JP2011010528A - Method of forming coil member and assembling device for the coil member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To form a coil member while suppressing a deformation of a cross-sectional shape over a wide range, when winding a rectangular wire edgewise.SOLUTION: An assembling device includes a feeding section 60, a guiding section 50, a support member 51 and a bending section 40. The support member 51 includes a core member C for defining the bending radius of a rectangular wire 10 and restricting members 51a, 51b for restricting the rectangular wire on both sides. The bending section 40 is provided with a pressing circular board 41 and a ditch covering/pressing board 42, having a U-shaped cross-sectional shape. A turnable base 46 of the bending section 40 is rotated clockwise, and the rectangular wire 10 is pressed against the core member C by means of the pressing circular board 41 and the ditch covering/pressing board 42 so as to bend the rectangular wire 10. During the bending operation, horizontal state is kept in the vicinity of the support member 51, that is a restricting section by means of the ditch covering/pressing board 42 and a pressing groove board 58, swelling in the restricting section can be homogenized, preventing dielectric degradation and forming a coil with less distortions.

Description

  The present invention relates to a method for forming a coil member having a structure in which a flat wire is wound in an edgewise manner and an assembling apparatus therefor.

  In general, a coil member disposed in a motor, a generator, a reactor, a transformer, or the like is configured by winding a thin copper wire many times. For example, a motor stator generally has a structure in which a copper wire having a substantially circular cross section is wound around a tooth portion of a core or a split core. On the other hand, recently, a structure using a rectangular wire having a rectangular cross section has been proposed.

In patent document 1, it winds in the edgewise shape on both sides of the rectangular wire between the restraint members provided in the both sides of the bending roll. At that time, the inner wall surfaces of the respective restraining members are in close contact with both long-side surfaces of the inner portion extending from the inner end of the bent portion to the vicinity of the center of the width. Moreover, the inner wall surface of each restraining member is in a non-contact state with the outer portion from the vicinity of the center of the bending portion to the outer end.
In Patent Document 2, the rectangular wire is wound in an edgewise manner while pressing the inner portion of the flat wire with the restraining member. At this time, a part of the flat wire is constrained to a restraint dimension shorter than the short side of the flat wire within the range of elastic deformation.

JP 2006-288025 A JP 2008-228435 A

In general, it is known that the cross-sectional shape changes from a rectangular shape when a rectangular wire is bent edgewise. As shown in FIG. 5A, the method of the short side dimension of the rectangular wire before being bent is a, and the long side dimension is b. When this is bent edgewise, it changes as shown in FIG. At this time, the short side dimension a + α on the inner peripheral side increases, and the short side dimension on the outer peripheral side decreases.
Therefore, in each of the above-mentioned documents, in order to suppress the change in the cross-sectional shape as much as possible, a method for restraining the rectangular wire is devised.

On the other hand, when there is no said restraining member, as shown by the broken line of FIG.5 (b), the cross section of a bending part swells greatly on an inner peripheral side. Such bulging is suppressed by the restraining members of each document.
In both cases, bending is performed by rotating the abutting bending guide with the length of one side sent before the bending part, but only the bending part is restricted in the vertical direction. It is. Therefore, only one side of the straight portion to be bent (side where the bending guide is in contact) is constrained, and the upper surface is free. For this reason, the bent straight portion is twisted obliquely, the bulge of the bent portion becomes uneven, the stress load on the constrained portion increases, and the insulation film of the rectangular wire is damaged, or the final coil shape is There is a problem of distortion.

  An object of the present invention is to provide a method and an assembling apparatus capable of forming a coil member excellent in dimensional accuracy and insulation of a coil while suppressing a bulge on the inner peripheral side when winding a rectangular wire in an edgewise shape. It is to provide.

  The method for forming a coil member according to the present invention is a method for forming a coil member formed by winding a flat wire in an edgewise manner. And it includes the step of sending the flat wire in the wire length direction and the step of bending the flat wire by the previous pressing member through the support member having the core member and the restraining members on both sides thereof. When bending, the pressing member is rotated around the core member while pressing the flat wire to the core member side by the pressing member restraining the long side and the short side of the cross section of the flat wire.

  By this method, by maintaining the restraint portion and the horizontality before and after the restraint portion, the bulge at the restraint portion can be made uniform and insulation deterioration can be prevented. Furthermore, a coil with less distortion can be formed by maintaining the horizontality other than the restraint portion.

  As the pressing member, it is preferable to use a member longer than the length of each side of the coil member. Thereby, a coil member can be formed, without giving a crack and deformation | transformation to a part of coil member.

  As the pressing member, it is preferable to use a member that restrains a region wider than the long side part of the cross section of the rectangular wire on both sides. Thereby, the horizontality of a bending process part and the wire of the part contact | abutted to a press member can be maintained.

It is preferable that the interval of the portion that constrains the long side portion of the cross section of the pressing member is configured to be changeable and the following switching is performed. That is, in the feeding step, the interval between the portions that restrain the long side portion of the pressing member is increased, and in the bending step, the interval is reduced.
By this method, in the step of feeding the flat wire, the flat wire is not rubbed strongly with the portion that restrains the long side portion of the pressing member. Therefore, damage to the insulating film and deterioration of the shape of the flat wire can be suppressed.
On the other hand, in the bending process, it is possible to narrow the interval between the portions that restrain the long side portion of the cross section of the pressing member to the same extent as the short side portion (thickness). However, the distance between the portions that constrain the long side portion is set to a thickness that takes into account the bulge on the inner peripheral side of the bent portion. This is because the bending portion immediately before has a thickness larger than the cross-sectional thickness of the flat wire.

As the flat wire, a divided flat wire in which a plurality of flat wires are bundled so that the outer shape of the cross section is rectangular may be used. Thereby, the deformation resistance when the flat wire is bent is reduced, and the change in the cross-sectional shape is also reduced.
Further, when the coil current frequency is f, the coil wire width is d, the magnetic flux density amplitude is Bmax, and the resistivity of the coil material is ρ, the coil vortex loss w is expressed by the following equation: w = π ² f ² d ² Bmax ² / 6ρ
Represented by Since the coil wire width is reduced to (1 / number of coil wires), the coil vortex loss w is reduced.

  The coil member assembling apparatus of the present invention includes a feed member that sends a flat wire, a support member that supports the flat wire when it is bent, and a pressing member that presses the flat wire against the support member. And a central part which restrains the short side part of the cross section of a flat wire in a press member, and the side part which covers the long side part of the cross section of a flat wire on the both sides are provided.

  Thereby, the above-mentioned formation method can be implemented. Therefore, the horizontality at the time of bending can be maintained.

  The central portion of the pressing member preferably has a length dimension that is greater than each side of the coil member. Thereby, the generation | occurrence | production of the damage | wound and deformation | transformation by having been pressed by the edge part of the press member to a part of coil member can be suppressed.

  It is preferable that the side part of a press member has the width dimension which covers the whole long side part of the cross section of a flat wire. Thereby, the horizontality at the time of a bending process can be maintained.

  It is preferable that the interval between the side portions of the pressing member is configured to be switchable. This makes it possible to switch the interval between the feeding process and the bending process. And in the peripheral area | region of a bending area | region, the change of a cross-sectional shape can be made as small as possible, preventing the failure | damage of an insulating film.

  According to the method for forming a coil member or the assembling apparatus of the present invention, it is possible to make the bulge at the restrained portion uniform by maintaining the horizontality of the wire during bending, and to prevent deterioration of insulation. Furthermore, a coil with less distortion can be formed by maintaining the horizontality other than the restraint portion.

It is a top view which shows schematic structure of the assembly apparatus of the coil member which concerns on embodiment of this invention. (A)-(c) is a top view which shows the initial bending procedure of the coil in a bending part with the structure of a guide part and a bending part. (A)-(c) is a top view which shows the procedure wound after a flat wire is bent. (A), (b) is sectional drawing which shows the state of the supporting member in a bending process and a sending process in order. (A), (b) is sectional drawing which respectively shows the initial cross-sectional shape of a flat wire, and the cross-sectional shape of the bent part. It is a figure which shows the relationship between the space | interval d of a restraint member, and the dimension change (alpha). It is a perspective view which shows the structure of the coil member 20 and split core 71 which concern on embodiment. It is sectional drawing which shows the schematic structure of the stator of the motor in embodiment.

-Coil member assembly equipment-
FIG. 1 is a plan view showing a schematic configuration of a coil member assembling apparatus according to an embodiment of the present invention. FIGS. 2A to 2C are plan views showing the initial bending procedure of the coil in the bent portion, together with the structure of the guide portion and the bent portion. FIGS. 3A to 3C are plan views showing a procedure in which the flat wire is wound after being bent. 4A and 4B are cross-sectional views showing the state of the support member in the bending step and the feeding step in order.

The assembling apparatus according to the present embodiment includes a feeding part 60, a guide part 50, and a bending part 40.
The feed unit 60 includes several rolls 61 arranged vertically. And the flat wire 10 is sent to wire length by the rotation, being pinched by each roll 61. By repeating the feeding and bending of the flat wire 10, the flat wire 10 is wound into a shape surrounding the core, and the coil member 20 is formed.

  As shown in FIGS. 4A and 4B, the flat wire 10 of the present embodiment has a substantially rectangular cross-sectional shape composed of a short side and a long side. And the flat wire 10 has the copper wire 10a whose cross section is substantially rectangular shape, and the insulating film 10b which coat | covers the copper wire 10a. The insulating film 10b is made of an imide resin typified by polyimide, polyamideimide, polyesterimide or the like.

  The guide unit 50 includes a guide stand 55, a first guide plate 52 and a second guide plate 53 mounted on the guide stand 55, and a pressing plate 58 attached on each of the guide plates 52 and 53. ing. The flat wire 10 is sandwiched between the first and second guide plates 52 and 53 and slides on the guide table 55 while the horizontal position is held constant by the pressing plate 58. As shown in the partial sectional view on the left side of FIG. 2A, a gap s is set between each guide plate 52, 53 and the flat wire 10. Due to the presence of the gap s, the flat wire 10 can be smoothly slid even if the end surface is slid when the flat wire 10 is cut. Moreover, the 1st guide plate 52 has the flat part 52a and the slope part 52b for raising the wound coil member upwards. The holding plate 58 is also provided with an inclination corresponding to the inclination of the inclined surface portion 52 b of the first guide plate 52.

A support member 51 that supports the flat wire 10 is disposed at the terminal portion of the guide portion 50 in the bending process. As shown in FIGS. 4A and 4B, the support member 51 includes a core member C and hook-shaped restraining members 51a and 51b on both sides thereof. The restraining members 51a and 51b restrain the movement in the thickness direction (the short side direction of the cross section) when the flat wire 10 is bent. The interval between the restraining members 51a and 51b is configured to be switchable between a position shown in FIG. 4 (a) and a position shown in FIG. 4 (b). As a mechanism for switching, there are a well-known common mechanism, a vertical movement mechanism using a cylinder, and the like.
The upper restraining member 51a has a slope portion 51x for lifting the wound coil on the flat portion 51y.

The bending portion 40 includes a turntable 46 that can rotate about the central axis of the core member C, a pressing disc 41, and a pressing groove plate 42. The pressing disk 41 presses the flat wire 10 supported by the support member 51 in the direction of the core member C. As shown in the partial cross-sectional view on the right side of FIG. 2A, the pressing groove plate 42 has a central portion 42a that is continuous with the pressing disc 41 at its base portion, and side portions 42b on both sides thereof. That is, the pressing groove plate 42 has a U-shaped groove into which the flat wire 10 enters. The groove width f is set to a value between the top dead center Pud and the bottom dead center Pld shown in FIG. Further, the length of the pressing groove plate 42 is set longer than the length of the long side of the coil member 20 described later.
The pressing groove plate 42 inserts the flat wire 10 into this groove and gives a bending moment over a wide range of the flat wire 10. In this embodiment, the pressing disk 41 and the pressing groove plate 42 constitute a pressing member.

  Similarly to the restraining members 51a and 51b, the groove width f of the side portion 42b of the pressing groove plate 42 can be configured to be switchable.

  A turntable 43 is attached to the turntable 46 so as to be movable along the periphery thereof. A gripping member including a fixed portion 45 and a moving portion 44 is attached to the parallel moving table 43. The moving unit 44 can move in the horizontal direction in the parallel moving table 43, and can hold the flat wire 10 between the moving unit 44 and the fixed unit 45. Further, the gripping member composed of the moving part 44 and the fixed part 45 is movable in the vertical direction (paper surface direction in the figure). That is, the gripping member is positioned below when avoiding interference with the flat wire 10 and positioned above when gripping the flat wire 10.

-Coil member forming method-
Next, a method for forming a coil member will be described with reference to FIGS. 2 (b) to 2 (c) and FIGS. 3 (a) to 3 (c).
First, as shown in FIG. 2B, the turntable 46 is rotated approximately 90 ° clockwise. A bending angle greater than 90 ° is required for springback. At this time, the flat wire 10 is pressed against the core member C by the pressing disk 41 and the pressing groove plate 42. Further, a bending moment is applied by the pressing groove plate 42 in a wide range of the rectangular wire 10. Thereby, the front-end | tip part of the flat wire 10 is bent about 90 degrees. At this time, the restraining members 51a and 51b of the support member 51 are at the positions shown in FIG. When the groove width f of the side portion 42b of the pressing groove plate 42 can be switched, the groove width f is also narrowed. Further, the gripping member made up of the fixed portion 45 and the moving portion 44 is always positioned below.

  During the bending process, the flat wire 10 is prevented from being deformed in the short side direction of the cross section by the restraining members 51 a and 51 b and the pressing groove plate 42.

Next, in the step shown in FIG. 2C, the turntable 46 is rotated approximately 90 ° counterclockwise to return to the initial position. And the flat wire 10 is sent out to the wire length direction by the roll 61 (refer FIG. 1) of the sending part 60. FIG. The feed amount at this time is substantially equal to the length of one side of the coil member. At this time, the restraining members 51a and 51b of the support member 51 are at the positions shown in FIG. When the groove width f of the side portion 42b of the pressing groove plate 42 can be switched, the groove width f is also increased.
Thereafter, the gripping member composed of the fixed portion 45 and the moving portion 44 is moved upward. Then, the moving unit 44 is moved leftward in the figure, and the rectangular wire 10 is gripped by the fixed unit 45 and the moving unit 44.

  Next, in the step shown in FIG. 3A, the turntable 46 is rotated approximately 90 ° clockwise to bend the flat wire 10. At this time, the holding of the flat wire 10 is continued by the holding member including the fixed portion 45 and the moving portion 44.

  By repeating the bending and feeding described above, the coil member 20 is formed by winding the rectangular wire 10 in an edgewise manner as shown in FIG.

Next, when the formation of the coil member 20 is completed, the coil is sent out to a predetermined position in the step shown in FIG. At this time, the coil member 20 is moved while being gripped by the gripping member including the fixed portion 45 and the moving portion 44. It is also possible to send out the coil in a state where the end of the coil is cut by a cutting mechanism (not shown).
However, after that, the coil can be taken out by releasing the grip.

FIG. 7 is a perspective view showing structures of the coil member 20 and the split core 71 according to the embodiment. In FIG. 7, the copper wire is displayed as one rectangular wire, but it is also possible to have a structure in which a plurality of copper wires are assembled as described above. The coil wires 11 are electrically connected to each other at the two terminals 21 and 22 at both ends.
Further, the coil member 20 may be a so-called cassette coil by being molded with a resin indicated by a broken line in the drawing except for the two terminals 21 and 22.

  The split core 71 has a yoke portion 71a and a teeth portion 71b. In this embodiment, although the powder core structure is employ | adopted, you may use a laminated steel plate. In the case of a powder compact structure, the broken line portions shown in FIG.

  The broken line shown in the coil member 20 of FIG. 7 has shown the external shape of resin which has molded the flat wire 10 of the coil member 20. FIG. The teeth 71b of the split core 71 are fitted into the inner peripheral side of the molded coil.

FIG. 8 is a cross-sectional view showing a schematic structure of a stator 80 of the motor in the present embodiment. In FIG. 8, the display of the mold resin is omitted for easy viewing. As shown in FIG. 8, the stator 80 is obtained by assembling a plurality of divided stators 70 in an annular shape.
However, when assembling, first, the plurality of split cores 71 are combined in an annular shape, and then enclosed and assembled from the outside using a ring member or the like. In the present embodiment, a core in which the split cores 71 are assembled is used as the core, but the core may be integrated without being split.

  A rotor (not shown) provided with a permanent magnet is disposed inside the stator 80. The split core 71 includes a yoke portion 71a and a teeth portion 71b protruding from the yoke portion 71a toward the rotor. In the present embodiment, the split core 71 is formed by compression molding magnetic powder having an insulating film. However, it may be a laminate of silicon steel plates coated with a resin insulating layer.

  A coil member 20 as a resin-molded cassette coil is set on the teeth 71 b of the split core 71. In addition, the insulator which coat | covers the teeth part 71b is unnecessary because the coil member 20 is resin-molded. A split stator 70 is configured by the split core 71 and the coil member 20.

  According to the present embodiment, in the process of feeding the rectangular wire 10, the interval between the restraining members 51a and 51b is made wider than that in the bending process. Therefore, damage to the insulating film 10b in the feeding process is prevented. Further, in the bending step, the bulge of the rectangular wire 10 in the short side direction can be suppressed by narrowing the interval between the restraining members 51a and 51b. The principle will be described below.

It is assumed that the flat wire 10 has a rectangular cross-sectional shape composed of a short side dimension a and a long side dimension b as shown in FIG. When this is bent edgewise, the shape shown in FIG. 5B is obtained. That is, the short side dimension on the center side of the bending increases to a + α. At the same time, the short side dimension outside the bend is reduced. Further, the long side dimension is reduced to b-β.
In order to reduce the dimensional change α, the distance d between the restraining members 51a and 51b should be as close as possible to the short side dimension a. However, if the distance d between the restraining members 51a and 51b is reduced, the following problem occurs.

FIG. 6 is a diagram showing the relationship between the distance d between the restraining members 51a and 51b and the dimensional change α. Although the dimensional change α decreases as the interval d becomes narrower, the bottom dead center Pld exists as a range to prevent damage to the insulating film. There is also a top dead center Pud where the dimensional change α is saturated.
When the distance d is equal to or less than the bottom dead center Pld, the insulating film 10b is damaged. However, the bottom dead center Pld differs depending on the assembly apparatus, the structure of the flat wire, the process conditions, and the like.
In the present embodiment, in the feeding process, a gap h (see FIG. 4B) is provided between the restraining members 51a and 51b. By expanding the gap further than the value obtained by adding the bulging part at the time of bending to the short side dimension before processing, the flat wire 10 does not rub against the restraining members 51a and 51b strongly, and the insulation film 10b is prevented from being damaged. The

Furthermore, since the pressing groove plate 42 is bent while pressing the short side portion and the long side portion of the cross section of the flat wire 10, deformation of the peripheral region of the bending region can also be suppressed.
In particular, when the groove width f of the pressing groove plate 42 can be switched, the groove width f of the side portion 42b of the pressing groove plate 42 can be increased in the feeding process as compared with the bending process. Therefore, damage to the insulating film 10b can be prevented.

In the present embodiment, the length of the pressing groove plate 42 is longer than the length of the long side of the coil member 20. Therefore, scratches and deformation caused by being pressed at the tip of the pressing groove plate 42 do not remain in a part of the coil member 20.
Therefore, the coil member 20 having a good shape can be assembled.

(Other embodiments)
In the above embodiment, the rectangular wire 10 is bent at approximately 90 ° to form the coil member 20 wound in a rectangular shape, but the present invention is not limited to this. The present invention can also be applied to the formation of a coil member wound into a shape such as a parallelogram, a rhombus, etc., in which the flat wire 10 is bent at an angle different from 90 °.

  The structure of the embodiment of the present invention disclosed above is merely an example, and the scope of the present invention is not limited to the scope of these descriptions. The scope of the present invention is indicated by the description of the scope of claims, and further includes meanings equivalent to the description of the scope of claims and all modifications within the scope.

  The coil member forming method and assembly apparatus of the present invention are components such as motors (including linear motors), generators, reactors, transformers and the like disposed in industrial motors, hybrid vehicles, electric vehicles, fuel cell vehicles, robots, and the like. Can be used for the manufacture of

C Core member 10 Flat wire 10a Copper wire 10b Insulating film 11 Coil wire 12 Copper wire 13 Insulating film 20 Coil member 21 and 22 Terminal 40 Bending part 41 Pressing disk 42 Pressing groove board 42a Central part 42b Side part 43 Parallel moving table 44 Moving part 45 Fixed part 46 Turntable 50 Guide part 51 Support member 51a, 51b Restraining member 51x Slope part 51y Flat part 52 First guide plate 53 Second guide plate 55 Guide base 58 Holding plate 60 Feed part 61 Roll 70 Divided stator 71 Divided core 71a Yoke part 71b Teeth part 80 Stator

Claims (9)

A method for forming a coil member by winding a rectangular wire having a rectangular cross-sectional shape composed of a short side portion and a long side portion in an edgewise manner,
Sending the flat wire in the wire length direction (a);
The pressing member is pressed to the core member side while pressing the rectangular wire to the core member side by the pressing member that holds the rectangular wire between the core member and the restraining members on both sides of the core member and restrains the long side portion and the short side portion of the cross section of the rectangular wire. A step (b) of bending the rectangular wire by rotating around
The formation method of the coil member containing this. In the method for forming a coil member according to claim 1,
In the step (b), a method for forming a coil member, wherein the pressing member is longer than the length of each side of the coil member. In the formation method of the coil member according to claim 1 or 2,
In the step (b), a method for forming a coil member, wherein the pressing member is one that restrains a region wider than the long side portion of the cross section of the rectangular wire on both sides. In the formation method of the coil member according to any one of claims 1 to 3,
The interval of the portion that constrains the long side portion of the cross section of the pressing member is configured to be changeable,
In the step (a), the interval between the portions that restrain the long side portion of the pressing member is widened,
In the step (b), the coil member forming method of narrowing an interval between portions that restrain the long side portion of the pressing member. In the formation method of the coil member according to any one of claims 1 to 4,
A method for forming a coil member, wherein as the flat wire, a divided flat wire in which a plurality of flat wires are bundled so that the outer shape of the cross section is rectangular is used. A feed member that sends a rectangular wire with a rectangular cross section in the wire length direction;
A support member for supporting the flat wire when bending the flat wire;
A pressing member that presses the flat wire against the support member when bending the flat wire;
With
The coil member assembling apparatus, wherein the pressing member is a member having a central portion that constrains a short side portion of a cross section of the flat wire and side portions that cover a long side portion of the cross section of the flat wire on both sides thereof. The coil member assembling apparatus according to claim 6,
The coil member assembling apparatus, wherein a central portion of the pressing member has a length dimension larger than each side of the coil member. The coil member assembling apparatus according to claim 6 or 7,
The coil member assembling apparatus, wherein the side portion of the pressing member has a width dimension that covers the entire long side portion of the cross section of the rectangular wire. In the assembly apparatus of the coil member as described in any one of Claims 6-8,
The coil member assembling apparatus is configured so that the interval between the side portions of the pressing member can be switched.

Images