JP2011050215A - Winding method and apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a winding method and apparatus which hardly cause a space between a first turn and a second turn of a coil made by winding a rectangular conductor. <P>SOLUTION: The winding method includes a strut section 23b that has a circular arc surface to be brought into contact with a rectangular conductor 10 to guide it and is brought into contact with a first surface of the rectangular conductor 10 to support the rectangular conductor 10, a bending jig 24 that is abutted against the rectangular conductor 10 to press it, a flange 23a for gripping a second surface of the rectangular conductor 10 perpendicular to a surface of the rectangular conductor 10 to be brought into contact with the strut section 23b, and a slanted guide 26 for feeding a wound rectangular conductor 10 to a next turn, and forms a coil 50 by winding the rectangular conductor 10. In the winding method, the second surface of the rectangular conductor 10 is pressed by the strut section 23b, and the bending jig 24 is made to work on the rectangular conductor 10 so that the rectangular conductor 10 may run on the slanted guide 26 arranged at the farthest position away from the flange 23a within the elastic limit of the rectangular conductor 10, and then the rectangular conductor 10 is bent by means of the bending jig 24 to form a coil tightly. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a technique related to a coil winding method and a coil winding apparatus for forming a coil using a rectangular conductor.

In recent years, motors mounted in automobiles and the like are required to be smaller and have higher output. For this reason, in order to increase the cross-sectional area of a coil and to improve a space factor, using a rectangular conductor for a coil is examined.
However, there are various problems associated with using a rectangular conductor for the coil. Various studies have been made on conventional techniques as shown in Patent Documents 1 to 3.

Patent Document 1 discloses a technique regarding an edgewise coil winding method and apparatus.
Specifically, a rectangular conductor is disposed between a fulcrum roller having a flange and a vendor gear, and the coil using the rectangular conductor is bent by edgewise bending the rectangular conductor by rotating the bender gear around the fulcrum roller. Technology to form. In addition, a pitch feed guide is installed, and the flat conductor is inclined to form a climbing portion between the first turn and the second turn. Also, when edgewise bending is performed, the fulcrum roller with flange is pressed downward, and the flat conductor is pressed against the table, resulting in swelling and bending wrinkles that occur during edgewise bending. Is preventing.

Patent Document 2 discloses a technique regarding a winding method and a winding device.
Specifically, the flat conductor is arranged and supported between two support rollers and a bending roller, and the bending roller is rotated about the support roller on one side, thereby realizing edgewise bending of the flat conductor. ing. The support roller, which is the center of bending, has a flange. When edgewise bending is performed, the flat conductor is held by the flange, and the pitch feed spacer forms the run-up portion between the first and second turns. is doing.

Patent Document 3 discloses a technique relating to a coil manufacturing method, a motor coil, and a motor stator.
Similarly to Patent Document 1 and Patent Document 2, a shaft with a guide that functions in the same manner as the support roller and a fixed chuck corresponding to a bender gear are provided, and the fixed chuck moves on the rotary table, whereby the rectangular conductor is edgewise bent. By preparing a tapered portion in the scraper, the coil can be wound spirally.

JP 2007-74881 A JP 2003-264965 A JP 2008-178199 A

However, Patent Documents 1 to 3 are considered to have the problems described below.
Each of Patent Documents 1 to 3 includes an inner support means such as a fulcrum roller that supports the inside of the edgewise bending process of the flat conductor, and a bending means that performs edgewise bending process by abutting and pressing the flat conductor. And a clamper that holds down the upper surface of the flat conductor, and an inclined guide that forms a run-up portion of the first turn and the second turn. However, the applicant has confirmed that a gap S between the first turn and the second turn as illustrated in FIG. 7 described later opens depending on the distance between the clamper and the inclined guide.

In forming the coil, if the gap S between the turns is opened, the coil is formed in a spring shape. A coil formed with a spring-like gap S is a problem when placed on the stator. This is because if the spring-like coil is arranged in the stator as it is, the space factor of the coil is lowered, so that the rectangular conductors of the coil need to be held on the stator side in close contact with each other.
When the function of holding on the stator side is provided, problems such as difficulty in assembly and an increase in the process occur. As a result, the yield and production cost are also affected.

  Therefore, in order to solve such problems, the present invention provides a winding method and a winding device in which a gap between a first turn and a second turn of a coil formed by winding a flat conductor is less likely to occur. With the goal.

In order to achieve the above object, the winding method according to the present invention has the following characteristics.
(1) An inner support means having an arcuate surface that contacts and guides a flat conductor and supports the first face; bending means that contacts and presses the flat conductor; In a winding method comprising: gripping means for gripping a second surface adjacent to one surface; and an inclined guide for sending the wound rectangular conductor to the next turn, and winding the rectangular conductor to form a coil.
The inclined guide disposed at a position where a stress generated in the rectangular conductor is below an elastic limit when the rectangular conductor is pressed onto the inclined guide by pressing the second surface of the rectangular conductor, The bending means is operated so that the rectangular conductor rides, and the rectangular conductor is bent by the bending means, whereby the coil is formed in close contact.

(2) In the winding method according to (1),
The inclined guide is disposed at a position adjacent to the gripping means and opposed to a bending position of the bending means with the gripping means interposed therebetween.

In order to achieve the above object, the winding device according to the present invention has the following characteristics.
(3) Inner support means that has an arcuate surface that contacts and guides a flat conductor and supports the first face, supports the bending means by contacting and pressing the flat conductor, and the flat conductor Comprises a gripping means for gripping a second surface orthogonal to the first surface, and an inclined guide for sending the wound rectangular conductor to the next turn, and winding the rectangular conductor to form a coil. In the device
The inclined guide is arranged at a position where a stress generated in the flat conductor is below an elastic limit when the flat conductor is gripped by the gripping means and the bending means is operated.

(4) In the winding device according to (3),
The inclined guide is disposed adjacent to the gripping means and at a position facing the bending position of the bending means with the gripping means interposed therebetween.

With the winding method according to the present invention having such characteristics, the following operations and effects can be obtained.
The winding method of the invention described in the above (1) includes an inner support means that has an arcuate surface that contacts and guides a flat conductor and supports the first face, and abuts and presses the flat conductor. Bending means, gripping means for gripping the second surface adjacent to the first surface of the flat conductor, and an inclined guide for sending the wound flat conductor to the next turn, and winding the coil by winding the flat conductor In the winding method to be formed, when the second surface of the flat conductor is held by the gripping means, and the flat conductor gets on the inclined guide, the flat guide is placed on the inclined guide disposed at a position where the stress generated in the flat conductor is below the elastic limit. Bending means is applied so that the conductor rides, and the flat conductor is bent by the bending means, thereby forming the coil in close contact.

  When winding the flat conductor, the inclined guide is disposed at a position where the stress generated in the flat conductor is below the elastic limit. That is, a part of the rectangular conductor gripped by the gripping means becomes a restraint point, and when the rectangular conductor rides on the inclined guide, the riding portion becomes a point where stress acts. In other words, the inclined guide is disposed at a position where the stress generated in the flat conductor when the climbing portion of the first turn and the second turn of the coil is formed is below the elastic limit of the flat conductor. It is possible to form a coil so that the second turn is in close contact. For this purpose, it is desirable to dispose the point where the stress acts as far as possible from the constraint point.

Due to the structure of the inclined guide, it is necessary that the height of the inclined guide is higher than the upper surface of the holding means so that the holding means for pressing the second surface of the flat conductor can get over the flat means. Therefore, when the flat conductor is plastically deformed to form the first turn and the second turn, the coil is formed in a spring shape as shown in the problem. However, according to the method of the invention, the coil can be formed by stress on the flat conductor that does not exceed the elastic limit of the flat conductor when the first and second turns are formed. It can form in the state which mutually adhered.
Since the coils can be formed in close contact with each other, a function for holding the rectangular conductors of the coils in close contact with each other when arranging the coils on the stator is not required, and cost reduction, improvement in yield, and the like can be expected.

Further, in the configuration of the invention described in (2) above, in the winding method described in (1), the inclined guide is positioned adjacent to the gripping means and opposed to the bending position of the bending means with the gripping means interposed therebetween. Is to be placed.
It is desirable that the position of the inclined guide is as far as possible from the gripping means. Therefore, by arranging the inclined guide at the position farthest from the gripping means, the coil can be wound so as to be less than the elastic limit of the flat conductor. Here, the inclination guide is furthest away from the gripping means when the coil is formed by one turn with four sides, the side gripped by the gripping means and edgewise bent is the first side, the adjacent side is the second side, If the opposing sides are the third side and the fourth side adjacent to the third side, it is desirable that the fourth side is placed on the inclined guide.

Then, since a part of the fourth side of the coil passes through the upper part of the gripping means, the tilt guide and the gripping means are substantially located adjacent to each other and the bending means is in the bending position. The inclined guide is disposed at a position facing the bending means with the gripping means interposed therebetween.
Then, by applying a force to the fourth side to form the first turn and the second turn riding portion, it is possible to minimize the gap between the first turn and the second turn.

With the winding device according to the present invention having such characteristics, the following operations and effects can be obtained.
The configuration of the invention of the above (3) includes an inner support means that has an arcuate surface that contacts and guides a flat conductor and supports the first face and a bending means by contacting and pressing the flat conductor. And a winding means for holding the second surface perpendicular to the first surface and an inclined guide for sending the wound flat rectangular conductor to the next turn, and winding the rectangular conductor to form a coil. In the wire device, the inclined guide is disposed at a position where the stress generated in the flat conductor is below the elastic limit when the flat conductor is gripped by the gripping means and the bending means is operated.

When the inclined guide grips the flat conductor with the gripping means and causes the bending means to act, the stress generated in the flat conductor is arranged at a position below the elastic limit. A coil in which a gap between the first turn and the second turn is not easily generated can be formed.
Since the coils can be formed in close contact with each other, a function for holding the rectangular conductors of the coils in close contact with each other when arranging the coils on the stator is not required, and cost reduction, improvement in yield, and the like can be expected.

Further, in the configuration of the invention of (4) above, in the winding device described in (3), the inclined guide is disposed adjacent to the gripping means and at a position facing the bending position of the bending means with the gripping means interposed therebetween. Is.
Therefore, the tilt guide and the gripping means are substantially located adjacent to each other, and when the bending means is in the bending position, the tilt guide is disposed at a position facing the bending means across the gripping means. Is done.
Then, by applying a force to the fourth side to form the first turn and the second turn riding portion, it is possible to minimize the gap between the first turn and the second turn.

It is a perspective view of the principal part of the winding apparatus of this embodiment. It is a perspective view of a coil of this embodiment. It is the schematic diagram showing a mode that the 1st corner of a rectangular conductor of this embodiment was edgewise bent. It is the schematic diagram showing a mode that the 2nd corner of a rectangular conductor of this embodiment is edgewise bent. It is the side view seen from the arrow A of FIG. 1 of this embodiment. It is the side view seen from the arrow B of FIG. 1 of this embodiment. It is a perspective view of the coil wound by the prior art. It is a perspective view of the coil | winding apparatus supposing the prior art. It is the side view seen from the arrow C side of the winding device supposing a prior art. It is a model figure of the cantilever which simplified the flat conductor of this embodiment. It is a graph of the stress strain curve of general copper.

First, an embodiment of the present invention will be described.
In FIG. 1, the perspective view of the principal part of the winding apparatus of this embodiment is shown.
The winding device 100 includes a circular table 21, a side guide 22, a clamper 23, a bending jig 24, and a base 25.
The circular table 21 has a clamper 23 at the center. The side guide 22 plays a role of guiding the side surface of the flat conductor 10.
The clamper 23 has a function of clamping the flat conductor 10 in the thickness direction. The clamper 23 is provided with a flange portion 23a serving as a gripping means and a post portion 23b serving as an inner support means, and has a function of acting on the upper surface of the flat conductor 10 to maintain a predetermined height. When edgewise bending is performed, it is possible to suppress changes in thickness.

The bending jig 24 performs edgewise bending of the flat conductor 10 by applying force to the side surface of the flat conductor 10 by rotating around the clamper 23 when the flat conductor 10 is edgewise bent. By winding the flat conductor 10 along the support column 23b, the flat conductor 10 is edgewise bent to form any one of the first corner R1 to the fourth corner R4. The angle of rotation is 90 ° + α, and in consideration of the amount of springback that occurs when the flat conductor 10 is edgewise bent, the flat conductor 10 can be bent 90 °. Move.
The base 25 is a base of the winding apparatus 100, and includes a circular table 21, a side guide 22, a bending jig 24, and the like. In addition, although it has the taper surface 25a, it is set as the height which does not interfere with the flat conductor 10, when the flat conductor 10 is edgewise bent.

The inclined guide 26 is fixed to the base 25 and forms the first and second turn-up portions of the flat conductor 10. The inclined guide 26 includes a first inclined surface 26a, a second inclined surface 26b, a guide surface 26c, and a top surface 26d. The inclined guide 26 is disposed adjacent to the clamper 23.
The first inclined surface 26 a and the second inclined surface 26 b are formed as gentle inclined surfaces so that the flat conductor 10 rides on the upper surfaces of the flat conductor 10 and the clamper 23 of the previous turn when the flat conductor 10 is edgewise bent. Has been. The guide surface 26 c has a function of guiding the side surface of the flat conductor 10. The height of the top surface 26d of the inclined guide 26 is substantially the same as the height of the clamper 23 in a state where the flat conductor 10 is suppressed.
Although not shown in FIG. 1, a feed mechanism for the flat conductor 10 and an unwinding mechanism from a bobbin around which the flat conductor 10 is wound are provided.

FIG. 2 shows a perspective view of the coil.
The coil 50 is formed by edgewise bending the flat conductor 10. The number of windings is 7 turns, and the winding is performed from the first turn T1 to the seventh turn T7. The flat conductor 10 is a conducting wire in which an insulating coating is provided around a conductor having a flat cross section. The conductor is made of a highly conductive metal such as copper, and the insulating coating is made of a highly insulating material such as enamel.
The first terminal portion 50a and the second terminal portion 50b are formed on one side of the coil end so as to protrude.
The number of turns of the coil 50 is set to 7 for convenience of explanation, but the number of turns is set for convenience of design.

Next, the winding method of the coil 50 of this embodiment is demonstrated.
FIG. 3 is a schematic diagram showing a state in which the first corner of the flat conductor is edgewise bent. FIG. 4 is a schematic diagram showing a state where the second corner of the flat conductor is edgewise bent. In addition, although the flange part 23a of FIG.3 and FIG.4 should be shown as a continuous line, it has shown with the imaginary line for description.
First, the flat conductor 10 is first fed a predetermined distance by a feed mechanism (not shown), and then the clamper 23 holds a second face adjacent to the first face of the flat conductor 10 at right angles. Then, as shown in FIG. 3, the bending jig 24 is rotated around the clamper 23 to perform edgewise bending of the flat conductor 10 while pressing the first surface of the flat conductor 10 against the outer peripheral surface of the clamper 23. . In FIG. 3, the bending jig 24 is applied to the flat conductor 10 in order to form the first corner R1. At this time, the short side of the coil 50 newly overlaps the rectangular conductor 10.

Thereafter, the clamper 23 that clamps the flat conductor 10 is unclamped, the flat conductor 10 is fed a predetermined distance, and the flat conductor 10 is clamped by the clamper 23 again. Thereafter, as shown in FIG. 4, the bending jig 24 is applied to the flat conductor 10 in order to form the second corner R <b> 2. As a result, the second corner R2 is formed by edgewise bending. At this time, the long side of the coil 50 is newly overlapped with the flat conductor 10.
3 and 4 are repeated to form the third corner R3 and the fourth corner R4, and the coil 50 is formed.

Since this embodiment is the said structure, there exists an effect | action and effect which are demonstrated below.
First, the point which can suppress generation | occurrence | production of the clearance gap between the flat conductors 10 of the coil 50 formed with the coil | winding apparatus 100 is mentioned.
FIG. 5 shows a side view as seen from the direction of arrow A in FIG. Moreover, the side view seen from the arrow B of FIG. 1 is shown in FIG. However, for convenience of explanation, a partial cross-sectional view is shown, and the winding state in FIG. 6 is different from that in FIG.
When the coil 50 is wound by the winding device 100, as shown in FIG. 5, the flat conductor 10 is laminated on the upper side with the clamper 23 interposed therebetween. In FIG. 5, the first turn T <b> 1 and the second turn T <b> 2 are stacked on the upper portion of the clamper 23. Similarly, in FIG. 6, when the third turn T3 is formed, the first turn T1 and the second turn T2 are stacked while being held by the inclined guide 26.

FIG. 7 shows a perspective view of a coil wound by the prior art.
FIG. 8 is a perspective view of a winding device that assumes the prior art.
In FIG. 9, the side view seen from the arrow C side of the winding apparatus supposing the prior art is shown.
The coil 150 is in a state in which a gap S is generated and wound in a coil shape. This is a coil substantially equivalent to the coil 50 shown in FIG. 2, but differs in that a gap S is generated.
The coil 150 is wound around a winding device 200 shown in FIG. The difference from the winding device 100 is the configuration of the base 125 and the inclined guide 126.

The base 125 and the inclined guide 126 are integrally formed. And as shown in FIG. 9, seeing from the arrow C side of FIG. 8, the slope is formed. This slope is formed so that the vicinity of the clamper 123 gradually becomes the highest position from the taper surface 125a, and has a function of forming a riding portion so that the first turn T1 rides on the second turn T2, for example. Yes.
A coil 150 as shown in FIG. 7 is formed by winding the flat conductor 10 in this way.

The difference between the winding device 100 of the present embodiment and the conventional winding device 200 is in the shape of the inclined guide 26 and the like. This is because the winding device 100 is designed to act on the coil 50 at the top surface 26d of the inclined guide 26, while the winding device 200 is designed to act on the coil 150 from the portion of the tapered surface 125a. -ing
FIG. 10 shows a model diagram of a cantilever beam obtained by simplifying a rectangular conductor.
In this model diagram, the point at which the flat conductor 10 is gripped by the clamper 23 or the clamper 123 is defined as a reference point K0, and a first action point P1 that acts on the flat conductor 10 with a tapered surface 125a and a top surface 26d of the inclined guide 26. A second action point P2 acting on the flat conductor 10 is shown.
Actually, the first action point P1 acts on the rectangular conductor 10 with the second corner R2 formed, and the second action point P2 acts on the rectangular conductor 10 with the fourth corner R4 formed. Although different, here the rectangular conductor 10 is shown in a straight line for comparison as a model.

According to FIG. 10, the distance from the reference point K0 to the first action point P1 is shown as the first distance X1, and the distance from the reference point K0 to the second action point P2 is shown as the second distance X2.
Comparing the first action point P1 and the second action point P2, as shown, the second distance X2 is longer than the first distance X1.
If the first stress F1 and the second stress F2 shown in FIG. 10 are equal, the longer the second distance X2 is, the more the second stress F2 acts on the second action point P2 is the first action point P1. The amount of distortion generated in the flat conductor 10 is smaller than when the stress F1 is applied.

FIG. 11 shows a graph of a stress strain curve of copper.
Since copper is used for the flat conductor 10, the elastic limit ER is at a position as shown in FIG. When distortion occurs in the flat conductor 10 beyond the elastic limit ER, the flat conductor 10 undergoes plastic deformation during processing.
According to the applicant's investigation, in the case of the winding method using the winding device 200, it has been found that the stress at the first action point P1 far exceeds the elastic limit ER and causes plastic deformation. Therefore, the gap S is generated as in the coil 150.

As shown in FIG. 5 or FIG. 6, the gap S always occurs between the second turn T2 and the third turn T3 during winding. This is because it is necessary to avoid the thickness of the clamper 23 that holds the flat conductor 10. Therefore, when the flat conductor 10 is wound beyond the elastic limit ER of the flat conductor 10 in the configuration of the winding device 200, the coil 150 is formed in a coil shape with a gap S as shown in the coil 150.
However, by arranging the position of the inclined guide 26 on the side of the clamper 23 as in the configuration of the winding device 100, the distance of the second action point P2 can be gained like the second distance X2, and as a result, the elasticity The flat conductor 10 can be wound around the coil 50 without exceeding the limit ER.

That is, it is possible to perform winding in a state where the gap S between the rectangular conductors 10 is not generated as in the coil 50 instead of the coil 150.
This is because the elastic limit ER is not exceeded when the coil 50 is wound. Therefore, even if the coil is wound in the state shown in FIG. 5 or 6 or expanded between the second turn T2 and the third turn T3, A force acts in the direction of contraction, and a state in which no gap is generated as in the first turn T1 and the second turn T2 can be obtained.

If the gap S is formed like the coil 150, it is difficult to shrink it like the coil 50. Therefore, when the coil 150 is inserted into a stator core (not shown), it is necessary to attach a component that holds the coil 150 as described in the problem.
However, if the coil can be formed in a state where the gap S is not generated as in the coil 50, a part for holding the coil 50 is not required, so that the manufacturing becomes easy and the manufacturing cost can be expected to be reduced.

Such a gap S between the coils 50 is more likely to occur when, for example, the coil 50 is double-wrapped. This is because the edgewise bending process from the first corner R1 to the fourth corner R4 is performed twice at each turn from the first turn T1 to the seventh turn T7, and the gap S is further generated. It becomes easy.
However, since the winding can be performed so as not to exceed the elastic limit ER when forming the climbing portion of the first turn T1 and the second turn T2, the present invention is effective even when the coil 50 is double wound. It is.

Although the invention has been described according to the present embodiment, the invention is not limited to the embodiment, and by appropriately changing a part of the configuration without departing from the spirit of the invention. It can also be implemented.
For example, it does not prevent changing the material shown in the present embodiment. Moreover, it does not prevent changing the configuration within the scope of the design matters.
Further, the present invention can be applied even if the shape of the coil is changed according to design specifications, such as the number of turns of the coil 50 or double winding as described above.

DESCRIPTION OF SYMBOLS 10 Flat conductor 21 Circular table 22 Side guide 23 Clamper 23a Flange part 24 Bending jig 25 Base 25a Tapered surface 26 Inclined guide 26a First inclined surface 26b Second inclined surface 26c Guide surface 26d Top surface 50 Coil 50a First terminal portion 50b Second terminal portion 100 Winding device ER Elastic limit

Claims (4)

An inner support means that has an arcuate surface that contacts and guides the flat conductor and supports the first face; a bending means that contacts and presses the flat conductor; and the first face of the flat conductor; In a winding method comprising: gripping means for gripping an adjacent second surface; and an inclined guide for sending the wound rectangular conductor to a next turn, and winding the rectangular conductor to form a coil.
Holding the second surface of the rectangular conductor by the gripping means;
When the rectangular conductor rides on the inclined guide, the bending means is caused to act on the inclined guide disposed at a position where the stress generated in the rectangular conductor is less than an elastic limit, and the rectangular conductor A winding method characterized by forming a coil in close contact by bending the wire with the bending means. The winding method according to claim 1, wherein
The winding method, wherein the inclined guide is disposed adjacent to the gripping means and at a position facing the bending position of the bending means with the gripping means interposed therebetween. An inner support means that has an arcuate surface that contacts and guides the flat conductor and supports the first face, supports the bending means by abutting and pressing the flat conductor, and the flat conductor is connected to the first conductor. In a winding apparatus comprising: gripping means for gripping a second surface orthogonal to one surface; and an inclined guide for sending the wound rectangular conductor to the next turn, and winding the rectangular conductor to form a coil.
The winding apparatus according to claim 1, wherein the inclined guide is disposed at a position where a stress generated in the flat conductor is below an elastic limit when the flat conductor is gripped by the gripping means and the bending means is operated. In the winding device according to claim 3,
The winding apparatus, wherein the inclined guide is disposed adjacent to the gripping means and opposed to a bending position of the bending means with the gripping means interposed therebetween.

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