JP2014075952A - Coil manufacturing system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable one-time bending even for a quadrupolar machine in manufacturing a coil of a rotary electric machine.SOLUTION: The coil manufacturing system comprises an edgewise bending device 18, a flatwise bending device 19, a cutting device 21 and a cut surface finishing device 105. The edgewise bending device 18 performs edgewise bending of laminated conductors at the end portion in a lateral-width direction in a lump. The flatwise bending device 19 performs flatwise bending of the laminated conductors at the edgewise bent end portion in the direction of laminating. The cutting device 21 cuts the flatwise bent end portion to a predetermined length. The cut surface finishing device 105 finishes the cut surface of the laminated conductor at the cut end portion. The edgewise bending device 18 may have an edgewise bent coil restraint mechanism which prevents the displacement of a conductor during forming by restraining the linear portion and the end portion in their lateral-width directions and thickness directions.

Description

  The present invention relates to a coil manufacturing system for a rotating electrical machine.

  A coil of a rotating electrical machine is composed of a large number of conductors laminated with an insulator in the thickness direction, a linear portion along the axial direction of the rotating body, and an end portion along an arc of the rotating body connecting both ends of the linear portion. The two conductors are manufactured by joining each conductor at each end portion.

  A generator for a thermal power plant is usually a two-pole machine, and the rotor coil has a laminated thickness of conductors in the radial direction of about 300 mm to 600 mm. Manufacture.

  A technology of a rotor coil batch bending apparatus for this purpose is known. This rotor coil batch bending apparatus has an advantage that a coil can be manufactured from laminated conductors at a time, but 90 ° bending (hereinafter referred to as “edgewise bending” or “EW bending”) in which 90 ° bending is performed in the width direction of the conductor. By performing the processing, the inner side of the conductor tends to swell and the outer side tends to be thinned at the corner which is a bent portion of the coil. For this reason, in order to prevent the leakage of the cooling medium from the corner, an operation of adjusting the thickness of each conductor of the coil has occurred.

  Also in arc bending (hereinafter referred to as “flatwise bending” or “FW bending”), the coil does not adhere to the mold and there is variation in coil forming accuracy, and extra length is added to the coil end when cutting in the next process. Then, the work of adjusting the finish while measuring the coils one by one to the regular length has occurred.

  On the other hand, generators for nuclear power plants are usually quadrupole machines, and the rotor coil has a high conductor stack height of 450 to 1000 mm in the radial direction, and the number of coil stacks is twice that of a two-pole machine. Double the equipment capacity is required. In addition to the higher stacking height than the two-pole machine, the outer shape of the rotor into which the coil is fitted is also larger than the two-pole machine, so the length of the arc portion of the coil is longer than that of the two-pole machine.

  For this reason, even if a simple scaled-up version of the batch bending apparatus is manufactured, it is necessary to increase the working height of the coil linear portion because the arc becomes long. When the work height is increased, the accessibility of the worker is deteriorated, and the danger of a crash is caused because the work is accessed using a scaffold or a step.

Japanese Patent No. 3825578

  Even if the generator rotor coil batch bending device for thermal power is simply scaled up to produce a nuclear bending device, the workability is poor and the forming accuracy is not improved, so the number of correction work after bending increases. There was a problem that.

  For this reason, in the manufacture of coils for a four-pole machine, conventionally, a plurality of flat bars formed by brazing have been manufactured. For a coil of a two-pole generator, a brazing operation is required in the process of joining two sets of coils that have been collectively bent at both ends. In this connection, the conductors of the same layer are joined at one joint, and the conductors of the layers shifted further at the other joint are joined by brazing.

  On the other hand, in the case of a 4-pole machine, since the same bending cannot be performed even in a part where EW bending is performed in the 2-pole machine, it is necessary to join by brazing. The machine has two joints, whereas the quadrupole machine has six joints and triples. In addition, since the number of layers to be joined at each location is larger in the 4-pole machine than in the 2-pole machine, the manufacture of the coil for the 4-pole machine requires more labor than in the 2-pole machine.

  Accordingly, an object of the present invention is to provide a coil manufacturing system for a rotating electrical machine that enables batch bending even in a quadrupole machine.

  In order to achieve the above-described object, according to the present invention, a coil to be fitted into a slot formed on the outer peripheral surface of a rotor shaft of a rotating electrical machine is integrally molded for each slot or formed by dividing a plurality of coils into a plurality of blocks. In the coil manufacturing system, all the flat conductors extending in the longitudinal direction for the same slot are aligned in the width direction so that the end portions at both ends of the laminated conductor are bent in the same direction. An edgewise bending apparatus that performs edgewise bending, which is a bending process of the laminated conductors in the lateral width direction, for each of the laminated conductors, and the laminated conductor of the end portion that has been edgewise bent. A flat-wise bend, which is a bending process in the direction of the lamination, so that each can be bent in the same direction. Wise bending device, cutting device that cuts each end portion that has been flatwise bent so as to have a predetermined length, and cutting of the laminated conductor of each end portion that has been cut by the cutting device And a cut surface finishing device for finishing the surface.

  ADVANTAGE OF THE INVENTION According to this invention, the coil manufacturing system of the rotary electric machine which enables collective bending also in a 4-pole machine can be provided.

It is a perspective view which shows the coil in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a conceptual perspective view of the rotor which attached the coil to the rotor shaft. It is a perspective view which shows the change of the shape of the conductor in the coil manufacture process in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a top view which shows the external shape of the one side of the coil collective bending system in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the external shape of the one side of the coil collective bending system in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a top view which shows the external shape of the EW bending apparatus in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the external shape of the EW bending apparatus in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. FIG. 8 is a side view taken along line VIII-VIII in FIG. 6 showing a coil restraining guide portion of an EW bending coil restraining mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. It is a front view which shows the external shape of the coil press mechanism in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a partial top view which shows the relationship with the conductor of the coil press mechanism in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a top view which shows the external shape of the EW bending template correction | amendment mechanism in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the external shape of the EW bending template correction | amendment mechanism in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a flowchart which shows the EW correction bending step in the coil manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the external shape of the FW bending apparatus and coil correction fixing mechanism in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a side view which shows the external shape of the FW bending apparatus and coil correction fixing mechanism in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the external shape of the shaping | molding part of the FW bending mechanism in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the 1st state of the coil edge part in FW bending load adjustment in the coil manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the 2nd state of the coil edge part in FW bending load adjustment in the coil manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the 3rd state of the coil edge part in FW bending load adjustment in the coil manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the 4th state of the coil edge part in FW bending load adjustment in the coil manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the 5th state of the coil edge part in FW bending load adjustment in the coil manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the 6th state of the coil edge part in FW bending load adjustment in the coil manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is a flowchart which shows the step regarding FW bending load adjustment in the coil manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the external shape of the FW bending coil width restraint guide in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a side view which shows the external shape of the FW bending coil width | variety restraint guide in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. FIG. 25 is a cross-sectional view taken along line XXI-XXI in FIG. 24 showing the outer shape of the FW bending coil guide mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. It is a front view which shows the external shape of the coil cutting device and cutting part finishing device in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a side view which shows the external shape of the coil cutting device and cutting part finishing apparatus in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a front view which shows the external shape of the coil conveyance mechanism in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a side view which shows the external shape of the coil conveyance mechanism in the coil manufacturing system and method of the rotary electric machine which concerns on embodiment of this invention. It is a block diagram which shows the structure of the automatic manufacturing system by the product specification data in the coil manufacturing method of the rotary electric machine which concerns on embodiment of this invention.

  Hereinafter, a coil manufacturing system and a coil manufacturing method according to embodiments of the present invention will be described with reference to the drawings. Here, the same or similar parts are denoted by common reference numerals, and redundant description is omitted.

  FIG. 1 is a perspective view showing a coil in a coil manufacturing system and method for a rotating electrical machine according to an embodiment of the present invention. The coil 10 includes a laminated conductor 101 in which conductors 100 are laminated in the thickness direction, and an insulator is interposed between the conductors 100 adjacent to each other on the upper and lower sides of the laminated conductor 101.

  The coil 10 includes a straight portion 11, a corner portion 12, and an end portion 16. In order to improve the performance of the rotating electrical machine, it is desirable to make the length of the straight portion 11 longer, and in terms of performance, the bending radius of the corner portion 12 is preferably as small as possible.

  FIG. 2 is a conceptual perspective view of a rotor in which a coil is attached to a rotor shaft. A slot portion (not shown) is formed on the surface of the rotor shaft 14 in the radial direction, and the coil 10 is inserted into the slot, and is firmly fixed and assembled with an insulator to manufacture a rotor. Two coils 10 function as a set of two coils.

  For this purpose, the respective conductors 100 are joined to each other at the brazed joints 69a and 69b where the end faces of the coil 10 are brought together. The conductors 100 of the same layer are joined at one brazing joint 69a, and the conductors 100 that are further shifted are joined at the other brazing joint 69b. In this way, the coil function is ensured as a whole.

  FIG. 3 is a perspective view showing a change in the shape of the conductor during the coil manufacturing process in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. FIG. 3A shows an initial state of the laminated conductor 101 in which a large number of conductors 100 are in a laminated state.

  One conductor 100 has a horizontally long rectangular cross section whose width is longer than its thickness, and extends in the longitudinal direction. Further, a groove extending in the longitudinal direction of the conductor 100 is formed in the center of one of the wide surfaces of each conductor 100, and the longitudinal ventilation hole 23 is formed by facing the conductor 100 in the direction of the groove. Is done.

  FIG. 3B shows a result of forming the corner portion 12 and the end portion 16 on both sides by EW bending in which both sides of the laminated conductor 101 are bent at an angle of 90 ° in the same direction. As shown in FIG. 3B, the bending direction is not the thickness direction of the conductor 100 but the horizontal width direction. In order to bend in the width direction, the conductor 100 is thick on the inside and thin on the outside as shown by the corner 12 in the figure, so that it is necessary to correct this.

  FIG. 3C shows a result of performing FW bending for bending the end portion 16 into an arc shape along the curved surface of the slit on the surface of the rotor shaft. Both end portions 16 are bent in an arc shape in the same direction. At this stage, there is a situation in which the conductors 100 of the end portion 16 are uneven in the lateral width direction, and this needs to be corrected.

  FIG. 3D shows that the conductors 100 need to be joined at the end portion of the end portion 16 as shown in FIG. However, since the cut surfaces do not have enough surfaces for joining, it is necessary to finish the cut surfaces.

  As in the case of a 4-pole machine, since the number of laminated conductors 100 constituting the laminated conductor 101 is large, as described above, ordinary bending and cutting are simply performed in each processing step of EW bending, FW bending, and cutting. However, the processing accuracy required for coil forming is not achieved, and correction or further finishing is required.

  FIG. 4 is a plan view showing the outer shape of one side of the coil batch bending system in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. FIG. 5 is a front view showing the outer shape of one side of the coil batch bending system in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention.

  In order to make the following description easy to understand, X, Y, and Z directions are taken as shown in the figure. The X direction and the Y direction are perpendicular to each other in the horizontal plane, and the Z direction is vertically upward.

  The coil batch bending system according to the present embodiment performs EW bending, FW bending, cutting, and cutting surface finishing on both sides of the laminated conductor 101, respectively. For this reason, two sets of unitized mechanisms are arranged on both sides of the laminated conductor 101.

  Specifically, an EW bending device 18, an FW bending device 19, a cutting device 21, and a cut surface finishing device 105 are provided. The EW bending device 18 performs EW bending on both sides of the laminated conductor 101. The FW bending device 19 performs FW bending on the end portion 16 generated by EW bending. The cutting device 21 cuts the end surface of the end portion 16, and the cutting surface finishing device 105 performs the finishing processing of the cutting surface by the cutting device 21.

  The coil batch bending system includes a plurality of rails 113 each extending in the X direction, and each of the EW bending device 18, the FW bending device 19, and the cutting device 21 has a construction base (not shown) that runs on the rail 113 and is movable. . The cut surface finishing device 105 is mounted on the construction base of the cutting device 21.

  The coil batch bending system includes a coil transport device 31. The coil conveying device 31 holds the straight portion 11 and conveys the coil 10 between the EW bending device 18 and the FW bending device 19.

  The coil 10 is basically placed along the X direction and is positioned based on the center reference in the X direction. The EW bending, FW bending, and cutting apparatus basically move with reference to the X direction, that is, the coil longitudinal center. However, when the straight portion 11 of the coil 10 is short, interference occurs when the two sets are close to the center, and therefore, the operation may be performed based on one side. That is, depending on the setting, the apparatus can move relative to the longitudinal direction of the coil 10 or the coil 10 can be moved.

  In order to solve the problem that the work center becomes high even if the batch bending apparatus for a two-pole machine is applied to a four-pole machine as it is, the radius of the end portion 16 of the coil 10 is not fixed without fixing the straight portion 11. The coil 10 is manufactured based on the center. Further, the apparatus is configured to perform FW bending in the horizontal direction so that the center of gravity of the coil 10 is downward and it is difficult to fall.

  In this way, even if the coil is increased in size, by changing the posture of the apparatus, an operator can access it, and molding and coil conveyance can be performed between processes.

  FIG. 6 is a plan view showing the outer shape of the EW bending apparatus in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. FIG. 7 is a front view showing the outer shape of the EW bending apparatus in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention.

  The EW bending device 18 has an EW bending shaft 106 in the center. Further, a coil restraining guide 49 for restraining the laminated conductor 101 is provided in order to prevent the laminated conductor 101 from shifting during EW bending.

  In addition, a hydraulic cylinder 48 for applying a load for EW bending and a turning rail 104 for rotating the hydraulic cylinder 48 are provided. The swivel rail 104 extends in a ring shape in the (XY) plane.

  Further, the EW bending device 18 includes an angle measurement unit 38 provided in the coil clamp unit 37 of the EW bending device 18 in order to confirm the angle of the end portion 16 after the EW bending. The angle measurement unit 38 may be, for example, a photoelectric sensor. Alternatively, a device that measures a position mechanically along the end portion may be used.

  8 is a side view taken along line VIII-VIII in FIG. 6 showing a coil restraining guide portion of the EW bending coil restraining mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention.

  As shown in FIG. 8, the coil restraining guide 49 has a shape surrounding the upper and lower surfaces and one side surface of the laminated conductor 101. Further, in the portion where the laminated conductor 101 contacts the EW bending shaft 106, the laminated conductor 101 is restrained by the coil restraining guide 49 and the EW bending shaft 106 so that there is no destination for deformation and escape.

  In the EW bending apparatus according to the present embodiment configured as described above, first, the laminated conductor 101 is preliminarily determined by using a template 24 preliminarily installed in the apparatus and a positioning pin (not shown) using the vent holes 23 processed in advance. The position is fixed.

  The fixed laminated conductor 101 is restrained by the coil restraining guide 49. Here, the hydraulic cylinder 48 applies a load to the coil restraint guide 49 from the lateral direction to a dimension corresponding to the theoretical dimension.

  The hydraulic cylinder 48 turns on the turning rail 104 with a load applied to the coil restraining guide 49 from the lateral direction. As a result, the coil restraining guide 49 rotates about 90 ° around the EW bending shaft 106 while restraining the laminated conductor 101. This rotation angle is controlled by the angle of the hydraulic cylinder 48 turning on the turning rail 104.

  Thereafter, the coil restraining guide 49 is opened, the coil 10 is removed, and the coil is conveyed by the coil conveying device 31 to the FW bending device 19 in the next process.

  When the laminated conductor 101 is bent at once, a large number of conductors 100 are laminated and formed, so that when the load is applied to the laminated conductor 101, the plasticity of the material of the conductor 100 flows in the opening direction, and as a result, the conductor In some cases, the cross section of 100 cannot be kept rectangular, or the corner 12 does not have an accurate shape.

  As a mechanism for preventing this phenomenon, the EW bending coil restraint mechanism 107 includes a coil restraint guide 49 and a hydraulic cylinder 48. As a result, the coil 10 cannot swell from the coil restraining guide 49 during coil forming, the plastic flow of the coil 10 is suppressed, and precise bending can be performed.

  FIG. 9 is a front view showing the outer shape of the coil press mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. FIG. 10 is a partial plan view showing the relationship with the conductor of the coil press mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention.

  The coil press mechanism 53 includes a lower press portion 54 and, together with the EW bending shaft 106, shapes the distortion of each laminated conductor 101 of the corner portion 12 after EW bending.

  The lower press part 54 is provided concentrically with the EW bending shaft 106. The lower press part 54 can move up and down independently of the EW bending shaft 106 and is driven by, for example, a hydraulic cylinder.

  The lower press portion 54 has a cylindrical shape extending in the vertical direction, and has a hole penetrating in the vertical direction. The outer diameter is a dimension that can sufficiently cover the outside of the corner portion 12 of the coil 10, and the inner diameter is substantially equal to the outer diameter of the EW bending shaft 106.

  Since each conductor 100 of the laminated conductor 101 is bent in the lateral width direction by EW bending, the plate thickness increases inside the EW bending, and the plate thickness decreases outside the EW bending. For this reason, the corner portion 12 having an influence in the thickness direction due to EW bending, and the laminated conductor 101 of the portion affected by the EW bending among the straight portion 11 and the end portion 16 are moved downward from the upper portion by the lower press portion 54. By compressing, unevenness in the thickness direction on the inside and outside of the EW bend is corrected.

  FIG. 11 is a plan view showing the outer shape of the EW bending template correction mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. FIG. 12 is a front view showing the outer shape of the EW bending template correction mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention.

  The angle of the end portion 16 as a result of the EW bending is measured by the angle measuring unit 38. Even if the coil restraining guide 49 is rotated by 90 °, the bending angle θ from the straight portion 11 of the end portion 16 after releasing the load is not 90 ° due to the spring back, and is, for example, a small angle of about 2 degrees. . Therefore, based on the angle measurement result by the angle measurement unit 38, the hydraulic cylinder 48 is turned on the turning rail 104 and the coil restraining guide 49 is rotated by an angle corresponding to this difference, thereby adjusting the finished angle.

  FIG. 13 is a flowchart showing an EW correction bending step in the method of manufacturing a coil for a rotating electrical machine according to the embodiment of the present invention.

  First, the specifications and specifications of the coil 10 to be manufactured are registered (S101). Specifications and specifications include the width and thickness of the coil 10, dimensions such as straight portions, and the number of layers of the laminated conductor 101. This is because the amount of springback when the coil 10 is bent varies somewhat depending on the width, thickness, and number of layers of the coil 10.

  After step S101, the database is accessed to obtain data necessary for coil manufacture for the specifications and specifications of the target coil 10 (S102).

  By structural analysis in advance, evaluate the overbend coefficient of the value of how many times the springback coil should be overbended with respect to the amount of springback when bending 90 °, and build a database of this ratio deep.

  For example, when 90 ° is formed when a certain coil is formed and a springback of 2 ° occurs, the angle to be overbended at this time is extracted from database data based on the coil specification data. When the overbend coefficient is twice, it is possible to accurately perform 90 ° bending by performing 4 ° overbend bending, which is twice the amount of springback in the second bending.

  After step S102, the angle of the EW bending target value is determined based on the acquired data (S103). EW bending is performed by setting the EW bending target value determined in step S103 (S104).

  After step S104, the load on the coil restraining guide 49 by the hydraulic cylinder 48 is released so that there is no load on the coil 10 (S105). After step S105, the contact position is confirmed again by changing the torque of the electric motor to be close to the coil 10 (S106).

  A measurement result by the angle measuring unit 38 of the rotation angle of the end unit 16, for example, encoder signal information is captured (S107).

  It is determined whether or not the rotation angle measurement result acquired in step S107 is within a specified allowable value range (S108). If it is determined that the value is within the specified allowable value, the EW bending ends (S109). On the other hand, if it is not within the prescribed tolerance, step S102 and subsequent steps are repeated.

  FIG. 14 is a front view showing the outer shape of the FW bending apparatus and the coil correction fixing mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. FIG. 15 is a side view showing the outer shape of the FW bending apparatus and the coil correction fixing mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. The coil correction fixing mechanism will be described later.

  The FW bending apparatus 19 includes an FW bending mold 20, a forming roller 36 (see FIG. 16), a hydraulic cylinder 57, and a face plate 56. The FW bending mold 20 FW-bends the laminated conductor 101 extending in the X direction from the back of the paper surface of FIG. 14 and the end portion 16 of the laminated conductor 101 EW-bent in the left side of FIG. When this is done, it becomes a mold for forming into an arc shape.

  The forming roller 36 presses the laminated conductor 101 against the FW bending mold 20 from above and performs FW bending. The hydraulic cylinder 57 is used to move the face plate 56. The positional relationship between the FW bending mold 20 and the coil 10 can be adjusted.

  In addition, an FW clamp correction mechanism 95 that corrects irregularities of the laminated conductor 101 of the end portion 16 for cutting before or after FW bending, and a coil correction fixing mechanism 103 that corrects disturbance of the laminated conductor 101 are provided.

  In order to improve conductivity, the coil material is often made of silver-drawn copper, but there is a tendency to work and harden because of processing such as cooling holes. For this reason, after processing a cooling hole etc., a coil material is annealed, residual stress is removed, and after honing the coil surface, it uses as a collective bending coil material.

  The coil 10 is slightly deformed by annealing, and is bent with a slight angle error caused by EW bending. In order to set the bent coil straight, an FW clamp correction mechanism 95 is provided.

  The FW clamp correction mechanism 95 includes an FW bending mold 20, a face plate 56, and a hydraulic cylinder 57. The face plate 56 has a rectangular flat plate shape extending in the YZ direction. The face plate 56 is in the position shown in FIG. 15 when the FW clamp correction mechanism 95 is operating, and is in close contact with the end portion 16 of the coil 10. The face plate 56 is moved by a hydraulic cylinder 57.

  Further, the face plate 56 is retracted to a position 56a indicated by a two-dot chain line in FIG. 15 except when the FW clamp correction mechanism 95 is in operation.

  Since the face board 56 comes into close contact with the side surface of the end portion 16 of the coil 10 by the FW clamp correction mechanism 95, the presence of a gap can be confirmed. When the gap tends to be inclined or when the gap is locally large, it can be visually observed that the coil is not straight. Therefore, the coil can be straightly corrected by hitting the face plate 56 with a hammer. .

  Moreover, although not shown in figure, you may correct | amend by pressing on the face board 56 with a press mechanism etc. FIG. The correction using the FW clamp correction mechanism 95 functions both before and after performing the FW bending process. However, by performing the correction before performing the FW bending process, it is possible to manufacture with high quality.

  FIG. 16 is a front view showing an outer shape of a molded part of the FW bending mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention.

  A concentric cylinder turning frame 109 is provided around the FW bending mold 20. A cylinder holding portion 108 is attached to the cylinder turning frame 109, and the cylinder holding portion 108 can turn along the cylinder turning frame 109. The cylinder holder 108 is turned by the rotation of the turning shaft 112.

  The turning shaft 112 extends radially from the rotation center of the cylinder turning frame 109 and moves in the circumferential direction by an electric motor and a gear (not shown) at the rotation center. The pivot shaft 112 is coupled to the cylinder holding portion 108.

  A molding cylinder 36a, a first cylinder 61a, a second cylinder 62a, a third cylinder 63a, and a fourth cylinder 64a are attached and fixed to the cylinder holding portion 108 at intervals in the circumferential direction. Each has an electric motor. A molding roller 36 is attached to the tip of the molding cylinder 36a and is pressed against the end portion 16 by the molding cylinder 36a. The forming roller 36 has a width that can cover the width of the end portion 16.

  The first cylinder 61a, the second cylinder 62a, the third cylinder 63a, and the fourth cylinder 64a have a first support roller 61, a second support roller 62, a third support roller 63, 4 support rollers 64 are attached, and a load can be transmitted to the laminated conductor 101 by each electric motor.

  The first support roller 61, the second support roller 62, the third support roller 63, and the fourth support roller 64 are respectively a first cylinder 61a, a second cylinder 62a, a third cylinder 63a, and a fourth cylinder. It is pressed against the end portion 16 by the cylinder 64a.

  The first support roller 61, the second support roller 62, the third support roller 63, and the fourth support roller 64 have a width that can cover the width of the end portion 16.

  FIGS. 17 to 22 are front views showing first to sixth states of the coil end portion in each step relating to FW bending load adjustment in the coil manufacturing method of the rotating electrical machine according to the embodiment of the present invention. Transition from the first state to the sixth state in numerical order.

  The forming roller 36 is pressed against the end portion 16 by the forming cylinder 36a from the upper part of the left and right center positions of the linear portion 11 of the coil 10, and pressurizes the end portion 16 (see FIG. 17).

In this state, when the turning shaft rotates and the first cylinder 61a comes to the upper part of the left and right center positions of the linear portion 11 of the coil 10, the first cylinder 61a pushes out the first support roller 61. The first support roller 61 is pressed against the end portion 16 by the first cylinder 61a to pressurize the end portion 16 (see FIG. 18).
The forming roller 36 pressurizes the end portion 16 along with the rotation of the turning shaft, and performs FW bending. The first support roller 61 also turns while maintaining a distance from the forming roller 36 and pressing the end portion 16.

Similarly, when the second cylinder 62a, the third cylinder 63a, and the fourth cylinder 64a come to the upper part of the left and right center positions of the linear portion 11 of the coil 10, the second support roller 62 and the third cylinder 63, respectively. The support roller 63 and the fourth support roller 64 are pushed out. The second support roller 62, the third support roller 63, and the fourth support roller 64 are pressed against the end portion 16 to pressurize the end portion 16 (see FIGS. 19 to 21 respectively).
Finally, while the first support roller 61, the second support roller 62, the third support roller 63, and the fourth support roller 64 all pressurize the end portion 16, the forming roller 36 rotates. FW bending of the remaining end portion 16 is performed (see FIG. 22).

  The pressurization of the forming roller 36, the first support roller 61, the second support roller 62, the third support roller 63, and the fourth support roller 64 detects the load torque of the electric motor as a current value. Is set in advance so that an output of 5 A is obtained for 100% of the output.

  FIG. 23 is a flowchart showing steps related to FW bending load adjustment in the method of manufacturing a coil for a rotating electrical machine according to the embodiment of the present invention.

  First, the position of the forming cylinder 36a is set above the center line of the linear portion 11 of the coil 10, the forming cylinder 36a is pressurized, and the forming roller 36 is pushed out (S201). It is detected that the forming roller 36 is seated on the laminated conductor 101 (S202). The detection means may be, for example, a method based on a change in torque, or a limit switch provided at a position corresponding to the seating position. The detection means is the same for the support roller.

  After step S202, the turning shaft 112 is rotated (S203). During this time, it is confirmed whether or not the rotation of the turning shaft 112 has become 15 ° (S204). When the rotation angle of the turning shaft 112 reaches 15 °, the rotation of the turning shaft 112 is stopped (S205).

  After step S205, the first cylinder 61a is pressurized. The first support roller 61 is pushed out (S206). It is detected that the first support roller 61 is seated on the laminated conductor 101 (S207).

  From this state, the turning shaft 112 is rotated (S208). During this time, it is confirmed whether or not the rotation of the turning shaft 112 has reached 30 ° (S209). When the rotation angle of the turning shaft 112 reaches 30 °, the rotation of the turning shaft 112 is stopped (S210).

  After step S210, the second cylinder 62a is pressurized. The second support roller 62 is pushed out (S211). It is detected that the second support roller 62 is seated on the laminated conductor 101 (S212).

  From this state, the turning shaft 112 is rotated (S213). During this time, it is confirmed whether or not the rotation of the turning shaft 112 has become 45 ° (S214). When the rotation angle of the turning shaft 112 reaches 45 °, the rotation of the turning shaft 112 is stopped (S215).

  After step S215, the third cylinder 63a is pressurized. The third support roller 63 is pushed out (S216). It is detected that the third support roller 63 is seated on the laminated conductor 101 (S217).

  From this state, the turning shaft 112 is rotated (S218). During this time, it is confirmed whether or not the rotation of the turning shaft 112 has reached 60 ° (S219). When the rotation angle of the turning shaft 112 reaches 60 °, the rotation of the turning shaft 112 is stopped (S220).

  After step S220, the fourth cylinder 64a is pressurized. The fourth support roller 64 is pushed out (S221). It is detected that the fourth support roller 64 is seated on the laminated conductor 101 (S222).

  From this state, the turning shaft 112 is rotated (S223). When the turning angle reaches a preset turning end angle, the turning is finished (S224).

  In the conventional FW bending mechanism in the existing machine, since the bending is performed by a pair of roller units, there is a problem that the coil material in the portion through which the bending roller passes rises and cannot be bent accurately. Further, even if the raised portion is brought into close contact with an external jig, it may not be brought into close contact, and an error may occur when cutting the coil.

  In this embodiment, after the relationship between the current value and the load is grasped, the forming roller 36, the first support roller 61, the second support roller 62, the third support roller 63, and the fourth support roller. The pressurization of 64 detects the motor load torque as a current value.

  For this reason, an appropriate load is applied according to the specifications and specifications of the coil. As a result, the laminated conductor 101 is always constrained at a constant interval even in a portion where the molding has been completed, and can be brought into close contact without lifting from the FW bending mold 20.

  In FW bending, if a bending force greater than the appropriate load is applied, only the coil surface layer is crushed and the coil stacking tends to shift. Therefore, it is desirable to bend with an optimum load, and damage to the coil surface may occur. Less.

  In FW bending, the bending load is affected by three conditions: coil thickness, coil width, and number of coil layers. This relationship is evaluated in advance by structural analysis, and a load according to three conditions is obtained by an approximate expression. Coil pressure is calculated by inputting the coil thickness, coil width, and number of coil layers from the product specifications and specification data.

  As a result, an appropriate load can be applied by exciting an equivalent current to the drive motors of the forming cylinder 36a, the first cylinder 61a, the second cylinder 62a, the third cylinder 63a, and the fourth cylinder 64a. It becomes possible.

  As described above, according to the present embodiment, it is possible to manufacture the coil 10 with little damage to the surface of the multilayer conductor 101 and less damage to the surface.

  FIG. 24 is a front view showing the outer shape of the FW bending coil width constraint guide in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. FIG. 25 is a side view showing the outer shape of the FW bending coil width constraint guide in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. FIG. 26 is a cross-sectional view taken along line XXI-XXI in FIG. 24 showing the outer shape of the FW bending coil guide mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention.

  The FW bending coil guide mechanism 115 includes two coil guides 68 and a holder 66. These coil guides 68 are provided in front of the forming roller 36 in the turning direction, that is, on the opposite side to the first support roller 61 and the like so as to sandwich both side surfaces of the laminated conductor 101 of the end portion 16. Each coil guide 68 has a flat plate shape extending vertically.

  A holder 66 is provided to accommodate the coil guide 68. The holder 66 is formed so as to contact two adjacent side surfaces of the two coil guides 68 and extends vertically.

  A stopper 67 is provided at the upper end of the coil guide 68 so that the coil guide 68 does not fall from the holder 66. The side surface of the coil guide 68 on the side of the laminated conductor 101 is chamfered by about 30 degrees in the traveling direction and the backward direction so that it does not bite into the laminated conductor 101.

  In many cases, the laminated conductor 101 composed of a large number of layers has a non-flat coil cross section due to the deformation in the EW bending in the previous process and the influence of annealing performed before coil bending.

  As described above, the molding roller 36 is positioned after positioning the molding start position with respect to the irregular coils due to the molding effect of the previous process to some extent or the annealing effect before the coil bending process. Is moved to a position in contact with the coil 10.

  At this time, the position of the forming roller 36 is finely adjusted to a position where the coil guide 68 enters the coil equally, and the coil guide 68 is guided at the center of the coil 10. By performing FW bending in this state, it is possible to suppress the generation of a lateral load generated on the side surface in the FW bending direction, and to shape the coil straight.

  Next, with reference to FIG. 14 and FIG. 15, a coil correction fixing mechanism in a coil manufacturing system and method for a rotating electrical machine according to an embodiment of the present invention will be described.

  The coil correction fixing mechanism 103 includes a FW bending mold 20, a face plate 56, and a fastening plate 71. The fastening plate 71 is provided at a position facing the face plate 56 across the laminated conductor 101 of the end portion 16.

  A screw hole 70 is provided in the fastening plate 71. Further, a screw hole (not shown) is provided at a position corresponding to the face plate 56. The fastening plate 71 is formed so as to be fixed to the face plate 56 by screws (not shown).

  Note that when the fastening plate 71 partially covers the laminated conductor 101 of the end portion 16 as shown in FIG. 22, a plurality of fastening plates 71 may be used to cover the whole. Or you may cover the whole with one sheet.

  The laminated conductor 101 molded in the FW bending process is not completely in close contact with the FW bending mold 20 due to the effects of plastic deformation and springback generated by the molding. If the coil forming is finished in this state and the cutting operation of the next process is performed, the coil 10 is completely brought into close contact with the rotor when the coil is assembled. The parts 69 do not match and a brazing joint failure occurs.

  According to the present embodiment, after the FW bending, the face board 56 is moved to the side of the laminated conductor 101 and is brought into close contact with the laminated conductor 101. By tightening the screws, the laminated conductor 101 is fastened to the face board 56 side by the face board 56 and the plurality of fastening plates 71, and the unevenness in the lateral width direction of the laminated conductor 101 of the end portion 16 can be renewed. it can.

  FIG. 27 is a front view showing the outer shape of the coil cutting device / cutting section finishing device in the coil manufacturing system / method for a rotating electrical machine according to the embodiment of the present invention. FIG. 28 is a side view showing the outer shape of the coil cutting device / cutting portion finishing device in the coil manufacturing system / method for a rotating electrical machine according to the embodiment of the present invention.

  The cutting device 21 includes a cutting head 72, a rotation mechanism 74, a motor 75 with brake, a motor 77 for cutting, and a vertical shaft 79. The rotation mechanism 74 is driven by a motor 75 with brake, and rotates the cutting head 72 between a cutting position and a non-cutting position.

  The cutting head 72 has a disk-shaped tip saw 78. The tip saw 78 is not limited to a band saw with a saw blade. The cutting motor 77 rotates the saw of the cutting head 72. The vertical shaft 79 drives the cutting head 72 up and down.

  The cutting unit finishing device 110 includes a finishing head 73, a rotation mechanism 74, a motor 75 with brake, and a switching motor 114. The finishing head 73 has an end mill 76 and is provided coaxially with the cutting head 72.

  There is a switching rotation shaft (not shown) near the intermediate point on the axis between the rotation center of the cutting head 72 and the rotation center of the cutting motor 77, and the switching rotation shaft is rotated by the switching motor 114. The cutting head 72 and the finishing head 73 are coupled to each other in a direction perpendicular to the axial direction of the rotating shaft for switching. Switching between the cutting device 21 and the cutting portion finishing device 110 is performed by the switching motor 114 for switching. This is done by rotating the shaft. Further, the rotation mechanism 74 moves between the finishing position and the non-finishing position.

  The rotating mechanism 74 is selected to have a sufficient holding torque so as not to be affected by the cutting load during cutting or finishing.

  At the time of cutting, the end mill 76 rotates to a position where it does not interfere with the laminated conductor 101 and surrounding structures, and the cutting device 21 cuts the coil. The cutting head 72 is cut by rotating the cutting saw 77 by rotating the electric motor 77 for cutting, and moving the cutting blade 80 up and down by the vertical shaft 79 to scrape the laminated conductor 101.

  After the cutting by the cutting device 21 is completed, the cutting device 21 once retracts in the direction opposite to the laminated conductor 101. By rotating the electric motor of the rotation mechanism 74, the finishing head 73 can be rotated to face the direction of the laminated conductor 101 and finish processing without interfering with surrounding structures. The end mill 76 used for the finishing head 73 employs an end mill 76 having a diameter that is twice or more the lateral width of the laminated conductor 101 to the extent that vibration does not occur during finishing.

  In addition, it is desirable to select a tool that has a large number of blades of the end mill 76 and can perform continuous cutting.

  Cutting with the cutting device 21 is cutting with a saw capable of cutting the coil 10 quickly. In general, since the thickness of the saw is thin and the rigidity is low, the coil 10 may be bent and cut when it is cut. If cutting is performed in consideration of the bending due to the cutting, it is necessary to finish the coil 10 after cutting with a grinder or the like, and a large number of finishing steps are required.

  On the other hand, in this embodiment, manual work such as subsequent adjustment and care can be greatly reduced by efficiently cutting and finishing the laminated conductor 101.

  FIG. 29 is a front view showing the outer shape of the coil transport mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention. FIG. 30 is a side view showing the outer shape of the coil transport mechanism in the coil manufacturing system and method for a rotating electrical machine according to the embodiment of the present invention.

  The coil transfer device 31 includes a holder 88, an air cylinder 90, a movement shaft 91 in the width direction, a movement shaft 92 in the longitudinal direction, and vertical movement shafts 93a and 93b. The holder 88 is configured by three surfaces corresponding to the upper surface, the lower surface, and one side portion of the multilayer conductor 101, and holds the multilayer conductor 101 of the linear portion 11. The air cylinder 90 clamps and fixes the side surface of the laminated conductor 101 on the side not facing the side surface of the holder 88.

  The moving shaft 91 in the width direction moves the laminated conductor 101 in the apparatus width direction, the moving shaft 92 in the longitudinal direction moves in the longitudinal direction of the coil, and the up and down moving shaft 93 moves in the up and down direction. The laminated conductor 101 is formed so as to be conveyed.

  The transport of the laminated conductor 101 is usually performed by a crane. However, if the movement of the coil between the devices is also performed by the crane, it takes time to wait for the crane or to attach and detach the hanging jig. By carrying it, it is not necessary to wait for the crane or to attach or detach the hanging jig, and it is possible to reduce the carrying time by making the coil move freely between the devices.

  As described above, according to the present embodiment, even when the number of layers of the laminated conductor is large as in the case of a quadrupole machine and the length of the end portion is long, collective bending is possible.

  FIG. 31 is a block diagram showing a configuration of an automatic manufacturing system based on product specification data in the coil manufacturing method of the rotating electrical machine according to the embodiment of the present invention.

  The automatic manufacturing system includes a database 111, a product information extraction unit 82, a product specification information development unit 84, a progress control unit 86, an EW bending device 18, an FW bending device 19, a cutting device 21, a cutting unit finishing device 110, and a coil conveying device 31. Is provided.

  The database 111 stores specification data of each rotating electrical machine and data for coil manufacture. The product information extraction unit 82 extracts product information related to information necessary for coil manufacture of the rotating electrical machine from the book information such as drawings and specifications about the target rotating electrical machine.

  The product specification information expansion unit 84 receives the specification data of the target rotating electrical machine as an input, and acquires data related to coil manufacturing necessary for each machining process from the database 111. The progress controller 86 automatically advances each machining step while managing the condition setting and progress of each step.

  Here, the product specification information data includes the total coil length, the number of coil slots, the slot pitch angle, the coil width, the coil thickness, the number of layers, the FW bending radius, the pole angle, and the like.

  Based on the product specification information, the product specification information expansion unit 84 calculates parameters necessary for coil manufacture.

  The product specification information is collected in the progress control unit 86, and data is transferred from the progress control unit 86 to, for example, a drive control unit included in each device via the communication cable, whereby the specification information is shared between the devices.

  Further, information about each device including the position of each device is collected in the progress control unit 86, and data is transferred from the progress control unit 86 to a drive control unit included in each device through, for example, a communication cable. Is shared between the devices.

  According to the present embodiment configured as described above, by inputting information on the target product, that is, the rotating electrical machine, data necessary for coil manufacture is automatically obtained while utilizing the data accumulated in the database 111. Is generated.

  Further, the progress control unit 86 automatically advances the processing steps in the EW bending device 18, the FW bending device 19, the cutting device 21, and the cutting portion finishing device 110, and the coil 10 is manufactured.

[Other Embodiments]
As mentioned above, although some embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention.

  Moreover, you may combine the characteristic of each embodiment.

  Furthermore, these embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention.

  These embodiments and their modifications are included in the scope and gist of the invention, and are also included in the invention described in the claims and the equivalents thereof.

  DESCRIPTION OF SYMBOLS 10 ... Coil, 11 ... Linear part, 12 ... Corner | angular part, 14 ... Rotor shaft, 16 ... End part, 18 ... EW bending apparatus, 19 ... FW bending apparatus, 20 ... FW bending mold, 21 ... Cutting apparatus, 23 ... Ventilation hole, 24 ... template, 31 ... coil conveying device, 35 ... hydraulic cylinder, 36 ... molding roller, 36a ... molding cylinder, 37 ... coil clamp part (axial locking mechanism), 38 ... angle measuring part, 48 ... hydraulic cylinder 49 ... Coil restraint guide, 53 ... Coil press mechanism, 54 ... Lower press part, 56 ... Face plate, 57 ... Hydraulic cylinder, 61 ... First support roller, 62 ... Second support roller, 63 ... Third Support roller, 64 ... fourth support roller, 61a ... first cylinder, 62a ... second cylinder, 63a ... third cylinder, 64a ... fourth cylinder, 66 Holder, 67 ... Stopper, 68 ... Coil guide, 69, 69a, 69b ... Brazed joint, 70 ... Screw hole, 71 ... Fastening plate, 72 ... Cutting head, 73 ... Finishing head, 74 ... Rotating mechanism, 75 ... Motor with brake, 76 ... End mill, 77 ... Electric motor for cutting, 78 ... Chip saw, 79 ... Vertical axis, 80 ... Cutting blade, 82 ... Product information extraction unit, 83 ... PLC, 84 ... Product specification information development unit, 86 ... Progression Control unit 88 ... Holder, 90 ... Air cylinder, 91 ... Movement axis in the width direction, 92 ... Movement axis in the longitudinal direction, 93, 93a, 93b ... Vertical movement axis, 95 ... FW clamp correction mechanism, 100 ... Conductor, 101 DESCRIPTION OF SYMBOLS ... Laminated conductor, 103 ... Coil correction fixing mechanism, 104 ... Turning rail, 105 ... Cut surface finishing apparatus, 106 ... EW bending axis, 107 ... EW bending coil restraint mechanism, 1 8: cylinder holder, 109 ... cylinder turning Frames, 110 ... cutting unit the finishing unit, 111 ... database, 112 ... pivot shaft, 113 ... rails, 114 ... switching electric motor, 115 ... FW bending coil guide mechanism

Claims (8)

A coil manufacturing system in which a coil fitted in a slot formed on the outer peripheral surface of a rotor shaft of a rotating electrical machine is molded integrally for each slot or a plurality of coils are grouped into a plurality of blocks,
For each of the laminated conductors, the end portions of both ends of the laminated conductor in which all the flat conductors extending in the longitudinal direction for the same slot are aligned in the width direction and laminated in the thickness direction are bent in the same direction. An edgewise bending device that performs edgewise bending, which is a bending process of the laminated conductors in a transverse width direction,
A flatwise bending device that performs flatwise bending, which is a bending process in the direction of the laminated layer, so that each of the laminated conductors of the end portion subjected to the edgewise bending can be bent in the same direction;
A cutting device for cutting the respective end portions subjected to the flatwise bending so as to have a predetermined length;
A cut surface finishing device for finishing the cut surface of the laminated conductor of each of the end portions cut by the cutting device;
A coil manufacturing system comprising:   The edgewise bending apparatus includes an edgewise bending restraining mechanism that restrains the lateral direction and the thickness direction of the straight part and the end part, respectively, to prevent the displacement of the conductor during molding. The coil manufacturing system according to claim 1.   The edgewise bending apparatus has a coil press mechanism for eliminating an increase in thickness difference between the inner side and the outer side of each conductor in the edgewise bending portion after the edgewise bending. The coil manufacturing system according to claim 1 or 2.   The edgewise bending device includes a clamp mechanism capable of fixing the laminated conductor after finely adjusting a position of the edgewise bending device to secure a target straight line length before the edgewise bending, and the clamping mechanism The coil manufacturing system according to any one of claims 1 to 3, further comprising a lock mechanism that fixes the position of the coil. The flatwise bending apparatus is:
A molding cylinder that is movable along the end portion and has a roller at the tip to apply a bending load to the laminated conductor;
A plurality of support guides arranged annularly and spaced apart from the forming cylinder, each having a roller at the tip;
Among the plurality of support guides, a control unit for controlling the load and timing when rotating by adding a load to the end portion in order from the support guide near the corner of the edgewise bending,
The coil manufacturing system according to any one of claims 1 to 4, wherein the coil manufacturing system includes:   The flatwise bending apparatus has a coil correction fixing mechanism that fixes the laminated conductor of the end portion in order to correct a coil shift due to the flatwise bending process by a guide that constrains a lateral width direction of the coil. The coil manufacturing system according to any one of claims 1 to 5.   The coil cutting system according to any one of claims 1 to 6, wherein the cutting device includes a finishing mechanism that finishes an end surface of the end portion after the cutting.   The coil transfer mechanism for transferring the coil between the edgewise bending device, the flatwise bending device, and the cutting device is provided. Coil manufacturing system.

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