JP2003264965A - Winding method and winding apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a winding method and a winding apparatus which raise precision in shape of a winding part and eliminate the need for installation operation of a crossover. <P>SOLUTION: There are provided a support roller 22 which supports in the middle of a wire material 9, a feeding mechanism 70 which feeds the wire material 9 to the support roller 22, a fixing mechanism 40 which fixes and supports the wire material 9 before the support roller 22, a bending roller 23 which abuts with the wire material 9 extending from the support roller 22, and a roller shifting mechanism 30 which shifts the bending roller 23 in the bending direction of the wire material 9. Winding is performed by repeating a process in which the wire material 9 is bent along the support roller 22 by shifting the bending roller 23 along with the wire material 9 by the roller shifting mechanism 30. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in a wire winding method and a wire winding device for a core of an electric motor, a generator or the like.

[0002]

2. Description of the Related Art Conventionally, when the diameter of a wire is large and it is difficult to directly wind the wire around the core, the wire is preliminarily wound using a winding core jig having a square cross section to form a winding portion. Later, there was a winding method in which this winding portion was fitted into each tooth.

[0003]

However, in such a conventional winding method, when the rigidity of the wire is high, it is difficult to wind the wire in a quadrangle along the jig.
There are problems that the shape of the corner portion of the winding portion varies, the straight portion of the winding portion bends, and the gap between the winding portion and the core becomes large.

Further, it is not possible to continuously form a plurality of winding wire portions and connecting wire portions connecting the winding wire portions corresponding to the stator core and the like, and after the winding wire portions are fitted into the respective teeth, the respective winding wire portions are fitted. The work of arranging the crossover part between them was required.

The present invention has been made in view of the above problems, and provides a winding method and a winding device which improve the shape accuracy of the winding portion and eliminate the work of disposing the connecting wire portion. The purpose is to

[0006]

A first aspect of the present invention relates to a winding method for winding a wire rod without using a winding jig, and a support roller for supporting the wire rod in the middle thereof and a wire rod for the support roller. Using a feed mechanism, a fixing mechanism that fixes and supports the wire rod in front of the support roller, a bending roller that contacts the wire rod extending from the support roller, and a roller moving mechanism that moves the bending roller in the bending direction of the wire rod, The roller moving mechanism moves the bending roller together with the wire rod to wind the wire rod while repeating the step of bending the wire rod along the support roller.

A second invention is characterized in that, in the first invention, a plurality of winding wire portions wound around the core and a connecting wire portion connecting the winding wire portions are alternately and continuously formed. And

According to a third aspect of the present invention, in a winding device for winding a wire rod without using a winding jig, a support roller for supporting the wire rod midway, and a feed mechanism for feeding the wire rod to the support roller, A fixing mechanism that fixes and supports the wire material in front of the support roller, a bending roller that contacts the wire material that extends from the support roller, and a roller moving mechanism that moves the bending roller in the bending direction of the wire material are bent by the roller moving mechanism. The roller is moved along with the wire rod so that the wire rod is bent along the support roller.

According to a fourth aspect of the present invention, in the third aspect, the bending roller has a groove for engaging a wire on its outer periphery, and the bending roller is attached so as to be inclined with respect to the supporting roller.
The bending roller bends the wire along the supporting roller so that the wire is inclined with respect to the supporting roller.

A fifth aspect of the invention is the third or fourth aspect of the invention, further comprising a pitch feed spacer which is in sliding contact with the bent wire rod, and the pitch feed spacer is attached so as to be inclined with respect to the support roller, and is bent. The wire rod slants against the support roller by sliding contact with the pitch feed spacer.

[0011]

According to the first and third inventions,
A winding portion formed by winding a wire has a corner portion that curves along the support roller and a portion that linearly extends through each corner portion, and is wound using a conventional winding jig. As compared with the method described above, the gap formed between the core and the core can be reduced, the coil can be downsized, and the resistance of the coil can be reduced to improve the performance of the electric motor and the like.

Furthermore, the size and shape of the winding portion can be easily changed by changing the feed amount of the wire rod by the feed mechanism and the radius of curvature of the support roller.

According to the second aspect of the present invention, a plurality of winding portions and the connecting wire portion are continuously formed and assembled to the core, so that the work of disposing the connecting wire portion unlike the conventional device is unnecessary. , Productivity can be reduced by increasing the productivity of the stator.

According to the fourth aspect of the present invention, the wire rod is bent by the inclined bending roller, and is wound in a line with no gap, thereby increasing the space factor of the wire rod.

According to the fifth aspect of the present invention, the wire rod is guided by the inclined pitch feed spacers and wound in a line without any gap, thereby increasing the space factor of the wire rod.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the accompanying drawings.

In FIG. 12, a core 8 constitutes a stator of an inner rotor type three-phase electric motor, and twelve teeth (magnetic poles) 8a which are arranged radially and protrude in the inner diameter direction.
And each of the winding portions 90 having the twelve slots 8b opened between them and the wire 9 being wound around each tooth 8a in advance.
U, 90V and 90W are housed in each slot 8b to form a stator coil. This stator has U, V, W
The winding parts 90U, 90V, 90W that compose each phase of
They are formed side by side in the circumferential direction.

In FIG. 1, reference numeral 1 denotes a winding device which bends a wire 9 to automatically manufacture winding parts 90U, 90V, 90W. The wire 9 is made of a thick wire having a large outside diameter, and can maintain its shape when it is bent by the winding device 1 without using a winding jig, as described later. The wire rod 9 is supplied from the reel 3 which is a wire rod supply source.

Here, three axes X, Y, and Z which are orthogonal to each other are set, the X axis is the horizontal front-back direction, the Y axis is the horizontal lateral direction, and the Z axis is the horizontal direction.
It is assumed that the axis extends in the vertical direction.

This winding device 1 includes a feeding mechanism 70 for feeding the wire 9 in the Y-axis direction, an intermediate positioning mechanism 50, a fixing mechanism 40 for fixing and supporting the wire 9, and a winding mechanism 10 for bending the wire 9. Prepare

The feed mechanism 70 is movable up and down by an air cylinder 76 to grip the wire 9 in the middle thereof, a movable base 72 for supporting the chuck 75, and the movable base 72 movable in the Y-axis direction with respect to the frame. Rails 71 that are supported by a ball screw 73 that is screwed to the moving base 72 side, and a ball screw 7
And a servo motor 74 for rotating and driving 3. The servo motor 74 is fixed on the pedestal, and the rotation of the ball screw 73 by the servo motor 74 moves the moving table 72,
The wire 9 gripped by the chuck 75 is sent in the Y-axis direction.

The intermediate positioning mechanism 50 has two pairs of pins 57 which are set up at the inlet and the outlet so that the wire 9 can be inserted therethrough.
A chuck 55 that moves up and down by an air cylinder 56 to grip the middle of the wire 9 and a slider 5 that supports the chuck 55.
2, a rail 71 that supports the slider 52 so as to be movable in the Y-axis direction with respect to the gantry, a ball screw 53 that is screwed to the slider 52 side, and a servo motor 54 that rotationally drives the ball screw 53. The servo motor 54 is fixed on the pedestal, and the rotation of the ball screw 53 by the servo motor 54 moves the slider 52.

The fixing mechanism 40 is provided with a chuck 45 which moves up and down by an air cylinder 46 and holds the wire 9 in the middle thereof.
It is fixedly installed on the frame. The chuck 45 has triangular grooves extending in the Y-axis direction formed in the upper and lower members that grip the wire 9.
The middle of the wire 9 is fixedly supported at a predetermined position.

As shown in FIGS. 2A and 2B, the winding mechanism 10 is in contact with the two support rollers 21 and 22 that support the wire 9 in the middle thereof and the wire 9 extending from the support roller 22. A bending roller 23 and a roller moving mechanism 30 for moving the bending roller 23 in the bending direction of the wire 9.
The roller moving mechanism 30 moves the bending roller 23 together with the wire 9 to bend the wire 9 along the support roller 22.

The support rollers 21 and 22 are rotatably attached to the support base 11, and the support base 11 is fixed to the pedestal. Each of the support rollers 21 and 22 is attached so as to sandwich the wire rod 9 extending in a straight line from the chuck 45 of the fixing mechanism 40 from above and below.

The roller moving mechanism 30 comprises a lever 13 on which the bending roller 23 is rotatably mounted, and an actuator 14 for rotating the lever 13 with respect to the support 11. The rotation center of the lever 13 is arranged coaxially with the rotation center of the support roller 22. That is, the bending roller 23 moves with an arcuate locus around the support roller 22. The wire 9 is bent along the support roller 22.

The lever 13 rotates in an angle range of 90 °,
The upper position where the bending roller 23 is engaged with the wire 9 linearly extending from the supporting rollers 21 and 22, and the supporting rollers 22 to 9
The wire rod 9 is moved in an arc shape between the wire rod 9 bent at 0 ° and the lower position.

Each of the rollers 22 and 23 has an annular groove on the outer circumference thereof, and the annular groove engages with the wire 9. In the plan view of FIG. 2B, the bending roller 23 is attached so as to be inclined by an angle θ with respect to the support roller 22 (a plane including the Y axis and the Z axis), and the lever 13 rotates to bend. The roller 23 bends the wire 9 so that the wire 9 is inclined by an angle θ with respect to the support roller 22.

A pitch feed spacer 15 which is in sliding contact with the bent wire 9 is attached to the support 11. The pitch feed spacer 15 has a wedge-shaped cross section, and its surface is attached to the support base 11 so as to be inclined with respect to the support roller 22 (a plane including the Y axis and the Z axis), and is bent to this surface. The wire 9 is configured to incline with respect to the support roller 22 as the wire 9 slides.

The wire 9 is bent by the tilted bending roller 23, and then guided by the pitch-feeding spacer 15 which is also tilted, so that the wire 9 shown in FIG.
As shown in (b) and (c), they are aligned and wound without a gap.

A procedure for the winding device 1 to wind the winding portion 90U will be described.

1. As shown in (a) and (b) of FIG.
The wire 9 fed from the reel 3 is linearly extended, passed between the rollers 21 to 23, and fixed by the chuck 45. At this time, the bending roller 23 to the lead wire portion 91
U is extended.

2. As shown in (a) and (b) of FIG.
Rotate the actuator 14 to move the lever 13 to 90
Rotate by 90 ° and bend the wire 9 by 90 ° along the support roller 22.

3. As shown in (a) and (b) of FIG.
The lever 13 is rotated to the upper position, the servo motor 74 is rotationally operated to move the movable base 72, and the wire 9 is fed in the Y-axis direction by a predetermined amount corresponding to the circumferential width of the tooth 8a.

4. As shown in FIG. 7, the lever 13 is rotated to the lower position, and the wire 9 is moved along the support roller 22 by 90 degrees.
° Fold.

5. As shown in FIG. 8, the lever 13 is rotated to the upper position and the wire 9 is fed by a predetermined amount corresponding to the axial width (height) of the tooth 8a.

6. As shown in FIG. 9, the lever 13 is rotated to the lower position, and the wire 9 is moved along the support roller 22 by 90 degrees.
° Fold.

7. As shown in FIG. 10, the lever 13 is rotated to the upper position to feed the wire 9 by a predetermined amount corresponding to the circumferential width of the tooth 8a.

8. As shown in FIGS. 11A and 11B, the lever 13 is rotated to the lower position, and the wire 9 is bent 90 ° along the support roller 22.

By performing the above operations 1 to 8, one winding portion of the winding portion 90U is formed. By repeating the operations of 1 to 8, the wire rods 9 are aligned and wound, and a winding of a predetermined width and a predetermined layer is performed to form a winding portion 90U.

9. After forming the winding portion 90U for one tooth 8a in this way, the wire 9 is fed by a predetermined amount corresponding to the connecting wire portion 92U between the teeth 8a, and the operations of 1 to 8 are performed again, whereby the winding portion 90U Form one roll. This process is repeated 4 winding parts 90
After forming U, the wire 9 is passed through a cutter device (not shown).
Disconnect.

As described above, the winding device 1 includes the four winding portions 90U and the three connecting wire portions 92 connecting the winding portions 90U.
By continuously forming U and assembling it to the core 8, the work of disposing the connecting wire portion unlike the conventional device is unnecessary, the productivity of the stator is improved, and the cost of the product is reduced.

The winding portion 90U has a corner portion that curves along the support roller 22 and a portion that linearly extends through each corner portion, and reduces the gap formed between the core 8 and the tooth 8a. Compared to the conventional winding method using a winding jig, the length of the wire rod 9 that constitutes the winding portion 90U is shortened, the coil is downsized, and the resistance of the coil is reduced to reduce the coil resistance. Performance can be improved.

Furthermore, by changing the feed amount of the wire 9 by the feed mechanism 70, the radius of curvature of the support roller 22, and the like,
The size and shape of the winding portion 90U can be easily changed.

The intermediate positioning mechanism 50 and the fixing mechanism 4
0 may be eliminated and the feeding mechanism 70 may be provided with a function of a fixing mechanism for fixing and supporting the wire 9.

The support rollers 21 and 22 and the bending roller 23 are rotatably provided, but not limited to this, the support rollers 21 and 22 are fixedly provided on the support base 11, and the bending roller 23 is provided to the lever 13. The wire 9 may be fixedly mounted on the support roller 21, 22 and the bending roller 23 to be fed by sliding.

It is obvious that the present invention is not limited to the above-mentioned embodiments and various modifications can be made within the scope of the technical idea thereof.

[Brief description of drawings]

FIG. 1 is a perspective view of a winding device showing an embodiment of the present invention.

FIG. 2A is a side view of the winding device and FIG. 2B is a plan view of the winding device.

FIG. 3A is a side view showing winding operation, and FIG.
Is a plane showing winding operation, and (c) is a front view showing winding operation.

FIG. 4A is a side view showing a winding operation, and FIG.
FIG. 6 is a plan view showing a winding operation.

FIG. 5A is a side view showing the winding operation, and FIG.
FIG. 6 is a plan view showing a winding operation.

FIG. 6A is a side view showing winding operation, and FIG.
FIG. 6 is a plan view showing a winding operation.

FIG. 7 is a side view showing the same winding operation.

FIG. 8 is a side view showing the same winding operation.

FIG. 9 is a side view showing the same winding operation.

FIG. 10 is a side view showing the same winding operation.

FIG. 11A is a side view showing a winding operation,
FIG. 6B is a plan view showing the winding operation.

FIG. 12 is a sectional view of the same stator.

[Explanation of symbols] 1 winding device 9 wire rod 10 winding mechanism 21,22 Support roller 23 Bending roller 30 Roller moving mechanism 40 fixing mechanism 50 Intermediate positioning mechanism 70 Feed mechanism 90U winding part 92U Crossover section

Claims (5)

[Claims] 1. A supporting roller for supporting the wire in the middle thereof, a feeding mechanism for feeding the wire to the supporting roller, a fixing mechanism for fixing and supporting the wire in front of the supporting roller, and a wire extending from the supporting roller. A bending roller and a roller moving mechanism that moves the bending roller in the bending direction of the wire rod are used. The roller moving mechanism moves the bending roller together with the wire rod to repeat the step of bending the wire rod along the supporting roller to wind the wire. A winding method characterized by carrying out. 2. The winding according to claim 1, wherein a plurality of winding portions wound around the core and a connecting wire portion connecting the winding portions are formed alternately and continuously. Method. 3. A support roller for supporting the wire in the middle, a feeding mechanism for feeding the wire to the support roller, a fixing mechanism for fixing and supporting the wire in front of the support roller, and a wire rod extending from the support roller. The present invention is characterized by including a bending roller and a roller moving mechanism that moves the bending roller in the bending direction of the wire rod, and the roller moving mechanism moves the bending roller together with the wire rod to bend the wire rod along the support roller. And winding device. 4. The bending roller has a groove for engaging a wire on its outer periphery, the bending roller is attached so as to be inclined with respect to the supporting roller, and the bending roller bends the wire along the supporting roller. The winding device according to claim 3, wherein the wire rod is configured to be inclined with respect to the support roller. 5. A pitch feed spacer slidingly contacting the bent wire rod, wherein the pitch feed spacer is mounted so as to be inclined with respect to the support roller, and the bent wire rod slides in contact with the pitch feed spacer. The winding device according to claim 3 or 4, wherein the wire rod is inclined with respect to the support roller.