 42 and the core holding jigs 50 are
displaced at a maximum stroke. As a result, as shown in
FIG. 13, the core holding jigs 50 are brought maximally
close to each other, thereby making up an annular assembly.
While the radially inward displacing jigs 42 and the
core holding jigs 50 are displaced, the holder 52 is
positioned by the protrusive cylindrical member 68, which is
fitted into the first bearing 140 in the columnar member
134, and by the engaging shaft 208 that is fitted in the
second bearing 142. Since the columnar member 134 is
positioned substantially centrally in the radial direction
of the holder 52, the radially inward displacing jigs 42 and
the core holding jigs 50, as well as the separate cores 48,
are displaced toward the center of the holder 52.
Inasmuch as the separate cores 48 are displaced at
substantially equal speeds toward the center of the
positioned holder 52, the separate cores 48 are prevented
from becoming shifted out of position. Consequently, the
core holding jigs 50 can be combined quickly into an annular
assembly.
The recesses 170 and the teeth 172 are disposed at
different positions on the yokes of the separate cores 48.
- 21 -
CA 02670849 2009-06-30
Since the core holding jigs 50 are placed together into the
annular assembly, the recess 170 in the yoke of one of the
separate cores 48 receives the tooth 172 on the yoke of an
adjacent right separate core 48, and the tooth 170 on the
yoke of the one adjacent separate core 48 is fitted into the
recess 172 in the yoke of an adjacent left separate core 48.
When the separate cores 48 are placed together by
interfitting engagement of the recesses 170 and the teeth
172, the separate cores 48 jointly make up an annular stator
300. The spacers 44, which are made of an insulating
material, prevent adjacent coils 54 from becoming short-
circuited.
At the same time, the coils 54 are compressed radially
inward as a result of being pressed by the radially inward
displacing jigs 42.
In the stator 300, the separate cores 48 have
respective heights which are equal to each other. This is
because when the stator 300 is assembled, the separate cores
48 have lower surfaces thereof pressed by the core lower
surface pressing members 114, which are resiliently urged by
the third helical springs 118, while the upper surfaces
thereof are held by the teeth 172 of the arms 162, which
engage within respective recesses 170 provided in the yokes.
Then, the pressing cylinders 200 are actuated to extend
the fourth rods 202 vertically downward (see FIG. 11). The
fourth rods 202 press the cover members 168, thereby
displacing the coupling pins 166 and the first coil upper
surface pressing members 164 toward upper surfaces of the
coils 54. Finally, the first coil upper surface pressing
members 164 apply pressing forces to the upper surfaces of
- 22 -
CA 02670849 2009-06-30
the coils 54.
Lower surfaces of the coils 54 are supported by the
coil lower surface pressing members 110. Therefore, when
pressing forces are applied to upper surfaces of the coils
54, the coils 54 are subjected to reactive forces from the
coil lower surface pressing members 110. Stated otherwise,
pressing forces are applied to lower surfaces of the coils
54 by the coil lower surface pressing members 110.
Consequently, after the coils 54 have been compressed
radially of the annular stator 300, the coils 54 are
compressed from lower and upper surfaces thereof as the
pressing cylinders 200 are actuated. The coils 54 thus
compressed increase the space factor inside the annular
stator 300.
According to the present embodiment, the coils 54 are
compressed and the stator 300 is assembled, simply by
setting the core holding jigs 50 with the separate cores 48
mounted thereon onto the holder 52, and then lowering the
movable plate 38 toward the holder 52, thereby causing the
cams 186 to displace the radially inward displacing jigs 42
and the core holding jigs.50. In other words, the stator
300 can be assembled highly efficiently.
Then, the first arm 204 and the second arm 206 of the
chuck 188 are displaced toward each other, thus causing the
horizontal hands thereof to hold the small flange 132 of the
holder 52. Thereafter, the vertically moving cylinder 40 is
actuated to retract the second rod 41 vertically upward.
The movable plate 38 is lifted to release the holder 52,
which holds the stator 300 away from the radially inward
displacing jigs 42, as shown in FIG. 2. At this time, the
- 23 -
CA 02670849 2009-06-30
first helical spring 74 and the second helical springs 108
are extended, so as to enable the cylindrical member 66 and
the radially inward displacing jigs 42 to return to their
original positions, under the resiliency of the first and
second helical springs 74, 108.
The spacers 44 are released from the insertion slots
124 of the support members 122, and are elevated in unison
with the stator 300 while being interposed between the
adjacent coils 54.
Since the lower distal end of the engaging sleeve 212
remains engaged in the cavities 174 in upper surfaces of the
core holding jigs 50, the fourth helical springs 160 remain
compressed, thereby holding the core holding jigs 50 closely
to each other. In other words, the stator 300 will not
become disintegrated.
Next, the working base moving cylinder 28 is actuated
to extend the second rod 41 to the left. The base plate 20
and the table 22 are displaced to the left along the guide
rails 16a, 16b until the base plate 20 engages with the
first limit switch 32, whereupon the base plate 20 and the
table 22 stop moving. At this time, the casing 14 is
positioned below the vertical moving device 36 (see FIG. 1).
Then, the vertically moving cylinder 40 is actuated
again to extend the second rod 41 vertically downward,
thereby lowering the movable plate 38. As a result, as
shown in FIG. 14, the stator 300 together with the holder 52
starts to be inserted into the casing 14. The stator 300
and the casing 14 jointly makeup an electric rotary machine
when the stator 300 is fully inserted.
Finally, the chuck 188 releases the small flange 132 of
- 24 -
CA 02670849 2009-06-30
the holder 52, and the movable plate 38 is elevated.
Thereafter, the arms 162 of the holder 52 are lifted, and
the holder 52 is pulled off. The holder 52 is released,
leaving only the stator 300 inside the casing 14.
According to the present embodiment, as described
above, the stator 300 can continuously be assembled and
inserted into the casing 14. Therefore, the stator 300 can
be manufactured highly efficiently.
The separate cores 48 have connectors at the ends of
the coils 54 and silicone resin inlets on upper surfaces
thereof. Since the separate cores 48 of the produced stator
300 have heights that are equal to each other, as described
above, the connectors are accurately positioned at the ends
of the coils 54, and the silicone resin inlets are
accurately positioned on the upper surfaces of the separate
cores 48.
In the illustrated embodiment, the spacers 44 are
lifted in unison with the stator 300, so as to become
released from the support members 122. However, the spacers
44 may be replaced with shims, which are mounted in a non-
removable manner on the support members 122, wherein the
adjacent coils 54 are spaced apart from each other by the
shims.
According to such a modification, after the stator 300
has been produced, the movable plate 38 is lifted in order
to release the cams 186 from the cams 100. The second
helical springs 108 are extended, thereby causing the
radially inward displacing jigs 42 to be retracted. As a
result, the adjacent coils 54 become connected slightly
loosely.
- 25 -
CA 02670849 2009-06-30
Then, the spacer moving cylinder 78 is actuated in
order to retract the third rod 82. The coupling plate 84,
the elongate rods 86, and the pressing plate 90 are lowered
vertically downward, together with the spacer holding jigs
46 and the shims. The shims thus are retracted from between
the adjacent coils 54.
Thereafter, the coils 54 are radially and vertically
compressed, and the stator 300 is assembled and inserted
into the casing 14, as described above.
In the illustrated embodiment, the key cavities 175 for
moving the spacers 44 are defined in the core holding jigs
50. However, alternatively, the key cavities 175 may also
be defined in the radially inward displacing jigs 42.
Although a certain preferred embodiment of the present
invention has been shown and described in detail, it should
be understood that various changes and modifications may be
made to the disclosed embodiment without departing from the
scope of the invention as set forth in the appended claims.
- 26 -
