JP7366818B2 - Segment coil manufacturing device and manufacturing method - Google Patents

Description

The present disclosure relates to a segment coil manufacturing device and manufacturing method that manufactures segment coils by forming bent portions on straight wire rods.

BACKGROUND ART Conventionally, a segment forming apparatus is known that uses a plurality of molds to form a wire into a coil shape (see, for example, Patent Document 1). This segment forming device includes a pair of coil guides that feed wire rods in the lateral direction, and a pair of shoulder bending dies that perform shoulder bending processing on the wire rods fed by the coil guides. Each coil guide descends in conjunction with a corresponding one of the pair of shoulder bending dies when shoulder bending of the wire is performed. Thereby, shoulder bending can be performed without interfering with the pair of shoulder bending dies and the pair of coil guides while feeding the wire from the lateral direction.

JP 2019-187113 Publication

In the segment forming apparatus described in Patent Document 1, after the shoulder bending process for one wire rod is completed, each coil guide rises together with the corresponding shoulder bending die and returns to the initial position, at which point the next lowered object A wire rod is laterally supplied (inserted) into a pair of coil guides. For this reason, the waiting time from the completion of forming one wire rod to the start of processing of the next wire rod becomes long, and the time required to manufacture the segment coil also becomes long.

Therefore, the main purpose of the present disclosure is to shorten the time required to manufacture segment coils.

A segment coil manufacturing apparatus according to the present disclosure is a segment coil manufacturing apparatus that manufactures a segment coil by forming a bent part on a straight wire, and includes a first mold including a first molding surface and a first mold having a first molding surface. a second mold including a second molding surface that can be moved toward and away from the first molding mold, and that forms the bent portion on the wire rod together with the first molding surface of the first molding mold; a wire rod accommodating portion capable of accommodating the wire rods in an overlapping state in a third direction orthogonal to both the first and second directions so as to extend in a second direction orthogonal to the first direction; It is capable of moving toward and away from the first mold together with the mold, and receives one of the wire rods from the wire rod accommodating portion when the second mold is in a retracted position separated from the first mold. At the same time, as the second mold approaches the first mold, the wire is held by the first molding surface of the first mold and the second molding surface of the second mold. The wire transfer section includes a wire transfer section that moves the wire rod so as to move the wire rod.

In the segment coil manufacturing apparatus of the present disclosure, the second mold is brought close to the first mold along the first direction, so that the first molding surface of the first molding die and the second molding surface of the second molding mold are A bent portion can be formed on a straight wire by the forming surface. Further, in the manufacturing apparatus of the present disclosure, the wire rod storage section stacks the plurality of wire rods in a third direction orthogonal to both the first and second directions so as to extend in a second direction orthogonal to the first direction. It can be accommodated in any condition. Furthermore, the wire transfer section is capable of moving toward and away from the first forming die together with the second forming die, and when the second forming die is in a retracted position separated from the first forming die, one wire is transferred from the wire rod storage section. Accepts wire rods. Then, as the second mold approaches the first mold, the wire rod transfer section transfers the one wire between the first molding surface of the first molding mold and the second molding surface of the second molding mold. Move it so that it is held. As a result, when the second forming die separates from the first forming die and returns to the retracted position after processing of one wire rod is completed, the next wire to be processed is received from the wire rod storage section into the wire transfer section. passed on. Therefore, after the second forming mold returns to the retracted position, it is possible to immediately start processing the next wire rod, so that processing of the next wire rod can be started only after forming of one wire rod is completed. This can shorten the waiting time. As a result, according to the manufacturing apparatus of the present disclosure, it is possible to shorten the time required to manufacture the segment coil. In addition, since the wire rod accommodating section is capable of accommodating a plurality of wire rods, a large number of segment coils can be continuously manufactured by appropriately replenishing the wire rods in the wire rod accommodating section.

FIG. 1 is a perspective view showing a segment coil manufacturing apparatus of the present disclosure. FIG. 2 is a front view showing a segment coil manufactured by the segment coil manufacturing apparatus of the present disclosure. FIG. 2 is a plan view showing a segment coil manufactured by the segment coil manufacturing apparatus of the present disclosure. FIG. 1 is a side view showing a segment coil manufacturing apparatus of the present disclosure. FIG. 1 is a plan view showing a segment coil manufacturing apparatus of the present disclosure. It is a top view which shows the 2nd shaping|molding die included in the manufacturing apparatus of the segment coil of this indication. FIG. 3 is a front view showing a second mold included in the segment coil manufacturing apparatus of the present disclosure. FIG. 3 is a side view for explaining a procedure for manufacturing a segment coil using the segment coil manufacturing apparatus of the present disclosure. FIG. 2 is a plan view for explaining a procedure for manufacturing a segment coil using the segment coil manufacturing apparatus of the present disclosure. FIG. 2 is a plan view for explaining a procedure for manufacturing a segment coil using the segment coil manufacturing apparatus of the present disclosure. FIG. 3 is a side view for explaining a procedure for manufacturing a segment coil using the segment coil manufacturing apparatus of the present disclosure. It is a perspective view for explaining the manufacturing procedure of a segment coil by the segment coil manufacturing device of this indication.

Next, embodiments for carrying out the invention of the present disclosure will be described with reference to the drawings.

FIG. 1 is a perspective view showing a segment coil forming machine 10 that is a segment coil manufacturing apparatus of the present disclosure. The segment coil forming machine 10 shown in the figure is used to manufacture the segment coil 50 shown in FIGS. 2 and 3. The segment coil 50 forms a stator coil included in a stator (not shown) of a three-phase AC motor used as a driving source and/or generator of an electric vehicle or a hybrid vehicle. Further, the stator of the three-phase AC motor includes a stator core having a plurality of slots formed at intervals in the circumferential direction so as to extend in the radial direction.

As shown in FIGS. 2 and 3, the segment coil 50 includes two (pair of) leg portions 51 and 52 that extend linearly, and a crossover portion 53 that connects the two leg portions 51 and 52. , a convex portion 54 formed on the connecting wire portion 53 and a crank portion 55. In this embodiment, the crossover wire portion 53 of the segment coil 50 is formed to extend in a substantially arc shape when viewed from above (see FIG. 3). The legs 51 and 52 of the segment coil 50 are inserted into different slots of the stator core. Then, a plurality of (three) stator coils are formed by electrically joining (welding) the tips of the corresponding leg portions 51 and 52 of the plurality of segment coils 50 assembled to the stator core.

In the present embodiment, the segment coil 50 is a rectangular wire (see FIG. 1, conductive material such as copper wire, etc.), which is a wire rod with a rectangular cross section on the surface of which an insulating coating made of e.g. enamel resin is formed, into segments. It is formed by bending it into a substantially U-shape using a coil forming machine 10. As shown in FIGS. 2 and 3, the segment coil 50 includes a plurality of edgewise bent portions (first bent portions) e1, e2, which are bent in the edgewise direction (first bending direction) by the segment coil forming machine 10. e3, e4, e5, and e6, and a plurality of flatwise bent portions (second bent portions) f1 and f2 bent in the flatwise direction (second bending direction) by the segment coil forming machine 10.

The edgewise direction is a direction substantially perpendicular to the short side of the cross section of the flat wire FW, and the flatwise direction is a direction substantially perpendicular to the long side of the cross section of the flat wire FW. As shown in FIGS. 2 and 3, the convex portion 54 of the crossover wire portion 53 is formed by the edgewise bent portions e1, e2, e3, and e4. Further, a crank portion 55 of the crossover portion 53 is formed by the flatwise bent portions f1 and f2. Further, the edgewise bent portion e5 forms a shoulder portion that connects one leg portion 51 and the crossover wire portion 53, and the edgewise bent portion e6 forms a shoulder portion that connects the other leg portion 52 and the crossover wire portion 53. form.

As shown in FIGS. 1, 4, and 5, the segment coil forming machine 10 includes a first forming die 11 and a second forming die 12 that are arranged to face each other, and a pair of forming rollers as wire bending members. 13, a wire accommodating section 14 capable of accommodating a plurality of rectangular wires FW to be formed, and a control device 15 having a computer including a CPU, ROM, RAM, etc., various drive circuits, etc. (none of which are shown).

The first mold 11 is supported movably in the z-axis direction (third direction) in the figure, that is, in the vertical direction (in this embodiment, the vertical direction) by a base part (not shown) installed at the installation location of the segment coil molding machine 10. It is a movable type. The first mold 11 is moved up and down along the z-axis direction by a first actuator (not shown) that includes, for example, a fluid pressure cylinder or an electric motor, which is controlled by the control device 15 .

Further, as shown in FIG. 4, the first mold 11 has a first edgewise molding surface (third molding surface) 11e for molding edgewise bent parts e1, e2, e3, and e4 on the rectangular wire FW. , a first flatwise forming surface (first forming surface) 11f for forming flatwise bent portions f1, f2 on the flat wire FW. The first edgewise forming surface 11e is a concave surface that extends in the y-axis direction (first direction) in the figure and has a tolerance with the xz plane, and includes a plurality of curved surfaces corresponding to the edgewise bent portions e1, e2, e3, and e4. . The first flatwise molding surface 11f is the lower side (other side) of the first edgewise molding surface 11e in the z-axis direction, extends along the z-axis direction, and extends from both ends in the x-axis direction (second direction) in the figure. It is a convex surface that approaches the second mold 12 toward the center. Furthermore, the first flatwise molding surface 11f includes a curved surface corresponding to the flatwise bent portions f1 and f2.

The second mold 12 is a movable mold supported by the base portion so as to be movable forward and backward along the y-axis direction. The second mold 12 is moved toward or away from the first mold 11 along the y-axis direction by a second actuator (not shown) including, for example, a fluid pressure cylinder or an electric motor, which is controlled by the control device 15. can be moved forward and backward. In addition, as shown in FIGS. 6 and 7, the second mold 12 also has a second edgewise molding surface ( A fourth forming surface) 12e, and a second flatwise forming surface (second forming surface) 12f for forming flatwise bent portions f1 and f2 on the flat wire FW.

The second edgewise forming surface 12e is a convex surface that extends in the y-axis direction and has a tolerance with the xz plane, and includes a plurality of curved surfaces corresponding to the edgewise bent portions e1, e2, e3, e4, e5, and e6. The second flat-wise molding surface 12f extends along the z-axis direction on the upper side (one side) of the second edgewise molding surface 12e in the z-axis direction, and the first molding surface extends from both ends in the x-axis direction toward the center. It is a concave surface spaced apart from 11. Further, the second flatwise molding surface 12f includes a curved surface corresponding to the flatwise bent portions f1 and f2.

Furthermore, the second mold 12 includes a pair (two) of wire transfer parts 121 extending from the main body 120 of the second mold 12 toward the first mold 11 side. As shown in FIGS. 6 and 7, the pair of wire transfer parts 121 extend in the y-axis direction on both sides of the second edgewise forming surface 12e and the second flatwise forming surface 12f in the x-axis direction. Further, a receiving portion 122 is formed at the tip of each wire rod transfer portion 121, and the upper surface of each wire rod transfer portion 121 in the drawing is a flat wire support surface 125.

The receiving part 122 of each wire rod transfer part 121 is a notch part opened on the tip side (first mold 11 side) so as to be able to receive one flat wire FW, and has a support surface 123 and a pressing surface 124. including. The support surface 123 is a flat surface extending parallel to the xy plane below the wire support surface 125 in the z-axis direction. The length of the support surface 123 in the y-axis direction is determined to be sufficiently longer than the length (width) w in the direction along the short side of the flat wire FW, as shown in FIG. 4 and the like. Further, as shown in FIG. 7, the support surface 123 is formed on each wire rod transfer portion 121 so as to be located above the upper end of the second edgewise forming surface 12e of the second mold 12 in the z-axis direction. There is.

The pressing surface 124 is a flat surface that extends from the base end side of the support surface 123 upward in the z-axis direction in parallel to the xz plane. As shown in FIG. 4, the length (height) of the pressing surface 124 in the z-axis direction, that is, the distance L between the supporting surface 123 of the receiving part 122 and the wire supporting surface 125, is It is determined to be shorter than the length (height) h in the direction. In this embodiment, the difference (h-L) between the length h and the distance L approximately corresponds to the chamfered length of the corner of the flat wire FW.

The pair of forming rollers 13 as wire bending members form edgewise bent portions e5 and e6 on the flat wire FW together with the second edgewise forming surface 12e of the second forming die 12. One forming roller 13 is arranged on each side (outside) of the first forming die 11 in the x-axis direction. Each forming roller 13 is rotatably supported by a roller support member (not shown) that is supported by the base portion so as to be movable forward and backward along the z-axis direction (third direction). Each roller support member is raised and lowered along the z-axis direction independently and integrally with the first mold 11 by a third actuator (not shown) including, for example, a fluid pressure cylinder or an electric motor, which is controlled by the control device 15. I am made to do so. Further, as shown in FIG. 5, the rotating shafts of the pair of forming rollers 13 (see the dashed line in FIG. 5) are spaced apart from each other as they go from the first forming mold 11 side to the second forming mold 12 side. It is tilted with respect to the y-axis.

As shown in FIGS. 1 and 5, the wire storage section 14 includes a plurality of sets (for example, four sets in this embodiment) of a first support member 141 and a second support member 142 facing each other at intervals in the y-axis direction. include. The plurality of sets of first and second support members 141 and 142 are each fixed (positioned) to the base portion so as to be located above the second mold 12 in the z-axis direction. In the present embodiment, a pair of first and second support members 141 and 142 are arranged above each wire transfer section 121 of the second mold 12, and the second edgewise molding surface 12e of the second mold 12 and Two sets of first and second support members 141 and 142 are arranged above the second flatwise molding surface 12f.

As shown in FIG. 4, each first support member 141 has a support surface 141s extending parallel to the xz plane, and each second support member 142 also has a support surface 142s extending parallel to the xz plane. have Each first support member 141 and the corresponding second support member 142 are such that the second support member 142 is located on the first mold 11 side, and the support surfaces 141s and 142s are on the short side of the rectangular wire FW. They are positioned above the second mold 12 so as to face each other with a gap 143 in the y-axis direction which is determined to be slightly longer than the length w in the y-axis direction.

Further, each first support member 141 and the corresponding second support member 142 are connected to the first support member 141 when the second mold 12 is in the retracted position separated from the first mold 11 (see FIG. 4). The second mold 12 is arranged so that the support surface 141s of the member 141 is flush with the pressing surface 124 of each wire rod transfer section 121, or is located closer to the first mold 11 than the pressing surface 124 in the y-axis direction. positioned upwards. Thereby, the gap 143 between the support surfaces 141s and 142s is located above the receiving portion 122 of each wire transfer portion 121, that is, the support surface 123 in the z-axis direction when the second mold 12 is in the retracted position. Furthermore, between the lower surfaces of each of the first support members 141 and each of the second support members 142 in the drawing, and the wire rod support surfaces 125 of each wire transfer section 121 of the second mold 12 (and the upper surface of the main body 120), A gap g in the z-axis direction is formed. As shown in FIG. 4, the gap g is set to be slightly larger than the chamfered length of the corner of the flat wire FW (for example, about twice the chamfered length).

As shown in FIGS. 1 and 4, a plurality of rectangular wires FW are arranged to extend in the x-axis direction in the wire housing portion 14, that is, in the gap 143 in each pair of the first and second support members 141 and 142. are accommodated (inserted) in a stacked state in the z-axis direction. Further, when the second mold 12 is in the retracted position, only one flat wire FW is received in the receiving part 122 of each wire transfer part 121, as shown in FIG. It is supported by the first support member 141 and each second support member 142 from both sides in the y-axis direction. That is, when the second mold 12 is in the retracted position, the lower surface (the surface including the short side) of the one flat wire FW in the z-axis direction is supported from below by the support surface 123.

Next, a procedure for manufacturing the segment coil 50 using the segment coil forming machine 10 will be described with reference to FIGS. 4 and 8 to 12.

Prior to the start of manufacturing the segment coil 50 by the segment coil forming machine 10, the first mold 11 is moved to the initial position shown in FIG. 4, and the second mold 12 is moved to the retracted position shown in FIG. It will be done. In this state, the first flat-width molding surface 11f of the first molding die 11 and the second flat-width molding surface 12f of the second molding die 12 face each other. Furthermore, a plurality of rectangular wires FW are inserted (accommodated) in the gap 143 in each set of the first and second support members 141 and 142 in a state where they are overlapped in the z-axis direction. The lowest one of the rectangular wires FW inserted into each gap 143 falls into the receiving part 122 of each wire transfer part 121 due to gravity, and is supported by each support surface 123. Thereby, as shown in FIG. 4, preparation for forming the flat wire W is completed. In this embodiment, the insulating coating is removed from both ends of each flat wire FW so that the conductive material is exposed before the flat wire FW is inserted into each gap 143.

After the preparation for forming the rectangular wire W is completed, the control device 15 of the segment coil forming machine 10 causes the second forming die 12 including the pair of wire transfer parts 121 to approach the first forming die 11 along the y-axis direction. The second actuator corresponding to the second mold 12 is controlled as follows. As the second mold 12 approaches the first mold 11, as shown in FIG. 8 and FIG. It is pressed by the pressing surface 124 and moves toward the first mold 11 together with the pair of wire transfer parts 121. Furthermore, as the second mold 12 approaches the first mold 11, the wire support surface 125 of each wire transfer part 121 moves in the z-axis direction of the gap 143 between the corresponding first and second support members 141, 142. Close the opening on the lower side. As a result, the lowermost flat wire FW of the wire rod storage section 14 (inside each gap 143) is supported from below by the wire support surface 125 of each wire rod transfer section 121, and the flat wire FW is discharged from the wire rod storage section 14 ( falling) is regulated.

Furthermore, as the second molding die 12 approaches the first molding die 11, the pair of wire transfer parts 121 transfer the one rectangular wire FW to the first flat-width molding surface 11f of the first molding die 11. It is moved (carried) so as to be held by the second flatwise molding surface 12f of the second mold 12. Then, after the flat wire FW contacts both the first flat-width molding surface 11f and the second flat-width molding surface 12f, the control device 15 controls the second mold 12 to perform the first molding process until the second mold 12 reaches a predetermined position. The second actuator is controlled to stop the second mold 12 when it approaches the mold 11. As a result, the first flatwise forming surface 11f and the second flatwise forming surface 12f form the flatwise bent portions f1 and f2 on the straight flat wire FW, and the connecting wire portion 53 of the flat wire FW is formed. The corresponding parts are curved.

As described above, the first flatwise molding surface 11f is a convex surface that approaches the second molding die 12 from both ends in the x-axis direction toward the center, and the second flatwise molding surface 12f is a convex surface that approaches the second molding die 12 from both ends in the x-axis direction. It is a concave surface that is spaced apart from the first mold 11 toward the center. Furthermore, the pair of wire transfer parts 121 extend from the main body 120 of the second mold 12 so as to be located on both sides of the second flatwise molding surface 12f in the x-axis direction. Therefore, as the flatwise bent portions f1 and f2 are formed on one flat wire FW by the first and second flatwise forming surfaces 11f and 12f, as shown in FIG. can be separated from each wire transfer section 121.

After forming the flatwise bent portions f1 and f2, etc., the control device 15 controls the second actuator to move the second mold 12 slightly away from the first mold 11. Thereby, a minute gap is formed between the flat wire FW and the first and second flatwise molding surfaces 11f, 12f. Further, the control device 15 controls the first actuator to move the first mold 11 downward in the z-axis direction with respect to the second mold 12, as shown in FIG. As a result, edgewise bent portions e1, e2, e3, and e4 are formed on the rectangular wire FW by the first edgewise forming surface 11e of the first forming die 11 and the second edgewise forming surface 12e of the second forming die 12. Ru.

The control device 15 controls the first actuator to stop the first mold 11 when the first mold 11 has descended by a predetermined distance in the z-axis direction with respect to the second mold 12. Subsequently, the control device 15 causes the pair of forming rollers 13 to move in the z-axis direction relative to the first and second forming molds 11 and 12 while the rectangular wire FW is held in the first and second forming molds 12. The third actuator is controlled to move downward along the line by a predetermined distance. Thereby, each forming roller 13 has a portion of the rectangular wire FW held by the first and second forming molds 11 and 12 that protrudes from the first and second edgewise forming surfaces 11e and 12e on both sides in the x-axis direction. Both ends of the flat wire FW are pressed against the second edgewise molding surface 12e of the second mold 12 by the corresponding molding rollers 13. As a result, as shown by the two-dot chain line in FIG. 12, two linearly extending leg portions 51 and 52 are formed, and the manufacture of one segment coil 50 is completed.

After manufacturing one segment coil 50 is completed, the control device 15 controls the third actuator to raise the pair of forming rollers 13 to the initial position. Further, the control device 15 controls the first actuator to raise the first mold 11 to the initial position, and controls the second actuator to move the second mold 12 to the retracted position. As a result, the completed segment coil 50 falls from the first and second molds 11 and 12, and is recovered using a conveyor or the like as appropriate. When the second mold 12 returns to the retracted position, the gap 143 is unclosed by the wire support surface 125 of each wire transfer part 121, and the lowest of the rectangular wires FW inserted into each gap 143 is released. One of the wire rods on the side falls to the receiving part 122 of each wire transfer part 121 due to gravity and is supported by each support surface 123. This completes the preparation for forming the next flat wire W.

As described above, in the segment coil forming machine 10, the wire housing section 14 stores the plurality of rectangular wires FW so that they extend in the x-axis direction orthogonal to the y-axis direction, which is the moving direction of the second mold 12. They can be accommodated in a stacked state in the axial direction. In addition, each wire rod transfer section 121 can move toward and away from the first mold 11 together with the second mold 12, and when the second mold 12 is in a retracted position separated from the first mold 11, the wire rod One flat wire FW is received from the storage part 14. Then, as the second mold 12 approaches the first mold 11, each wire transfer section 121 transfers the one rectangular wire FW to the first flat-width molding surface 11f of the first mold 11 and the first flat-width molding surface 11f of the first mold 11. It is moved so that it is held by the second flatwise molding surface 12f of the second molding die 12.

As a result, when the second mold 12 separates from the first mold 11 and returns to the retracted position after the processing of one flat wire FW is completed, the next flat wire FW to be processed is placed in the wire rod storage section. 14 to each wire transfer section 121. Therefore, after the second mold 12 returns to the retracted position, it is possible to immediately start processing the next rectangular wire FW, so that after the molding of one rectangular wire FW is completed, the processing of the next rectangular wire FW is completed. The waiting time until processing of the line FW is started can be shortened. As a result, according to the segment coil forming machine 10, it is possible to shorten the time required to manufacture the segment coil 50.

In addition, since the wire storage section 14 can accommodate a plurality of rectangular wires FW, by appropriately replenishing the wire storage section 14 with rectangular wires FW, a large number of segment coils 50 can be connected in succession. can be manufactured. The timing for replenishing the wire rod accommodating portion 14 with the rectangular wire FW is preferably from the time when the second mold 12 starts moving from the retracted position toward the first mold 11 until it returns to the retracted position again. Further, the wire rod storage section 14 may be replenished with one flat wire FW, or a plurality of flat wires FW may be replenished into the wire rod storage section 14 at a time. Furthermore, the flat wire FW may be replenished from above the wire rod accommodating section 14 or from the side of the wire rod accommodating section 14 .

Furthermore, in the segment coil forming machine 10, the flat wires FW are accommodated in the wire housing section 14 in a state where they are stacked in the z-axis direction, that is, in the up-down direction (vertical direction). As a result, it becomes possible to quickly transfer the flat wire FW from the wire storage section 14 to the receiving section 122 of each wire rod transfer section 121 using gravity. It is possible to omit the actuator for receiving and receiving. However, the wire storage section 14 does not necessarily need to accommodate a plurality of rectangular wires FW in a vertically stacked state. That is, the wire storage section 14 may accommodate a plurality of flat wires FW in a diagonally stacked state with respect to the vertical direction, as long as gravity can be used to transfer the flat wires FW. .

Furthermore, in the segment coil forming machine 10 described above, the pair of wire transfer sections 121 are integrated with the second mold 12. Thereby, the actuator for conveying the wire from the wire storage part 14 to the processing position by the first and second flatwise forming surfaces 11f and 12f can be omitted. However, the pair of wire transfer parts 121 do not necessarily need to be integrated with the second mold 12. That is, a wire rod transfer member separate from the second mold 12 may be mechanically connected to the second mold 12, and a wire rod transfer member separate from the second mold 12 may be connected to the second actuator. The second mold 12 may be moved in synchronization with the second mold 12 by another actuator.

Further, in the segment coil forming machine 10, the wire rod storage section 14 is provided with a first support member 141 and a first support member 141, which face each other with a gap 143 in the y-axis direction and are positioned above the second mold 12 in the z-axis direction. 2 support members 142 are included. Further, the flat wire FW is accommodated in a gap 143 between each first support member 141 and the corresponding second support member 142 in the y-axis direction. Moreover, each wire transfer part 121 has a receiving part 122 located below the gap 143 between the corresponding first and second support members 141 and 142 when the second mold 12 is in the retracted position, and a second mold 12 is located on the side of the first mold 11 in the retracted position, and a wire rod supporting surface 125 that supports the flat wire FW accommodated in the wire rod accommodating portion 14 from below in the z-axis direction. This makes it possible to hold another flat wire FW in the wire storage section 14 while one flat wire FW is being processed. Note that the wire storage section 14 may include only one set of the first support member 141 and the second support member 142, as long as it is possible to stably support a plurality of flat wires FW.

Furthermore, in the segment coil forming machine 10, the receiving section 122 of each wire transfer section 121 has a support surface 123 that supports the lower surface of one flat wire FW in the z-axis direction, and a support surface 123 that supports the lower surface of one flat wire FW in the z-axis direction. and a pressing surface 124 that presses the first mold 11 toward the first mold 11 side. The distance L between the support surface 123 of the receiving part 122 and the wire support surface 125 is determined to be shorter than the length h along the long side of the flat wire FW, that is, the height (dimension) in the z-axis direction. ing. Thereby, it becomes possible to smoothly transfer the flat wires FW one by one from the wire storage section 14 to the receiving section 122 of each wire transfer section 121.

In the segment coil forming machine 10, the first mold 11 has a first edgewise molding surface extending in the y-axis direction toward the second molding mold 12 above the first flat-width molding surface 11f in the z-axis direction. 11e, and is movable in the z-axis direction with respect to the second mold 12. Furthermore, the second mold 12 includes a second edgewise molding surface 12e extending in the y-axis direction toward the first molding mold 11 below the second flatwise molding surface 12f in the z-axis direction. Further, the support surface 123 of the receiving section 122 of each wire rod transfer section 121 is located above the second edgewise forming surface 12e of the second forming mold 12 in the z-axis direction. As a result, by bringing the second mold 12 closer to the first mold 11 along the y-axis direction, the flat wire FW can be moved in the flatwise direction (y-axis direction) without contacting the second edgewise molding surface 12e. direction) with high precision.

As explained above, the segment coil manufacturing apparatus (10) of the present disclosure manufactures a segment coil (50) by forming bent parts (f1, f2) on a straight wire (FW). ), the first mold (11) including a first molding surface (11f) is capable of approaching and separating from the first mold (11) along a first direction (y), and a second mold (12) including a second molding surface (12f) that molds the bent portions (f1, f2) on the wire rod (FW) together with the first molding surface (11f) of the mold (11); a third direction perpendicular to both the first and second directions (x, y) such that the plurality of wire rods (FW) extend in a second direction (x) perpendicular to the first direction (y); (z), which can be accommodated in a stacked state, and which can be moved toward and away from the first mold (11) together with the second mold (12), and the second mold (12) receives one wire rod (FW) from the wire rod accommodating portion (14) when it is in a retracted position spaced apart from the first mold (11), and the second mold (12) approaches the first mold (11), the wire rod (FW) is moved between the first molding surface (11f) of the first mold (11) and the second mold (12). The second molding surface (12f) includes a wire transfer section (121) that is moved so as to be held by the second forming surface (12f).

In the segment coil manufacturing apparatus of the present disclosure, the second mold is brought close to the first mold along the first direction, so that the first molding surface of the first molding die and the second molding surface of the second molding mold are A bent portion can be formed in a straight wire by the forming surface. Further, in the manufacturing apparatus of the present disclosure, the wire rod storage section stacks the plurality of wire rods in a third direction orthogonal to both the first and second directions so as to extend in a second direction orthogonal to the first direction. It can be accommodated in any condition. Furthermore, the wire transfer section is capable of moving toward and away from the first forming die together with the second forming die, and when the second forming die is in a retracted position separated from the first forming die, one wire is transferred from the wire rod storage section. Accepts wire rods. Then, as the second mold approaches the first mold, the wire rod transfer section transfers the one wire between the first molding surface of the first molding mold and the second molding surface of the second molding mold. Move it so that it is held. As a result, when the second forming die separates from the first forming die and returns to the retracted position after processing of one wire rod is completed, the next wire to be processed is received from the wire rod storage section into the wire transfer section. passed on. Therefore, after the second forming mold returns to the retracted position, it is possible to immediately start processing the next wire rod, so that processing of the next wire rod can be started only after forming of one wire rod is completed. This can shorten the waiting time. As a result, according to the manufacturing apparatus of the present disclosure, it is possible to shorten the time required to manufacture the segment coil. In addition, since the wire rod accommodating section is capable of accommodating a plurality of wire rods, a large number of segment coils can be continuously manufactured by appropriately replenishing the wire rods in the wire rod accommodating section.

The first molding surface (11f) of the first molding mold (11) is a convex surface that approaches the second molding mold (12) from both ends toward the center in the second direction (x). The second molding surface (12f) of the second molding mold (12) may be a concave surface that is spaced apart from the first molding mold (11) from both ends toward the center in the second direction (x). The pair of wire transfer parts (121) may be extended from the second mold (12) so as to be located on both sides of the second molding surface (12f) in the second direction (x). Good too. Thereby, as the bent portion is formed on the wire by the first and second forming surfaces, it becomes possible to separate the wire from the wire transfer section. In addition, by integrating the pair of wire transfer parts with the second mold, it is possible to omit the actuator for conveying the wire from the wire storage part to the processing position by the first and second molding surfaces.

Furthermore, the third direction (z) may be an up-down direction. This makes it possible to quickly transfer the wire from the wire storage section to the wire transfer section using gravity, and it is possible to omit the actuator for transferring the wire from the wire storage section to the wire transfer section.

Further, the wire rod accommodating portion (121) is a first support member (141) that faces the first direction (y) with a gap (143) therebetween and is positioned above the second mold (12). and a second support member (142), the wire rod (FW) being overlapped in the gap (143) between the first support member (142) and the second support member (142). The wire transfer section (121) may be configured to accommodate the first support member (141) and the second support member (142) when the second mold (12) is in the retracted position. The receiving part (122) is located below the gap (143), and the wire rod accommodating part ( 14) and a wire support surface (125) that supports the wire (FW) housed in the wire rod (FW) from below. Thereby, it becomes possible to hold other wire rods in the wire rod accommodating part while processing one wire rod.

Furthermore, the receiving part (122) of the wire rod transfer part (121) has a support surface (123) that supports a lower surface of the wire rod (FW), and a supporting surface (123) that supports the lower surface of the wire rod (FW), and a support surface (123) that supports the lower surface of the wire rod (FW). 11), the distance (L) between the support surface (123) of the receiving portion (122) and the wire support surface (125) is , may be shorter than the dimension (h) of the wire (FW) in the third direction (z). Thereby, it becomes possible to smoothly transfer the wires one by one from the wire storage section to the receiving section of the wire transfer section.

The first molding die (11) also has a third molding surface (11e) extending in the first direction (y) toward the second molding mold (12) above the first molding surface (11f). and may be movable in the vertical direction with respect to the second molding die (12), and the second molding die (12) is located below the second molding surface (12f). The support surface (123) of the receiving part (122) may include a fourth molding surface (12e) extending in the first direction (y) toward the first molding die (11), and the supporting surface (123) of the receiving part (122) It may be located above the fourth molding surface (12e) of the second molding die (12). Thereby, by bringing the second mold closer to the first mold along the first direction, it is possible to accurately bend the wire in the first direction without contacting the fourth molding surface.

Furthermore, the manufacturing apparatus (10) is configured to perform the manufacturing process from the third and fourth molding surfaces (11e, 12e) of the wire (FW) held by the first and second molds (11, 12), respectively. A pair of bent wires that can come into contact with corresponding one of the parts protruding on both sides in the second direction (x) and can move in the vertical direction with respect to the first and second molds (11, 12). It may also include a member (13). Thereby, by moving the wire bending member in the vertical direction with respect to the first and second molds, it is possible to form two linearly extending leg portions of the segment coil.

The method for manufacturing a segment coil of the present disclosure includes a first mold (11) including a first molding surface (11f), and a first mold (11) that approaches and separates from the first mold (11) along a first direction (y). A second forming die (12 ), in which a plurality of the wire rods (FW) are arranged to extend in a second direction (x) perpendicular to the first direction (y). The wire rods are accommodated in the wire housing section (14) in an overlapping state in a third direction (z) perpendicular to both the first and second directions (x, y), and the second mold (12) The wire rod receiving section (121) is provided with a wire rod receiving section (121) that can approach and move away from the first mold (11) together with the second mold (12) when the wire rod storage section is in a retracted position away from the mold (11). One of the wire rods (FW) is delivered from the wire rod (FW), the wire rod transfer section (121) is brought close to the first mold (11) together with the second mold (12), and the wire rod (FW) ) is moved so as to be held by the first molding surface (11f) of the first molding mold (11) and the second molding surface (12f) of the second molding mold (12).

According to this method, it is possible to immediately start processing the next wire after the second forming die returns to the retracted position, so that the processing of the next wire can be started after the forming of one wire is completed. The waiting time until processing starts can be shortened.

Note that the invention of the present disclosure is not limited to the above-described embodiments, and it goes without saying that various changes can be made within the scope of the present disclosure. Further, the above-described embodiment is merely one specific form of the invention described in the Summary of the Invention column, and does not limit the elements of the invention described in the Summary of the Invention column.

The invention of the present disclosure can be used in the segment coil manufacturing industry.

10 segment coil forming machine, 11 first forming mold, 11e first edgewise forming surface, 11f first flatwise forming surface, 11e first edgewise forming surface, 12 second forming mold, 12e second edgewise forming surface, 12f second flatwise forming surface, 120 main body, 121 wire transfer section, 122 receiving section, 123 support surface, 124 pressing surface, 125 wire support surface, 13 forming roller, 14 wire storage section, 141 first support member, 141s, 142s support surface, 142 second support member, 143 gap, 15 control device, 50 segment coil, 51, 52 leg section, 53 crossover section, 54 convex section, 55 crank section, e1, e2, e3, e4, e5, e6 Edgewise bent portion, f1, f2 Flatwise bent portion.

Claims (7)

In a segment coil manufacturing device that manufactures a segment coil by forming a bent part on a straight wire,
a first mold including a first molding surface;
A second forming surface that is movable toward and away from the first forming mold along a first direction and that forms the bent portion on the wire together with the first forming surface of the first forming mold. The mold and
a wire rod accommodating portion capable of accommodating a plurality of wire rods in a state of being stacked in a third direction orthogonal to both the first and second directions so as to extend in a second direction orthogonal to the first direction;
The wire rod can be moved toward and away from the first mold together with the second mold, and when the second mold is in a retracted position separated from the first mold, one of the wire rods is removed from the wire rod storage section. and as the second mold approaches the first mold, the wire is moved between the first molding surface of the first mold and the second molding surface of the second mold. a wire transfer part that is moved so as to be held by the wire rod;
Equipped with
The first molding surface of the first molding die is a convex surface that approaches the second molding die from both ends toward the center in the second direction,
The second molding surface of the second mold is a concave surface that is spaced apart from the first mold from both ends toward the center in the second direction,
A segment coil manufacturing device, wherein the pair of wire transfer portions are extended from the second molding die so as to be located on both sides of the second molding surface in the second direction. 2. The segment coil manufacturing apparatus according to claim 1 , wherein the third direction is an up-down direction. The segment coil manufacturing apparatus according to claim 2 ,
The wire housing section includes a first support member and a second support member that face each other with a gap in the first direction and are positioned above the second mold,
The wire rod is accommodated in the gap between the first support member and the second support member,
The wire transfer part includes a receiving part located below the gap between the first support member and the second support member when the second mold is in the retracted position, and a receiving part located below the gap between the first support member and the second support member; A segment coil manufacturing apparatus comprising: a wire rod support surface that supports the wire rod accommodated in the wire rod storage section from below while being located on the side of the first molding die in the retracted position. The segment coil manufacturing apparatus according to claim 3 ,
The receiving part of the wire rod transfer part includes a support surface that supports a lower surface of the wire rod, and a pressing surface that presses the wire rod toward the first mold,
In the segment coil manufacturing device, the distance between the support surface of the receiving portion and the wire support surface is shorter than the dimension of the wire in the third direction. The segment coil manufacturing apparatus according to claim 4 ,
The first mold includes a third molding surface that extends in the first direction toward the second mold above the first molding surface, and is movable in the vertical direction with respect to the second mold. and
The second mold includes a fourth molding surface extending in the first direction toward the first molding mold below the second molding surface,
In the segment coil manufacturing apparatus, the support surface of the receiving portion is located above the fourth molding surface of the second molding die. The segment coil manufacturing apparatus according to claim 5 ,
The third and fourth molding surfaces of the wire held by the first and second molds are capable of abutting on corresponding one of the portions protruding from both sides in the second direction, respectively, and A segment coil manufacturing apparatus further comprising a pair of wire bending members movable in the vertical direction with respect to the first and second molds. a first mold including a first molding surface; the wire rod can be moved toward and away from the first mold along a first direction; the wire can be bent into a straight wire together with the first molding surface of the first mold; In a method for manufacturing a segment coil, the segment coil is manufactured using a second mold including a second molding surface for molding the segment coil,
The first molding surface of the first molding die is a convex surface that approaches the second molding die from both ends toward the center in a second direction perpendicular to the first direction,
The second molding surface of the second mold is a concave surface that is spaced apart from the first mold from both ends toward the center in the second direction,
A pair of wire transfer parts that can approach and move away from the first mold together with the second mold extend from the second mold so as to be located on both sides of the second molding surface in the second direction. and
A plurality of wire rods are accommodated in a wire rod accommodating part in a state in which they are stacked in a third direction perpendicular to both the first and second directions so as to extend in the second direction,
When the second mold is in a retracted position separated from the first mold, delivering one of the wires from the wire storage part to the pair of wire delivery and receiving parts,
The pair of wire transfer parts are brought close together with the second mold to the first mold, and the wire is moved between the first molding surface of the first mold and the second molding surface of the second mold. A method for manufacturing a segment coil that is moved so as to be held by.

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