This application claims priority to and the benefit of Korean Patent Application No. 10-2021-0157549 filed in the Korean Intellectual Property Office on Nov. 16, 2021, and Korean Patent Application No. 10-2021-0157550 filed in the Korean Intellectual Property Office on Nov. 16, 2021, the entire contents of which are incorporated herein by reference.
The present disclosure relates to a method of manufacturing a stator and a jig for manufacturing a stator, and more particularly, to a method of manufacturing a stator having a winding coil and a jig for manufacturing the stator.
A motor configured to convert electrical energy into kinetic energy includes a stator and a rotor. It is necessary to increase a space factor, which refers to a ratio of the volume occupied in a stator core by a coil, in order to improve the efficiency of the motor and reduce a loss of energy occurring on the coil wound around the stator.
However, in the related art, the increase in space factor of a slot causes problems that the coil cannot be properly inserted into the slot or damaged, the performance of the motor deteriorates due to the damage to the coil, or the safety is degraded.
In addition, in the case of a 3-phase motor in the related art, the coil supplied with a particular phase current (e.g., a U-phase current) among the currents with three phases is positioned further inward in the slot of the stator coil than the coil supplied with a current with another phase (e.g., a V-phase current or a W-phase current). For this reason, there is also a problem in that the physical properties of the coils are changed depending on the phases, which degrades the performance of the motor.
The present disclosure has been made in an effort to minimize damage to a coil during a process of inserting the coil into a slot of a stator core.
The present disclosure has also been made in an effort to minimize a deviation in physical properties of a coil that occurs depending on phases of provided currents.
An exemplary embodiment of the present disclosure provides a method of manufacturing a stator, the method including: a preparation step of preparing a coil material and a stator core having a plurality of slots arranged in a circumferential direction C; a winding step of manufacturing a winding coil by winding the coil material; and an insertion step of positioning the winding coil in upper regions of at least some of the plurality of slots and then dropping the winding coil into the at least some of the plurality of slots.
In the insertion step, the winding coil may be dropped into the slot by gravity.
A through-hole G may be defined in a central region of the stator core, the plurality of slots may communicate with the through-hole G, and in the insertion step, the winding coil may be positioned in the through-hole G, and then the winding coil may be dropped into the at least some of the plurality of slots.
In the insertion step, the plurality of slots of the stator core may be disposed in a vertical direction, and the winding coil may be moved in a horizontal direction so as to be positioned in the through-hole G.
In the preparation step, the coil material may be prepared to include a first material, and a second material formed separately from the first material, and in the winding step, the winding coil may include a first bundle formed by winding the first material, and a second bundle provided by winding the second material.
In the winding step, the winding coil may include first and second bundles formed by winding the coil material, and the first and second bundles may be integrated by being connected to each other.
In the winding step, the first bundle having a first hole H1 may be formed by winding one end of the first material in a first direction, and the second bundle having a second hole H2 may be formed by winding one end of the second material in a second direction.
In the winding step, the first bundle having a first hole H1 may be formed by winding one end of the coil material in a first direction, and then the second bundle having a second hole H2 may be formed by winding one end of the coil material in a second direction.
In the winding step, the first and second bundles may be spaced apart from each other in a direction in which an imaginary plane extends, the imaginary plane being formed perpendicular to a direction in which the first and second holes H1 and H2 are formed through the first and second bundles.
In the winding step, the first and second bundles may be spaced apart from each other in a direction in which the first and second holes H1 and H2 are formed through the first and second bundles.
In the winding step, the first bundle having a first hole H1 and the second bundle having a second hole H2 may be formed by winding one end and the other end of the coil material in first and second directions, respectively, that are opposite to each other.
Another exemplary embodiment of the present disclosure provides a jig for manufacturing a stator, which is configured to transfer a winding coil and drop the winding coil into a stator core, the jig including: a first region; and a second region coupled to one side of the first region, in which the first region has a first recessed portion recessed upward, and the second region has a second recessed portion recessed upward.
The first and second regions may respectively include: upper portions disposed at upper sides of the first and second regions, respectively; and lower portions disposed at lower sides of the first and second regions and connected to the upper portions, respectively. The first recessed portion may be disposed in a lower surface of the lower portion of the first region, and the second recessed portion may be disposed in a lower surface of the lower portion of the second region.
The first recessed portion may extend to two opposite surfaces of the lower portion of the first region, and the second recessed portion may extend to two opposite surfaces of the lower portion of the second region.
The jig may further include: a third region coupled to one side of the second region; and a fourth region coupled to one side of the third region, the third region may have a third recessed portion recessed upward, and the fourth region may have a fourth recessed portion recessed upward.
The first to fourth regions may be configured to be assembled to one another.
The first to fourth regions may be integrated with each other.
A width of the upper portion may be larger than a width of the lower portion.
The first recessed portion may extend to the upper portion of the first region, and the second recessed portion may extend to the upper portion of the second region.
The jig may have a shape of fan ribs in which a direction in which the first region extends and a direction in which the second region extends define a predetermined angle therebetween, and a direction in which the third region extends and a direction in which the fourth region extends define a predetermined angle therebetween.
The direction in which the second region extends and the direction in which the third region extends may be parallel to each other.
According to the present disclosure, it is possible to minimize damage to the coil during the process of inserting the coil into the slot of the stator core.
In addition, according to the present disclosure, it is possible to minimize a deviation in physical properties of the coil that occurs depending on the phases of provided currents.
Hereinafter, a method of manufacturing a stator and a jig for manufacturing a stator according to the present disclosure will be described with reference to the drawings.
Referring to
In addition, the method of manufacturing a stator may further include an insertion step of positioning the winding coil 300 in upper regions of at least some of the plurality of slots S provided in the stator core 100 and then dropping the winding coil 300 into the slots S.
More specifically, in the insertion step, the winding coil 300 may be dropped in a direction perpendicular to the ground surface and dropped into the slots S by gravity. That is, according to the present disclosure, in the insertion step, the winding coil 300 may be inserted into the slots S without receiving separate external power. Therefore, according to the present disclosure, it is possible to prevent the winding coil 300 from being damaged during the process of inserting the winding coil 300 into the slots S of the stator core 100.
More specifically, a through-hole G may be provided in a central region of the stator core 100, and the plurality of slots S may communicate with the through-hole G. In this case, in the insertion step of the method of manufacturing a stator according to the present disclosure, the winding coil 300 may be positioned in the through-hole G, and then the winding coil 300 may be dropped into the slots S. That is, referring to
More particularly, in the insertion step, the jig 400 and the winding coil 300 may move in parallel with the ground surface. To this end, as illustrated in
Meanwhile, referring to
More specifically, according to the first example of the present disclosure, in the winding step, the first bundle 310 having a first hole H1 may be made by winding one end of the first material 210 in a first direction D1 (e.g., clockwise), and the second bundle 320 having a second hole H2 may be made by winding one end of the second material 220 in a second direction D2 (e.g., counterclockwise).
In contrast, referring to
In this case, referring to
More specifically, referring to
In this case, as illustrated in
In contrast, as illustrated in
In contrast, according to the fourth example of the present disclosure, the timings of forming the first and second bundles 310 and 320 formed in one coil material 200 may overlap each other in a time series manner, unlike the second and third examples of the present disclosure. For example, according to the fourth example of the present disclosure, in the winding step, the first bundle 310 having the first hole H1 and the second bundle 320 having the second hole H2 may be provided by winding one end and the other end of the coil material 200 in opposite directions, i.e., the first direction (e.g., clockwise) and the second direction (e.g., counterclockwise). In this case, the timing of winding one end of the coil material 200 and the timing of winding the other end of the coil material 200 may overlap each other in a time series manner.
Meanwhile, the method of manufacturing a stator according to the present disclosure may further include, after the insertion step, a forming step of forming and processing ends of the winding coil and a connection step of connecting the winding coils.
Referring to
More specifically, the jig 400 may include a first region 410, a second region 420 coupled to one side of the first region 410, a third region 430 coupled to one side of the second region 420, and a fourth region 440 coupled to one side of the third region 430.
In this case, according to the present disclosure, the first region 410 may have a first recessed portion 412 recessed upward, the second region 420 may have a second recessed portion 422 recessed upward, the third region 430 may have a third recessed portion 432 recessed upward, and the fourth region 440 may have a fourth recessed portion 442 recessed upward.
More specifically, the first to fourth regions 410, 420, 430, and 440 may each include an upper portion 402 provided at an upper side of each of the first to fourth regions 410, 420, 430, and 440, and a lower portion 404 provided at a lower side of each of the first to fourth regions 410, 420, 430, and 440 and connected to the upper portion 402. In this case, the first recessed portion 412 may be formed in a lower surface of the lower portion 404 of the first region 410, the second recessed portion 422 may be formed in a lower surface of the lower portion 404 of the second region 420, the third recessed portion 432 may be formed in a lower surface of the lower portion 404 of the third region 430, and the fourth recessed portion 442 may be formed in a lower surface of the lower portion 404 of the fourth region 440.
In addition, the first recessed portion 412 may extend to two opposite surfaces of the lower portion 404 of the first region 410, the second recessed portion 422 may extend to two opposite surfaces of the lower portion 404 of the second region 420, the third recessed portion 432 may extend to two opposite surfaces of the lower portion 404 of the third region 430, and the fourth recessed portion 442 may extend to two opposite surfaces of the lower portion 404 of the fourth region 440.
Meanwhile, referring to
In addition, the jig 400 according to the present disclosure may have a shape of fan ribs in which a direction in which the first region 410 extends and a direction in which the second region 420 extends define a predetermined angle therebetween, and a direction in which the third region 430 extends and a direction in which the fourth region 440 extends define a predetermined angle therebetween. In contrast, the direction in which the second region 420 extends and the direction in which the third region 430 extends may be parallel to each other. More particularly, the second region 420 and the third region 430 may extend downward. Therefore, the second recessed portion 422 and the third recessed portion 432 may extend upward in a direction perpendicular to the ground surface. The first recessed portion 412 and the fourth recessed portion 442 may extend upward while being inclined at a predetermined angle with respect to the ground surface.
Meanwhile, referring to
Hereinafter, a method of manufacturing a stator and a coil winding jig according to another example of the present disclosure will be described with reference to
Referring to
In addition, the method of manufacturing a stator according to the present disclosure may further include an insertion step of inserting the winding coil 1300 manufactured in the winding step into a coil insertion jig 1600, and a dropping step of moving the coil insertion jig 1600 so that the winding coil 1300 is positioned in upper regions of at least some of the plurality of slots S and then dropping the winding coil 1300 into the slots S.
More specifically, in the dropping step, the winding coil 1300 may be dropped in a direction perpendicular to the ground surface and dropped into the slots S by gravity. That is, according to the present disclosure, in the dropping step, the winding coil 1300 may be inserted into the slots S without receiving separate external power. Therefore, according to the present disclosure, it is possible to prevent the winding coil 1300 from being damaged during the process of inserting the winding coil 1300 into the slots S of the stator core 1100.
More specifically, a through-hole G may be provided in a central region of the stator core 1100, and the plurality of slots S may communicate with the through-hole G. In this case, in the dropping step of the method of manufacturing a stator according to the present disclosure, the coil insertion jig 1600 may be moved so that the winding coil 1300 is positioned in the through-hole G, and then the winding coil 1300 may be dropped into the slots S. That is, referring to
More particularly, in the dropping step, the coil insertion jig 1600 and the winding coil 1300 may move in parallel with the ground surface. To this end, as illustrated in
Meanwhile, referring to
In this case, an interval between the second bundle 1320 and the third bundle 1330 may be larger than the interval between the plurality of winding regions 1302 in the second bundle 1320 and an interval between a plurality of winding regions 1302 in the third bundle 1330. In addition, an interval between the third bundle 1330 and the fourth bundle 1340 may be larger than the interval between the plurality of winding regions 1302 in the third bundle 1330 and an interval between a plurality of winding regions 1302 in the fourth bundle 1340.
According to the present disclosure, the state in which the bundles 1310, 1320, 1330, and 1340 of the winding coil 1300 manufactured by using the coil material are spaced apart from one another may be maintained. Therefore, it is possible to prevent the bundles 1310, 1320, 1330, and 1340 from being entangled during the process of inserting the winding coil 1300 into the slots S of the stator core 1100. Therefore, it is possible to minimize the occurrence of dead space in the slots S of the stator core 1100 that does not contribute to the performance. Therefore, it is possible to improve the space factor.
More specifically, according to the present disclosure, in the winding step, the coil material may be disposed on one surface of a coil winding jig 1500 having a shape extending in a longitudinal direction L of a shaft 1510, and then the coil winding jig 1500 may be rotated about the shaft 1510 as a rotation axis, such that the winding coil 1300 may be manufactured. Further, the first and second bundles 1310 and 1320 may be spaced apart from one another with protruding portions 1520 (see
Meanwhile, according to the present disclosure, in the winding step, a lower region of the winding coil may be formed after an upper region of the winding coil is formed. In addition, the first bundle 1310 may be formed after the second bundle 1320 is formed. The second bundle 1320 may be formed after the third bundle 1330 is formed. The third bundle 1330 may be formed after the fourth bundle 1340 is formed. Therefore, according to the present disclosure, the first bundle 1310 may be disposed closer to the top side than is the second bundle 1320. The second bundle 1320 may be disposed closer to the top side than is the third bundle 1330. The third bundle 1330 may be disposed closer to the top side than is the fourth bundle 1340.
Referring to
Referring to
Meanwhile, as illustrated in
In addition, referring to
Meanwhile, as illustrated in
According to the present disclosure, because the upper surface 1524 has the inclined section 1524a, the winding coil 1300 may easily slide along the inclined section 1524a when the winding coil 1300 is dropped from the coil winding jig 1500 so that the winding coil 1300 is inserted into the coil insertion jig 1600 in the insertion step. Therefore, the winding coil 1300 may be smoothly inserted into the coil insertion jig 1600. In contrast, according to the present disclosure, because the lower surface 1522 has the horizontal section 1522a, it is possible to effectively prevent the lower region (e.g., second bundle) of the winding coil 1300 from being moved upward toward the upper region (e.g., first bundle) of the winding coil 1300.
Referring to
According to the present disclosure, because the lateral surface 1526 has the curved surface section 1526a, it is possible to prevent the winding coil 1300 from being damaged by the protruding portion 1520 during the process in which the winding coil 1300 passes over the protruding portion 1520 in the insertion step.
The present disclosure has been described with reference to the limited embodiments and the drawings, but the present disclosure is not limited thereto. The present disclosure may be carried out in various forms by those skilled in the art, to which the present disclosure pertains, within the technical spirit of the present disclosure and the scope equivalent to the appended claims.
Number | Date | Country | Kind |
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10-2021-0157549 | Nov 2021 | KR | national |