JP2015070761A - Molding method and molding device for concentrically wound coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent both end parts of flat square conductor wire from moving accompanying bending deformation of a site corresponding to a coil end of the flat square conductor wire when bending the site.SOLUTION: By moving with stroke metal molds 42 and 44 in a predetermined direction toward a set flat square conductor wire 28, a site corresponding to a coil end part of the flat square conductor wire 28 is inserted between a plurality of fins 62, which are attached to the metal molds 42 and 44 and arranged parallely in a laminating direction of the set flat square conductor wire 28, so as to be bent toward the laminating direction, and pressed with processing surfaces 46 and 50, facing in an orthogonal direction orthogonal to the laminating direction of the set flat square conductor wire 28, of the metal molds 42 and 44, so as to be bent toward the orthogonal direction, in one step. Further when bending the corresponding site of the flat square conductor wire 28, both end parts of the flat square conductor wire 28 are held independently from the metal molds 42 and 44, which are moved with a stroke, using holding members 112 and 114 so as not to move in the predetermined direction.

Description

  The present invention relates to a forming method and a forming apparatus for concentric winding coils, and in particular, a plurality of different non-linear shapes in which coil end portions projecting from an axial end surface of a stator core are formed from a rectangular wire wound around a predetermined number of turns. The present invention relates to a molding method and a molding apparatus for molding a concentric winding coil.

  2. Description of the Related Art Conventionally, a forming method and a forming apparatus for forming a concentric winding coil having a plurality of different non-linear shapes with a coil end portion protruding from an end surface in the axial direction of a stator core from a rectangular wire wound around a predetermined number of turns are known. (For example, refer to Patent Document 1). The forming apparatus described in Patent Document 1 is an apparatus that cranks a portion corresponding to a coil end of a flat wire toward a laminating direction of a circuit and bends it in an orthogonal direction perpendicular to the laminating direction.

  Said shaping | molding apparatus is provided with the concave outer type | mold and the convex inner type | mold which make the shape of the coil end part of a concentric winding coil, and make a pair. Each of the outer mold and the inner mold has a processed surface oriented in an orthogonal direction orthogonal to the laminating direction of the flat conductor wire. In addition, a plurality of fins (blades) protruding from the processed surface toward the inner mold side are attached to the outer mold. The plurality of fins are arranged on the outer mold side by side in the laminating direction of the circumference of the flat conducting wire to be set.

  In the above molding apparatus, when the stroke is moved so that the outer die and the inner die approach each other with the flat wire set in the inner die, the coil end corresponding portion of the flat wire is first inserted between the fins. As a result, the wire is bent in the laminating direction and the portion corresponding to the coil end of the flat wire is sandwiched between the outer mold and the inner mold, and is bent in the orthogonal direction.

JP 2013-183534 A

  By the way, when the portion corresponding to the coil end of the flat wire is inserted between the fins, a frictional resistance is generated between the fin and the flat wire, so that the coil end is particularly bent during the above-mentioned lamination direction. If the part from the corresponding part to both ends of the flat wire is not fixed and is in a free state, the part from the coil end corresponding part to the tip of the flat wire is moved along with the bending of the coil end corresponding part. For this reason, when the part from the coil end corresponding part to both ends of the flat wire is not fixed at the time of molding, the coil end corresponding part to be originally formed contacts a part different from the desired part of the mold, and the coil end Inconveniences such as deterioration of molding accuracy of the corresponding part and peeling of the film occur.

  The present invention has been made in view of the above-described points, and can prevent both ends of the flat conductor from being moved along with the bending deformation when the coil end corresponding portion of the flat conductor is bent. It is an object of the present invention to provide a method and apparatus for forming a concentric coil that can be formed.

  The above-mentioned object is a forming method for forming a concentric coil having a plurality of different non-linear shapes with a coil end portion protruding from the axial end surface of the stator core from a rectangular wire wound around a predetermined number of turns, A die formed by imitating the shape of the coil end portion of the concentric winding coil is moved in a predetermined direction with respect to the set rectangular conductor wire in one step, and the rectangular conductor wire, A corresponding portion corresponding to the coil end portion is bent toward the stacking direction by inserting it between a plurality of fins that are attached to the mold and arranged in the stacking direction of the flat wire to be set. While processing and bending in the orthogonal direction by pressing on the processing surface of the die that is set in the orthogonal direction orthogonal to the stacking direction of the flat wire to be set When bending the corresponding portion of the flat wire, the flat wire is used independently of the mold that is moved by stroke so that both ends of the flat wire do not move in the predetermined direction using a gripping member. This is achieved by a method of forming a concentric coil that grips both ends of the coil.

  In addition, the above object is a forming apparatus for forming a concentric coil having a plurality of different non-linear shapes with coil end portions protruding from the axial end surface of the stator core from a rectangular conductor wire having a predetermined number of turns. A plurality of fins that are formed to simulate the shape of the coil end portion of the concentric winding coil and are arranged side by side in the stacking direction of the flat conductors to be set, and the rectangular conductors to be set A mold having a working surface oriented in an orthogonal direction perpendicular to the stacking direction, and a mold moving mechanism for moving the mold in a predetermined direction with respect to the set flat wire, and the mold In the stacking direction, the corresponding part of the rectangular wire corresponding to the coil end portion is inserted between the plurality of fins by the stroke movement by the mold moving mechanism. Bending and bending in the orthogonal direction by pressing on the processing surface, and when the corresponding part of the flat conductor is bent by the mold, both ends of the flat conductor Is achieved by a concentric-winding coil forming apparatus provided with gripping members for gripping both ends of the flat rectangular wire independently of the die moved in a stroke.

  ADVANTAGE OF THE INVENTION According to this invention, when the part corresponding to the coil end of a flat conducting wire is bent, it can prevent that the both ends of a flat conducting wire move with the bending deformation.

It is a block diagram of the stator by which the coil assembly which consists of a concentric winding coil which is one Example of this invention is mounted. It is a figure for demonstrating the method of comprising a coil assembly using the concentric winding coil of a present Example. It is a block diagram before the completion of shaping | molding of the concentric winding coil of a present Example. It is a block diagram after completion | finish of shaping | molding of the concentric winding coil of a present Example. It is a perspective view of the shaping | molding apparatus of the concentric winding coil of a present Example. It is a top view of the shaping | molding apparatus of the concentric winding coil of a present Example. It is a block diagram of the inner mold | type as a metal mold | die with which the shaping | molding apparatus of the concentric winding coil of a present Example is provided. It is a block diagram of the outer mold | type as a metal mold | die with which the shaping | molding apparatus of the concentric winding coil of a present Example is provided. It is a block diagram of the fin with which the shaping | molding apparatus of the concentric winding coil of a present Example is provided. It is a perspective view before the shaping | molding start by the shaping | molding apparatus of the concentric winding coil of a present Example. It is a perspective view after the completion of shaping | molding by the shaping | molding apparatus of the concentric winding coil of a present Example. It is the block diagram before the shaping | molding start by the shaping | molding apparatus of the concentric winding coil which is this modification, and after the completion of shaping | molding.

  Hereinafter, specific embodiments of a method for forming a concentric coil and a forming apparatus according to the present invention will be described with reference to the drawings.

  FIG. 1 shows a configuration diagram of a stator on which a coil assembly composed of concentric winding coils according to an embodiment of the present invention is mounted. FIG. 1A shows a state before completion of stator assembly, and FIG. 1B shows a state after completion of stator assembly. FIG. 2 is a diagram for explaining a method of forming a coil assembly using a plurality of concentric coils of the present embodiment. 2A shows the state before the completion of the assembly of the two concentric winding coils, and FIG. 2B shows the state after the completion of the assembly of the two concentric winding coils. . FIG. 3 shows a configuration diagram of the concentric winding coil of this embodiment before the completion of molding. Moreover, FIG. 4 shows the block diagram after completion | finish of shaping | molding of the concentric winding coil of a present Example. 3A and 3B and FIGS. 4A and 4B are perspective views, and FIGS. 3C and 4C are plan views.

  In this embodiment, the stator 10 is a stator that is used in a rotating electrical machine such as a three-phase AC motor, for example, and is arranged radially outside the rotor as a rotor via a predetermined air gap. The stator 10 generates a magnetic field that rotates the rotor when energized. The stator 10 includes a stator core 12 and a stator coil 14. The stator core 12 is a member formed in a hollow cylindrical shape, and is formed by laminating a plurality of insulation-coated electromagnetic steel plates in the axial direction. A cylindrical yoke made of a material obtained by compression-molding a soft magnetic powder coated with an insulating coating may be attached to the radially outer surface of the stator core 12.

  The stator core 12 includes a yoke 16 formed in an annular shape, and teeth 18 that protrude from the radially inner side surface of the yoke 16 toward the radially inner side (axial center side). A plurality of teeth 18 are provided in the circumferential direction on the radially inner side surface of the yoke 16 (for example, 96 pieces as shown in FIG. 1), and are provided at regular intervals along the circumferential direction. A slot 20 is formed between two teeth 18 adjacent in the circumferential direction.

  Each of the teeth 18 is wound with the stator coil 14 described above. A plurality of stator coils 14 (for example, 96 as shown in FIG. 1) are arranged in the circumferential direction on the radially inner side of the stator core 12. A plurality of stator coils 14 are arranged in the circumferential direction to constitute a coil assembly 22. The coil assembly 22 is formed in an annular shape along the circumferential direction by the plurality of stator coils 14. The coil assembly 22 is disposed by shifting the slots 20 in which the plurality of stator coils 14 are accommodated one by one in the circumferential direction, and the stator coils 14 adjacent to each other in the circumferential direction are stacked so that the lead wires of the stator coils 14 circulate. Constructed by overlapping in direction.

  Each stator coil 14 constitutes one of a U-phase coil, a V-phase coil, and a W-phase coil when the rotating electrical machine is applied to, for example, a three-phase AC motor. In this case, the U-phase coil, the V-phase coil, and the W-phase coil that are the stator coils 14 are wound around the teeth 18 in that order in the circumferential direction.

  The stator core 12 is composed of a plurality of (for example, 48 as shown in FIG. 1) divided cores 24 divided in the circumferential direction. That is, the stator core 12 is divided into a plurality of divided cores 24 in the circumferential direction. All the divided cores 24 have the same shape, and specifically, have a shape including the yoke 16 and the two teeth 18 corresponding to the same circumferential angle.

  The stator 10 also includes an insulating member 26 that ensures insulation between the stator core 12 and the stator coil 14. The insulating member 26 is provided for each divided core 24 of the stator core 12. The insulating member 26 has a shape that matches the shape of the split core 24. The insulating member 26 is made of paper or resin (for example, thermosetting resin or thermoplastic resin), and forms a thin insulating layer between the split core 24 and the stator coil 14.

  The split core 24 to which the insulating member 26 is attached is inserted into the coil assembly 22 from the outside in the radial direction so that the stator coil 14 of the coil assembly 22 is disposed in the slot 20 between the two teeth 18. . When all the divided cores 24 are assembled to the coil assembly 22, the stator 10 in which the stator core 12 and the stator coil 14 are assembled is configured.

  The stator coil 14 is constituted by a rectangular conducting wire having a rectangular cross section (specifically, a rectangular shape). Each of the stator coils 14 disposed in the circumferential direction is a concentric coil that is formed by bending a rectangular conductor wire that has been wound by a predetermined number of turns (for example, 5 turns). Hereinafter, the rectangular conducting wire before the completion of the molding of the stator coil 14 is referred to as a rectangular conducting wire 28, and the stator coil 14 after the completion of the molding is referred to as a concentric winding coil 14, respectively.

  The flat conducting wire 28 is formed in a substantially hexagonal shape that is wound around a predetermined number of turns as shown in FIG. 3 by winding a single straight wire around a substantially hexagonal die of the winding device. The In addition, it is preferable that the corner of the rectangular conducting wire 28 having a rectangular cross section is R-processed. The flat conducting wire 28 is made of a highly conductive metal such as copper or aluminum. The concentric winding coil 14 is bent on a substantially hexagonal flat wire 28 using a molding device described in detail later, so that both sides (described later) are wound around a predetermined number of turns as shown in FIG. The coil end portion is formed in a substantially hexagonal shape having a convex tip.

  The concentric winding coil 14 has slot portions 30 and 32 that are accommodated in the slots 20 of the stator core 12, and coil end portions 34 and 36 that protrude outward in the axial direction from both axial end portions of the stator core 12. doing. The slot portions 30 and 32 extend substantially linearly so as to penetrate the slot 20 of the stator core 12 in the axial direction. The coil end portions 34 and 36 are curved so as to connect the slot portions 30 and 32 to each other on the axially outer side with respect to both axial end portions of the stator core 12.

  The flat conductor 28 before forming is formed so that the slot-corresponding portions corresponding to the slot portions 30 and 32 of the concentric winding coil 14 are substantially linear and correspond to the coil end portions 34 and 36 of the concentric winding coil 14. The coil end corresponding parts connect the slot corresponding parts on both sides, and the conductive wires arranged in the stacking direction of the coil end corresponding parts are arranged in parallel. Of the conducting wires arranged in the stacking direction of the flat conducting wires 28, the slot-corresponding portion and the coil end-corresponding portion corresponding to the coil end portion 36 in each stage are formed on the same plane. On the other hand, the coil end corresponding portions corresponding to the coil end portions 34 of each step among the conductive wires arranged in the stacking direction of the flat conductive wires 28 are obliquely connected between the slot corresponding portions on both sides, thereby crossing the flat conductive wires 28 in the stacking direction. Are formed so that the lanes are changed by one stage for each of the conductors arranged in line.

  Both end portions of the concentric coil 14 protrude in the axial direction from one end surface of the stator core 12 in the axial direction, and are connected to lead wires such as another concentric coil 14 or external connection terminals. It protrudes to the same axial direction side (hereinafter referred to as the axial lead side). The coil end portion 34 is provided on the axial lead side, and the coil end portion 36 is provided on the axially opposite lead side opposite to the axial lead side. Hereinafter, the coil end portion 34 is referred to as a lead side coil end portion 34, and the coil end portion 36 is referred to as an anti-lead side coil end portion 36. The slot portion 30 is provided on one side in the circumferential direction, and the slot portion 32 is provided on the other side in the circumferential direction. Hereinafter, the slot portion 30 is referred to as the one-side slot portion 30, and the slot portion 32 is referred to as the other-side slot portion 32, respectively.

  The slot portions 30 and 32 are separated from each other in the circumferential direction around the axis by a predetermined angular distance. The concentric coil 14 is configured such that a plurality of conductors are laminated in the direction of the short side of the flat conductor 28. The concentric winding coil 14 is configured such that a predetermined gap is formed between conductive wires adjacent in the stacking direction. The concentric coil 14 is formed in a trapezoidal cross section so that the distance between the slot portions 30 and 32 changes according to the position in the stacking direction. The formation of the trapezoidal cross section is performed in order to properly accommodate the slot portions 30 and 32 of the concentric coil 14 in the slot 20. The concentric winding coil 14 is assembled to the stator core 12 so that the lamination direction of the conductive wires coincides with the radial direction orthogonal to the axial direction of the stator core 12.

  In the above-described concentric coil 14, when the number of turns of the flat conductor 28 is, for example, “5”, the number of conductors laminated in the non-lead side coil end portion 36, the one side slot portion 30, and the other side slot portion 32. , The lead-side coil end portion 34 has four layers of conductive wires.

  The coil end portions 34 and 36 of the concentric winding coil 14 are each formed in a plurality of different non-linear shapes. Specifically, each of the coil end portions 34 and 36 is formed in three types of non-linear shapes, and is bent in the direction of the short side of the flat conducting wire 28 and is stepped toward the radial direction of the stator core 12. Is bent into a circular shape (crank forming), bent into an arc shape that is curved in accordance with the circular arc of the annular stator core 12 (arc forming), and bent in the direction of the long side of the flat conductor 28. (Edgewise molding).

  The above-described crank forming and arc forming are bending processes in the rounding direction of the flat conductor 28, and the above edgewise forming is in the orthogonal direction perpendicular to the rounding direction of the flat conductor 28. Bending process. The above-described crank forming is a bending process performed for lane change between the conductors in the laminating direction of the round conductor 28. The above-mentioned circular arc forming is a bending process performed to efficiently accommodate the concentric winding coil 14 in the slot 20. The edgewise molding is a bending process performed to efficiently arrange the plurality of concentric winding coils 14 when the coil assembly 22 is configured.

  Next, with reference to FIGS. 5-11, the shaping | molding of the concentric winding coil 14 of a present Example is demonstrated.

  FIG. 5 shows a perspective view of the forming device 40 of the concentric winding coil 14 of the present embodiment. FIG. 5 shows a state before the concentric winding coil 14 is completely formed. FIG. 6 shows a plan view of the molding device 40 for the concentric winding coil 14 of the present embodiment. FIG. 7 shows a configuration diagram of an inner mold as a mold provided in the molding apparatus 40 of the concentric winding coil 14 of the present embodiment. FIG. 8 shows a configuration diagram of an outer mold as a mold provided in the molding apparatus 40 for the concentric coil 14 of the present embodiment. FIG. 9 shows a configuration diagram of fins included in the forming device 40 of the concentric coil 14 of the present embodiment. 7A, 8A, and 9A are perspective views, and FIGS. 7B, 8B, and 9B are plan views. Are shown respectively. FIG. 10 shows a perspective view of the concentric winding coil 14 according to the present embodiment before forming is started by the forming apparatus 40. Moreover, FIG. 11 shows the perspective view after the shaping | molding by the shaping | molding apparatus 40 of the concentric winding coil 14 of a present Example is completed.

  In the present embodiment, the concentric winding coil 14 is formed by bending a substantially hexagonal flat rectangular wire 28 that is wound in a predetermined number of turns by a forming device 40. The molding apparatus 40 includes an inner mold 42 that is an inner mold and an outer mold 44 that is an outer mold. The inner mold 42 is a mold that is disposed in the circumference of the set flat conducting wire 28 and is capable of holding the flat conducting wire 28 set on the outer peripheral surface side. Further, the outer metal mold 44 is a metal mold that is disposed outside the circumference of the flat conducting wire 28 to be set.

  Hereinafter, in the molding apparatus 40, the direction (axial direction) connecting the coil end corresponding portions on both sides of the flat wire 28 set in the inner mold 42 is defined as the first direction X, and the flat wire set in the inner mold 42. The direction in which the slots corresponding to the slots on both sides are spaced apart from each other is referred to as a second direction Y, and the direction in which the flat conductors 28 are set in the inner mold 42 is referred to as a third direction Z. The first direction X, the second direction Y, and the third direction Z are orthogonal to each other.

  The inner mold 42 includes a first inner mold 42-1 and a second inner mold 42-2. The first inner mold 42-1 and the second inner mold 42-2 are spaced apart in the first direction X. The first inner mold 42-1 and the second inner mold 42-2 are each formed in a substantially pentagonal mountain shape when viewed from the third direction Z. The first inner mold 42-1 is a mold provided on the axial lead side of the flat rectangular wire 28 to be set, and the second inner mold 42-2 is an axial direction of the flat rectangular wire 28 to be set. This is a mold provided on the side opposite to the lead.

  The first inner mold 42-1 is a convex shape formed in a convex shape. The first inner mold 42-1 includes a processed surface 46 formed by imitating the shape of the inner peripheral side of the lead-side coil end portion 34 of the concentric coil 14 after completion of molding, and the concentric coil. 14 has a machining surface 47 that is formed by imitating the shape of the inner peripheral side in the vicinity of the boundary (shoulder portion) between the 14 slot portions 30 and 32 and the lead-side coil end portion 34.

  The processing surface 46 is a surface facing in a direction substantially orthogonal to the third direction Z (substantially the first direction X or the second direction Y), and the processing surface 46 of the first inner mold 42-1 of the concentric winding coil 14. It is formed on a convex surface 48 facing the lead-side coil end portion 34. The processed surface 46 is a surface with which the inner peripheral surface of the short-side cross-section side of the lead-side coil end corresponding portion corresponding to the lead-side coil end portion 34 of the lead wire coil end portion 34 of the concentric winding coil 14 is in contact. It is. The processed surface 46 has an outer shape along the inner peripheral surface on the short side of the cross section of the lead-side coil end portion 34 of the concentric coil 14.

  The processing surface 47 is a processing surface facing a direction substantially orthogonal to the third direction Z (substantially the second direction Y), and the slot portion 30 of the concentric winding coil 14 of the first inner mold 42-1. 32 is formed so as to oppose. The processed surface 47 is a surface where the slot portions 30 and 32 of the concentric winding coil 14, that is, the inner peripheral surface on the short side of the cross section of the portion corresponding to the slot corresponding to the slot portions 30 and 32 of the flat wire 28 contacts. The processed surface 47 has an outer shape along the inner peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric coil 14.

  The second inner mold 42-2 is a convex shape formed in a convex shape. The second inner mold 42-2 includes a processed surface 50 formed by imitating the shape of the inner peripheral side of the non-lead-side coil end portion 36 of the concentric winding coil 14 after molding, and the concentric winding thereof. The coil 14 has a processed surface 51 simulating the shape on the inner peripheral side in the vicinity of the boundary (shoulder portion) between the slot portions 30 and 32 of the coil 14 and the non-lead-side coil end portion 36.

  The processing surface 50 is a surface that faces in a direction substantially orthogonal to the third direction Z (substantially the first direction X or the second direction Y), and is the surface of the concentric winding coil 14 of the second inner mold 42-2. It is formed on a convex surface 52 that faces the non-lead-side coil end portion 36. The processed surface 50 is the inner peripheral surface on the short side of the cross-section of the portion corresponding to the anti-lead side coil end corresponding to the anti-lead side coil end portion 36 of the flat lead wire 28, that is, the flat lead wire 28. Is the surface that touches. The processed surface 50 has an outer shape along the inner peripheral surface on the short side of the cross-section of the counter lead-side coil end portion 36 of the concentric coil 14.

  The processing surface 51 is a processing surface that faces in a direction substantially orthogonal to the third direction Z (substantially the second direction Y), and the slot portion 30 of the concentric winding coil 14 of the second inner mold 42-2. 32 is formed so as to oppose. The processed surface 51 is a surface where the slot portions 30 and 32 of the concentric winding coil 14, that is, the inner peripheral surface on the short side of the cross section of the portion corresponding to the slot corresponding to the slot portions 30 and 32 of the flat wire 28 contacts. The processing surface 51 has an outer shape along the inner peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric winding coil 14.

  The outer mold 44 includes a first outer mold 44-1 and a second outer mold 44-2. The first outer mold 44-1 and the second outer mold 44-2 are spaced apart in the first direction X. The first outer mold 44-1 is a mold provided on the axial lead side of the flat rectangular wire 28 to be set, and the second outer mold 44-2 is an axial direction of the flat rectangular wire 28 to be set. This is a mold provided on the side opposite to the lead.

  Between the first direction X between the first outer mold 44-1 and the second outer mold 44-2, the first inner mold 42-1 and the second inner mold 42-2 are aligned. It is arranged with. That is, the first outer mold 44-1, the first inner mold 42-1, the second inner mold 42-2 and the second outer mold 44-2 are serially arranged in that order in the first direction X. Be placed. The first outer mold 44-1 and the first inner mold 42-1 are spaced apart in the first direction X, and the second outer mold 44-2 and the second inner mold 42-2 are separated from each other. Are spaced apart in the first direction X.

  The first outer mold 44-1 is a concave mold formed in a concave shape that forms a pair with the first inner mold 42-1. The first outer mold 44-1 includes a processed surface 54 formed by imitating the shape of the outer peripheral side of the lead-side coil end portion 34 of the concentric coil 14 after completion of molding, and the concentric coil 14 thereof. The slot portions 30 and 32 have a processed surface 55 formed by imitating the shape of the outer peripheral side in the vicinity of the boundary (shoulder portion) with the lead-side coil end portion 34.

  The processing surface 54 is a surface that faces in a direction substantially orthogonal to the third direction Z (substantially the first direction X or the second direction Y), and is the surface of the concentric coil 14 of the first outer mold 44-1. It is formed on a concave surface 56 facing the lead side coil end portion 34. The processed surface 54 is a surface that is in contact with the outer peripheral surface of the lead-side coil end portion 34 of the concentric coil 14, that is, the short-side cross-sectional side of the portion corresponding to the lead-side coil end of the flat wire 28. The processing surface 54 has an outer shape along the outer peripheral surface on the short side of the cross section of the lead-side coil end portion 34 of the concentric winding coil 14.

  The processing surface 55 is a processing surface that faces in a direction substantially orthogonal to the third direction Z (substantially the second direction Y), and is the slot portion 30 of the concentric winding coil 14 of the first outer mold 44-1. 32 is formed so as to oppose. The processed surface 55 is a surface with which the outer peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric winding coil 14, that is, the slot corresponding portion of the flat wire 28 is in contact. The processed surface 55 has an outer shape along the outer peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric coil 14.

  The second outer mold 44-2 is a concave mold formed in a concave shape that forms a pair with the second inner mold 42-2. The second outer mold 44-2 includes a processed surface 58 formed by imitating the shape of the outer peripheral side of the non-lead side coil end portion 36 of the concentric coil 14 after completion of molding, and the concentric coil thereof. 14 has a processed surface 59 which is formed by imitating the shape of the outer peripheral side in the vicinity of the boundary (shoulder portion) between the 14 slot portions 30 and 32 and the non-lead-side coil end portion 36.

  The processing surface 58 is a surface facing in a direction substantially orthogonal to the third direction Z (substantially the first direction X or the second direction Y), and the processing surface 58 of the concentric winding coil 14 of the second outer mold 44-2. It is formed on the concave surface 60 facing the non-lead-side coil end portion 36. The processed surface 58 is a surface with which the outer peripheral surface on the short side of the cross-section of the portion corresponding to the anti-lead side coil end of the flat lead wire 28 is in contact with the anti-lead side coil end portion 36 of the concentric winding coil 14. The processed surface 58 has an outer shape along the outer peripheral surface on the short side of the cross-section of the counter lead-side coil end portion 36 of the concentric coil 14.

  The processing surface 59 is a processing surface facing in a direction substantially orthogonal to the third direction Z (substantially the second direction Y), and the slot portion 30 of the concentric coil 14 of the second outer mold 44-2. 32 is formed so as to oppose. The processed surface 59 is a surface with which the outer peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric coil 14, that is, the slot corresponding portion of the flat wire 28 contacts. The processed surface 59 has an outer shape along the outer peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric coil 14.

  The processed surface 46 of the first inner mold 42-1 and the processed surface 54 of the first outer mold 44-1 are formed in a shape suitable for edgewise forming the portion corresponding to the lead side coil end of the flat wire 28. Has been. The first inner mold 42-1 and the first outer mold 44-1 are molds for edgewise forming the lead-side coil end corresponding portion of the flat conducting wire 28. Further, the processing surface 50 of the second inner mold 42-2 and the processing surface 58 of the second outer mold 44-2 are suitable for edgewise forming the portion corresponding to the non-lead side coil end of the flat wire 28. It is formed into a shape. The second inner mold 42-2 and the second outer mold 44-2 are molds that edgewise mold the portion corresponding to the non-lead side coil end of the flat conducting wire 28.

  The first outer mold 44-1 has a plurality of fins 62. The first outer mold 44-1 having a plurality of fins 62 is a mold for crank-forming and arc-forming the lead-side coil end corresponding portion of the flat conducting wire 28. A plurality of fins 62 are arranged side by side in the third direction Z and are divided in the second direction Y. The fin 62 includes a first fin 62-1 and a second fin 62-2 that are divided in the second direction Y. A gap 64 is formed in the second direction Y between the first fin 62-1 and the second fin 62-2. The same number of first fins 62-1 and second fins 62-2 are provided.

  The number of fins 62 arranged side by side in the third direction Z (that is, each of the number of first fins 62-1 and the number of second fins 62-2) is the portion corresponding to the lead-side coil end of the flat wire 28. “1” more than the number of conductors stacked. For example, when the number of turns of the flat conductor 28 is “5”, that is, when the number of laminated conductors at the lead-side coil end corresponding portion of the flat conductor 28 is “4”, the conductors are arranged in the third direction Z. The number of the fins 62 to be arranged, the number of the first fins 62-1 and the number of the second fins 62-2 are each “5”.

  Each of the first fins 62-1 and each of the second fins 62-2 is formed in a substantially rectangular plate shape, and is in a direction orthogonal to the plate surface according to the arc of the annular stator core 12 (that is, the first fin 62-1). Curved arcuately in three directions Z). All the first fins 62-1 are arranged such that the curved plate surfaces face each other in the third direction Z. Further, all the second fins 62-2 are arranged so that the curved plate surfaces face each other in the third direction Z.

  All the first fins 62-1 and all the second fins 62-2 of the first outer mold 44-1 have a gap between the first fins 62-1 and a gap between the second fins 62-2. It arrange | positions mutually on concentricity so that it may form in the shape (namely, crank shape) which transferred the some conducting wire laminated | stacked on the lamination direction of the lead side coil end part 34 of the concentric winding coil 14. FIG. The concentric arrangement of the first fin 62-1 and the second fin 62-2 is based on the gap between the first fins 62-1 and the gap between the second fins 62-2. This is performed so that a shape suitable for arc-forming the end corresponding portion is formed.

  In addition, all the first fins 62-1 and all the second fins 62-2 are disposed so as to face each other obliquely in the second direction Y with the gap 64 interposed therebetween. The diagonal arrangement of the first fin 62-1 and the second fin 62-2 corresponds to the lead-side coil end of the flat conductor 28 by the gap 64 between the first fin 62-1 and the second fin 62-2. This is performed so that a shape suitable for cranking the part is formed. Specifically, the substantially center in the second direction Y of the lead-side coil end portion 34 of the concentric winding coil 14 is formed into a crank shape by the gap 64 between the first fin 62-1 and the second fin 62-2. Thus, the lane change of 0.5 stage can be performed between the slot portions 30 and 32 on both sides.

  Each first fin 62-1 and each second fin 62-2 are fixedly attached to the main body 66 of the first outer mold 44-1. A fin hole 68 for attaching the fin 62 is formed in the main body 66 of the first outer mold 44-1. The fin hole 68 is an insertion hole penetrating in the first direction X for inserting the first fin 62-1 and the second fin 62-2 from the outside, and faces the first direction X in which the processed surface 54 is formed. The concave surface 56 is open.

  The fin hole 68 is provided for each first fin 62-1 and each second fin 62-2. Each fin hole 68 is opened in an appropriate shape at a position where all the first fins 62-1 and all the second fins 62-2 of the main body 66 are appropriately arranged as described above. For example, it is opened so as to be curved in the third direction Z. The processed surface 54 is formed between the fin holes 68 on the concave surface 56 of the first outer mold 44-1.

  Extraction holes 70 and 72 are formed in the main body 66 of the first outer mold 44-1. The extraction holes 70 and 72 are insertion holes penetrating in the first direction X into which both end portions 28a and 28b of the flat conducting wire 28 set in the inner mold 42 can be inserted. Both end portions 28a, 28b of the flat wire 28 are portions that are formed in a similar shape to the slot-corresponding portion that extends substantially linearly from the coil end corresponding portion, and that extend substantially linearly from the position of the coil end corresponding portion, After the molding is completed, it is a part to be connected to a lead wire such as another concentric coil 14 or an external connection terminal. Note that these both end portions 28a and 8b may have a slightly curved shape.

  The extraction holes 70 and 72 can appropriately take out the tips of the end portions 28a and 28b of the rectangular conductor 28 in the state where the rectangular conductor 28 of the main body 66 is appropriately set in the inner mold 42. It is opened in a shape suitable for the position (specifically, a rectangular shape having an area slightly larger than the cross-sectional area of the flat conducting wire 28). The take-out hole 70 is a hole for taking out the end portion 28a on the one-side slot portion 30 side of the flat wire 28, and the take-out hole 72 is for taking out the end portion 28b on the other-side slot portion 32 side of the flat wire 28. It is a hole for.

  The main body 66 of the first outer mold 44-1 also has a bolt hole 74 for bolting the first fin 62-1 and a bolt hole 76 for bolting the second fin 62-2. Is formed. Each first fin 62-1 is formed with a bolt hole 78 for fixing the bolt. Each second fin 62-2 is formed with a bolt hole 80 for fixing the bolt.

  Each first fin 62-1 is inserted into the fin hole 68 of the main body 66 of the first outer mold 44-1, and then the bolt hole 74 of the main body 66 and the bolt hole 78 of the self first fin 62-1. By being fastened by bolts inserted into the first outer die 44-1, the first outer die 44-1 is attached and fixed to the main body 66. Each second fin 62-2 is inserted into the fin hole 68 of the main body 66 of the first outer mold 44-1, and then the bolt hole 76 of the main body 66 and the bolt of the second fin 62-2. By being fastened by a bolt inserted into the hole 80, it is attached and fixed to the main body 66 of the first outer mold 44-1.

  When each first fin 62-1 and each second fin 62-2 are attached and fixed to the main body 66 of the first outer mold 44-1, the first inner side from the concave surface 56 of the main body 66, that is, the processing surface 54, is obtained. It protrudes toward the mold 42-1 side. When the fixing to the main body 66 is performed, the front ends on the first direction X side of the first fins 62-1 and the second fins 62-2 are the first inner side of the first outer mold 44-1. In front of the first inner mold 42-1 rather than the end on the mold 42-1 side (that is, the end of the entire concave surface 56 and processed surface 54 on the first inner mold 42-1 side). To position.

  Note that the amount of protrusion of the first and second fins 62-1 and 62-2 from the concave surface 56 of the main body 66, that is, the processing surface 54, that is, the position of the tip of the first and second fins 62-1 and 62-2 depends on the presence of the fins 62. Any shape can be used as long as the shape of the portion corresponding to the coil end of the flat conducting wire 28 at the start of can be brought close to the desired crank shape and arc shape.

  Each first fin 62-1 has a first direction facing the second fin 62-2 and the front end on the Y direction side facing the second fin 62-2 via the gap 64, and the first inner mold 42-1 side. Each of the X-side tips is tapered. In addition, each of the second fins 62-2 faces the first fin 62-1 and the front end on the Y direction side facing the gap 64 and the first inner mold 42-1 side. The tip portions on the one-direction X side are each formed in a tapered shape. The taper shape of the fin 62 is such that the lead wire side coil end corresponding portion of the flat wire 28 is crank-shaped and arc-shaped in the third direction Z, and the lead wire 28 is laminated between the fins 62 in the stacking direction. Has a function to facilitate insertion into the gap.

  The first inner mold 42-1 is formed with a through hole 82 penetrating in the first direction X. The through hole 82 opens in the second direction Y together with the first direction X. In the through hole 82, the fin 62 protruding from the concave surface 56 of the first outer mold 44-1 toward the first inner mold 42-1 side in the process of forming the concentric winding coil 14 from the flat wire 28 is formed. It is an escape hole to be inserted. The through hole 82 is provided for each fin 62 (for each first fin 62-1 and each second fin 62-2). Each through hole 82 is opened in an appropriate shape at a position where all the fins 62 provided in the first outer mold 44-1 of the first inner mold 42-1 are appropriately inserted.

  The first inner mold 42-1 has a fin-like portion 83 formed in a fin shape due to the presence of the plurality of through holes 82. The same number of fin-shaped portions 83 as the number of steps of the flat conducting wire 28 in the stacking direction are provided. On the convex surface 48 of the first inner mold 42-1, the processed surface 46 is formed between the through holes 82. The processed surface 46 is a surface facing the first direction X of the fin-shaped portion 83 formed in the first inner mold 42-1.

  Further, the second outer mold 44-2 has a plurality of fins 84. The second outer mold 44-2 having a plurality of fins 84 is a mold for crank-forming and arc-forming the portion corresponding to the non-lead-side coil end of the flat wire 28. A plurality of fins 84 are arranged side by side in the third direction Z, and are divided into two in the second direction Y. The fin 84 includes a third fin 84-1 and a fourth fin 84-2 divided in the second direction Y. A gap 86 is formed in the second direction Y between the third fin 84-1 and the fourth fin 84-2. The same number of the third fins 84-1 and the fourth fins 84-2 are provided.

  The number of fins 84 arranged side by side in the third direction Z (that is, the number of third fins 84-1 and the number of fourth fins 84-2) is the portion corresponding to the anti-lead side coil end of the flat wire 28. It is “1” more than the number of conductors in the stack. For example, when the number of turns of the flat conductor 28 is “5”, that is, when the number of laminated conductors in the portion corresponding to the coil end of the flat conductor 28 is “5”, they are aligned in the third direction Z. The number of fins 84, the number of third fins 84-1, and the number of fourth fins 84-2 are each "6".

  Each of the third fins 84-1 and each of the fourth fins 84-2 is formed in a substantially rectangular plate shape, and is in a direction orthogonal to the plate surface according to the arc of the annular stator core 12 (that is, the first fins 84-1). Curved arcuately in three directions Z). All the third fins 84-1 are arranged so that the curved plate surfaces face each other in the third direction Z. Further, all the fourth fins 84-2 are arranged such that the curved plate surfaces face each other in the third direction Z.

  All the third fins 84-1 and all the fourth fins 84-2 of the second outer mold 44-2 have a gap between the third fins 84-1 and a gap between the fourth fins 84-2. It arrange | positions mutually on concentricity so that it may form in the shape (namely, crank shape) which transcribe | transferred the some conducting wire laminated | stacked in the lamination direction of the anti-lead side coil end part 36 of the concentric winding coil 14. FIG. The concentric arrangement of the third fins 84-1 and the fourth fins 84-2 is based on the gap between the third fins 84-1 and the gap between the fourth fins 84-2, on the opposite lead side of the flat wire 28. The coil end corresponding portion is formed so as to have a shape suitable for arc forming.

  In addition, all the third fins 84-1 and all the fourth fins 84-2 are disposed so as to face each other obliquely in the second direction Y through the gap 86. The diagonal arrangement of the third fins 84-1 and the fourth fins 84-2 is caused by the gap 86 between the third fins 84-1 and the fourth fins 84-2, so that the coil end on the side opposite to the lead of the flat conductor 28. This is performed so that a shape suitable for cranking the corresponding portion is formed. Specifically, the center in the second direction Y of the non-lead side coil end portion 36 of the concentric winding coil 14 is formed into a crank shape by the gap 86 between the third fin 84-1 and the fourth fin 84-2. By doing so, a lane change of 0.5 stages can be performed between the slot portions 30 and 32 on both sides.

  The third fins 84-1 and the fourth fins 84-2 are attached and fixed to the main body 88 of the second outer mold 44-2, respectively. A fin hole 90 for attaching the fin 84 is formed in the main body 88 of the second outer mold 44-2. The fin hole 90 is an insertion hole penetrating in the first direction X for inserting the third fin 84-1 and the fourth fin 84-2 from the outside, and faces the first direction X in which the machining surface 58 is formed. The concave surface 60 is open.

  The fin hole 90 is provided for each of the third fins 84-1 and each of the fourth fins 84-2. Each fin hole 90 is opened in an appropriate shape at a position where all the third fins 84-1 and all the fourth fins 84-2 are appropriately arranged as described above. For example, it is opened so as to be curved in the third direction Z. The processed surface 58 is formed between the fin holes 90 on the concave surface 60 of the second outer mold 44-2.

  The main body 88 of the second outer mold 44-2 also has a bolt hole 92 for fixing the third fin 84-1 with a bolt and a bolt hole 94 for fixing the fourth fin 84-2 with a bolt. Is formed. Each third fin 84-1 is formed with a bolt hole (not shown) for fixing the bolt. Each fourth fin 84-2 is formed with a bolt hole (not shown) for fixing the bolt.

  After the third fins 84-1 are inserted into the fin holes 90 of the main body 88 of the second outer mold 44-2, the third fins 84-1 are respectively inserted into the bolt holes 92 of the main body 88 and the bolt holes of the third fin 84-1. By being fastened by the inserted bolt, it is fixedly attached to the main body 88 of the second outer mold 44-2. The fourth fins 84-2 are inserted into the fin holes 90 of the main body 88 of the second outer mold 44-2, and then the bolt holes 94 of the main body 88 and the bolts of the self fourth fin 84-2. By being fastened by a bolt inserted into the hole, the second outer mold 44-2 is attached and fixed to the main body 88.

  When the third fins 84-1 and the fourth fins 84-2 are respectively attached and fixed to the main body 88 of the second outer mold 44-2, the second inner side from the concave surface 60, that is, the processing surface 58 of the main body 88, is obtained. Projects toward the mold 42-2 side. When the fixing to the main body 88 is made, the tips of the third fins 84-1 and the fourth fins 84-2 on the first direction X side are the second inner sides of the second outer mold 44-2. In front of the end on the mold 42-2 side (that is, the end of the entire concave surface 60 and processing surface 58 on the second inner mold 42-2 side) closer to the second inner mold 42-2. To position.

  Note that the amount of protrusion of the third and fourth fins 84-1 and 84-2 from the concave surface 60 of the main body 88, that is, the processing surface 58, that is, the position of the tip thereof is edgewise formed by the presence of the fins 84. Any shape can be used as long as the shape of the portion corresponding to the coil end of the flat conducting wire 28 at the start of can be brought close to the desired crank shape and arc shape.

  Each of the third fins 84-1, the first direction facing the fourth fin 84-2 and the front end portion on the Y direction Y side facing the gap 86, and the second inner mold 42-2 side. Each of the X-side tips is tapered. In addition, each of the fourth fins 84-2 faces the third fin 84-1 and the front end portion on the Y direction side facing the gap 86 and the second inner mold 42-2 side. The tip portions on the one-direction X side are each formed in a tapered shape. The taper shape of the fin 84 is such that each of the conductors in the stacking direction of the flat conductor 28 is connected between the fins 84 when cranking and arc-forming in the third direction Z are performed on the portion corresponding to the coil end on the opposite lead side of the flat conductor 28. It has a function to facilitate insertion.

  In addition, a through hole 96 penetrating in the first direction X is formed in the second inner mold 42-2. The through hole 96 opens in the second direction Y together with the first direction X. The through hole 96 has a fin 84 that protrudes from the concave surface 60 of the second outer mold 44-2 toward the second inner mold 42-2 in the process of forming the concentric winding coil 14 from the flat wire 28. It is an escape hole to be inserted. The through hole 96 is provided for each fin 84 (for each third fin 84-1 and for each fourth fin 84-2). Each through hole 96 is opened in an appropriate shape at a position where all the fins 84 provided in the second outer mold 44-2 of the second inner mold 42-2 are properly inserted.

  The second inner mold 42-2 has a fin-shaped portion 97 formed in a fin shape due to the presence of the plurality of through holes 96. The fin-shaped portions 97 are provided in the same number as the number of steps of the flat conducting wire 28 in the stacking direction. On the convex surface 52 of the second inner mold 42-2, the processed surface 50 is formed between the through holes 96. This processed surface 50 is a surface facing the first direction X of the fin-shaped portion 97 formed in the second inner mold 42-2.

  In the molding apparatus 40, as described above, the first outer mold 44-1, the first inner mold 42-1, the second inner mold 42-2, and the second outer mold 44-2 are the They are arranged in series in that order in one direction X. The first outer mold 44-1, the first inner mold 42-1, the second inner mold 42-2, and the second outer mold 44-2 are each in the first direction with respect to the base 98. Attached so as to be movable toward X.

  The first outer mold 44-1 is moved by the moving mechanism 100, the first inner mold 42-1 is moved by the moving mechanism 102, the second inner mold 42-2 is moved by the moving mechanism 104, and the second outer mold 44 is moved. -2 is moved by the moving mechanism 106 in the first direction X with respect to the base 98. Each of the moving mechanisms 100, 102, 104, and 106 is a mechanism that slides its own base with respect to the base 98 in the first direction X. A controller 110 mainly composed of a microcomputer is electrically connected to each of the moving mechanisms 100, 102, 104, and 106.

  The controller 110 is a control device that causes the forming device 40 to perform an operation necessary for forming the concentric winding coil 14 by bending the rectangular conducting wire 28 set in the forming device 40, and moves the operation command. This is performed for the mechanisms 100, 102, 104, and 106. Such an operation command may be issued when a predetermined switch operation is performed after the flat wire 28 is set in the molding apparatus 40. Each of the moving mechanisms 100, 102, 104, 106 directs the dies 44-1, 42-1, 42-2, 44-2 in the first direction X with respect to the base 98 according to a command from the controller 110. Move the stroke.

  In the present embodiment, the first inner mold 42-1, the second inner mold 42-2, the first outer mold 44-1, and the second outer mold 44-2 are all moved by the moving mechanism 100. , 102, 104, 106 are moved in the first direction X, but any of the molds 42-1, 42-2, 44-1, 44-2 may be fixed to the base 98. Good.

  The molding apparatus 40 also includes gripping members 112 and 114 that are attached to the base 98. The holding members 112 and 114 are respectively arranged outside the first direction X with respect to the first outer mold 44-1 in which the extraction holes 70 and 72 are formed. The gripping member 112 protrudes from the take-out hole 70 of the first outer mold 44-1 at the end 28a of the flat conducting wire 28 set in the inner mold 42 when the flat conducting wire 28 is bent. It is a member that holds the tip. Further, the gripping member 114 protrudes from the take-out hole 72 of the first outer mold 44-1 at the end portion 28b of the flat conductive wire 28 set in the inner mold 42 during the bending process of the flat conductive wire 28. It is a member which grasps the tip which is.

  Each of the holding members 112 and 114 has a structure in which the surfaces of the two flat plates 112a, 112b, 114a, and 114b are combined. The two flat plates 112a, 112b, 114a, 114b of the gripping members 112, 114 are fastened to each other by bolts 116, 118, respectively. Each of the grip members 112 and 114 is in contact with the long side of the flat conductor 28 and grips the ends of both ends 28a and 28b of the flat conductor 28 on the long side of the cross section. The gripping force with which each of the gripping members 112 and 114 grips the flat wire 28 is at least capable of fixing the end portions 28a and 28b to the base 98 or the gripping members 112 and 114 when the flat wire 28 is formed. It is enough.

  Each of the grip members 112 and 114 is attached to the base 98 so as to be swingable about the first direction X as an axis center. Each of the holding members 112 and 114 follows the rotation of the flat conductor 28 when the flat conductor 28 is bent, and when the flat conductor 28 rotates about the first direction X as a center of deformation. Swing. A guide groove for guiding the flat conducting wire 28 may be provided on the inner surface of the flat plates 112a, 112b, 114a, 114b.

  In the present embodiment, before the flat conducting wire 28 is set in the molding apparatus 40, the first outer mold 44-1 and the second outer mold 44-2 have both molds 44-1 and 44-2 that are connected to each other. The first inner mold 42-1 and the second inner mold 42-2 are positioned so as to be separated from each other by a predetermined maximum distance in one direction X, and both the molds 42-1 and 42-2 are first to each other. Positioned in the direction X to be separated by a predetermined minimum distance. At this time, between the first outer mold 44-1 and the first inner mold 42-1 and between the second outer mold 44-2 and the second inner mold 42-2, respectively. A gap sufficient to set the flat conducting wire 28 in the first direction X is formed.

  In this state, first, the substantially hexagonal flat conducting wire 28 is set in the inner mold 42. At this time, the flat conducting wire 28 is held on the outer peripheral surface side of the first inner mold 42-1 and the second inner mold 42-2. At this time, the flat conducting wire 28 is held so that the position in the third direction Z is optimal for bending the flat conducting wire 28 with the inner mold 42 and the outer mold 44. At this time, the rectangular conductor 28 is held such that both end portions 28a and 28b enter the extraction holes 70 and 72 of the first outer mold 44-1, and project outside from the extraction holes 70 and 72. The Further, at this time, the flat conducting wire 28 is fixed to the base 98 by the gripping members 112 and 114 gripping the ends of both end portions 28a and 28b protruding outside from the extraction holes 70 and 72.

  When the flat wire 28 is set in the inner mold 42 as described above, next, the first inner mold 42-1 and the second inner mold 42-2 are directed in the first direction X so as to be separated from each other. The first outer mold 44-1 is moved in the first direction X so as to approach the first inner mold 42-1 and the second outer mold 44-2 is moved. Is moved in the first direction X so as to approach the second inner mold 42-2.

  That is, after the flat wire 28 is set, the first inner die 42-1 and the first outer die 44-1 come close to each other and sandwich the portion corresponding to the lead side coil end of the flat wire 28 in the first direction. The second inner die 42-2 and the second outer die 44-2 are moved toward each other in the direction of X and the second outer die 44-2 approaches each other so as to sandwich the portion corresponding to the non-lead side coil end of the flat wire 28. The stroke is moved in one direction X.

  The stroke movement of the first inner mold 42-1 and the stroke movement of the second inner mold 42-2 are performed substantially simultaneously, and the stroke movement of the first outer mold 44-1 and the second outer mold 42-1 are performed. The stroke movement of the mold 44-2 is performed substantially simultaneously. Further, the stroke movement of the first inner mold 42-1 and the stroke movement of the first outer mold 44-1 are performed in synchronization, and the stroke movement of the second inner mold 42-2 and the second outer mold 42-1 are performed. The stroke movement of the mold 44-2 is performed in synchronization.

  In the process of moving the first outer mold 44-1 in the first direction X so as to approach the first inner mold 42-1, the lead side of the flat conducting wire 28 held by the inner mold 42 The conductive wires at the respective stages arranged in the third direction Z at the coil end corresponding site enter the gaps between the fins 62 of the first outer mold 44-1. In the course of the stroke movement, the fins 62 of the first outer mold 44-1 are inserted into the through holes 82 of the first inner mold 42-1.

  As described above, the front ends of the first and second fins 62-1 and 62-2 facing the second or first fins 62-2 and 62-1 via the gap 64 in the second direction Y side. And the front-end | tip part by the side of the 1st direction X which faces the 1st inner side metal mold | die 42-1 side is respectively formed in the taper shape. For this reason, the lead wires of each step at the lead-side coil end corresponding portion of the flat lead wire 28 smoothly enter the gap between the fins 62 due to the tip tapered surface of the fin 62 of the first outer mold 44-1. It is easy to be inserted into the gap.

  The lead of each step at the portion corresponding to the lead-side coil end of the flat lead 28 enters the gap between the fins 62 of the first outer mold 44-1, first, in the second direction Y of the lead of each step. The process starts when the approximate center enters the gap 64 between the first fin 62-1 and the second fin 62-2. And after that, the approach is performed so that the lead wire of each step enters the gap between the fins 62 in order from the approximate center of the second direction Y to both outer sides.

  Each level of the lead wire at the lead-side coil end corresponding portion of the flat lead wire 28 is formed so as to change the lane in one step by crossing the slot-corresponding portions on both sides diagonally. On the other hand, in the first outer mold 44-1, the fins 62 are arranged by the gap 64 between the first fin 62-1 and the second fin 62-2 of the lead-side coil end portion 34 of the concentric winding coil 14. By forming the approximate center of the second direction Y into a crank shape, a lane change of 0.5 steps can be performed between the slot portions 30 and 32 on both sides.

  For this reason, when the above approach is performed, first, the approximate center in the second direction Y of the lead wire of each step at the lead side coil end corresponding portion of the flat lead wire 28 is the tip corner portion of the first fin 62-1. The gap between the first fins 62-1 adjacent to the third direction Z and the second fins 62-2 adjacent to each other in the third direction Z. Fit the gaps together. In this case, the substantially center in the second direction Y of each step of the lead wire 28 at the portion corresponding to the lead-side coil end is bent into a crank shape so that a step is generated in the third direction Z (crank Molding).

  The fins 62 are attached and fixed to the first outer mold 44-1 so as to be arranged concentrically with each other while being curved in the third direction Z. For this reason, when the above-mentioned approach advances by moving the stroke toward the first direction X so that the first outer mold 44-1 approaches the first inner mold 42-1, the lead of the flat conductor 28 is obtained. The entire side coil end corresponding part fits into the gap between the first fins 62-1 adjacent in the third direction Z and the gap between the second fins 62-2 adjacent in the third direction Z, It is bent into an arc shape so as to curve in accordance with the arc of the annular stator core 12 (arc forming).

  Further, the processed surface 46 of the first inner mold 42-1 and the processed surface 54 of the first outer mold 44-1 are shapes suitable for edgewise forming the lead-side coil end corresponding portion of the flat conducting wire 28. Is formed. For this reason, the above approach has proceeded to a state where the lead-side coil end corresponding portion of the flat wire 28 is in contact with both the convex surface 48 of the first inner mold 42-1 and the concave surface 56 of the first outer mold 44-1. When further progressing later, the short side of the cross section of the portion corresponding to the lead-side coil end of the flat wire 28 is first formed by the processing surface 46 of the first inner mold 42-1 and the processing surface 54 of the first outer mold 44-1. It is pressed and clamped in the direction X (FIG. 10). In this case, the entire lead-side coil end corresponding portion of the flat conducting wire 28 is bent into a bent shape in the XY plane orthogonal to the third direction Z (edgewise molding).

  Similarly, in the process in which the second outer mold 44-2 is moved in the stroke in the first direction X so as to approach the second inner mold 42-2, the rectangular conductive wire held by the inner mold 42 is used. The lead wires of the respective stages arranged in the third direction Z at the portion 28 corresponding to the coil end corresponding to the lead side enter the gap between the fins 84 of the second outer mold 44-2. In the course of the stroke movement, the fins 84 of the second outer mold 44-2 are inserted into the through holes 96 of the second inner mold 42-2.

  As described above, the tip ends on the second direction Y side of the third and fourth fins 84-1 and 84-2 facing the fourth or third fins 84-2 and 84-1 via the gap 86, respectively. And the front-end | tip part by the side of the 1st direction X which faces the 2nd inner side metal mold | die 42-2 side is respectively formed in the taper shape. For this reason, the lead wires of each step at the portion corresponding to the coil lead end of the flat lead wire 28 smoothly enter the gap between the fins 84 by the tip tapered surface of the fin 84 of the second outer mold 44-2. It is easy to insert into such a gap.

  The lead of each step at the portion corresponding to the coil end of the rectangular lead wire 28 opposite to the lead 84 enters the gap between the fins 84 of the second outer mold 44-2. First, the second direction Y of the lead of each step Is started by entering the gap 86 between the third fin 84-1 and the fourth fin 84-2. And after that, the approach is performed so that the lead wires of each stage enter the gaps between the fins 84 in order from the approximate center of the second direction Y to both outer sides.

  The lead wires of each step at the portion corresponding to the coil lead end of the flat lead wire 28 are formed on the same plane as between the slot corresponding portions on both sides. On the other hand, in the second outer mold 44-2, the fins 84 are arranged by the clearance 86 between the third fins 44-1 and the fourth fins 84-2 on the anti-lead side coil end portion 36 of the concentric winding coil 14. By forming the approximate center of the second direction Y into a crank shape, a lane change of 0.5 steps can be performed between the slot portions 30 and 32 on both sides.

  For this reason, when the above approach is performed, first, the approximate center in the second direction Y of the lead wire of each step at the portion corresponding to the coil end of the flat lead wire 28 is the tip corner portion of the third fin 84-1. Between the third fin 84-1 adjacent to the third direction Z and the fourth fin 84-2 adjacent to the third direction Z. It fits so as to connect the gaps between them. In this case, the approximate center in the second direction Y of each step of the lead wire 28 at the portion corresponding to the coil end opposite to the lead end is bent into a crank shape so that a step is generated in the third direction Z ( Crank molding).

  The fins 84 are attached and fixed to the second outer mold 44-2 so as to be arranged concentrically with each other while being curved in the third direction Z. For this reason, when the above-mentioned approach advances by moving the stroke toward the first direction X so that the second outer mold 44-2 approaches the second inner mold 42-2, the flat conductor 28 is counteracted. The entire lead side coil end corresponding part fits into the gap between the third fins 84-1 adjacent in the third direction Z and the gap between the fourth fins 84-2 adjacent in the third direction Z. It is bent into an arc shape so as to be curved in accordance with the arc of the annular stator core 12 (arc forming).

  Furthermore, the processing surface 50 of the second inner mold 42-2 and the processing surface 58 of the second outer mold 44-2 are suitable for edgewise forming the portion corresponding to the coil end on the side opposite to the lead side of the flat wire 28. It is formed into a shape. For this reason, the above approach proceeds to a state where the portion corresponding to the coil end of the flat lead wire 28 is in contact with both the convex surface 52 of the second inner mold 42-2 and the concave surface 60 of the second outer mold 44-2. Then, when the process proceeds further, the short side of the cross section of the portion corresponding to the coil end of the flat lead wire 28 is formed by the processing surface 50 of the second inner mold 42-2 and the processing surface 58 of the second outer mold 44-2. It is pressed and clamped in the first direction X (FIG. 10). In this case, the entire portion of the flat lead wire 28 corresponding to the non-lead-side coil end is bent into a bent shape in the XY plane orthogonal to the third direction Z (edgewise molding).

  When the edgewise forming of the lead-side coil end corresponding portion and the anti-lead-side coil end corresponding portion of the flat wire 28 as described above is completed, the first outer die 44-1 is then turned into the first inner die 42-1. The second outer mold 44-2 is stroked toward the first direction X so as to be separated from the second inner mold 42-2. At the same time, the first inner mold 42-1 and the second inner mold 42-2 are moved in the stroke in the first direction X so as to approach each other. The stroke movement of the first outer mold 44-1 and the stroke movement of the second outer mold 44-2 may be performed substantially simultaneously.

  When such a stroke movement is made, a crank-shaped bending process in the third direction Z, an arc-shaped bending process in the third direction Z, and an XY plane orthogonal to the third direction Z are applied to the coil end corresponding part. The holding of the first outer mold 44-1 and the second outer mold 44-2 on the inner peripheral surface side with respect to the rectangular conductor wire 28 to which the bending process of the bent shape in FIG. The holding | maintenance to the outer peripheral surface side of the metal mold | die 42-1 and the 2nd inner side metal mold | die 42-2 is cancelled | released.

  Then, after the stroke movement of the first and second outer molds 44-1 and 44-2 and the first and second inner molds 42-1 and 42-2 is completed, the rectangular conducting wire 28 by the holding members 112 and 114 is completed. The gripping of the both end portions 28a and 28b at the tip ends is released. Here, the first and second outer molds 44-1 are maintained by holding the gripping members 112 and 114 until the holding by the first and second outer molds 44-1 and 44-2 is released. , 44-2 can be prevented from being deformed due to the fact that the flat wire 28 after molding is pulled by the dies 42, 44 due to friction with the fins 62, 84 at the time of releasing the holding. Thereafter, the concentric winding coil 14 can be removed after the molding is completed.

  As described above, in this embodiment, the coil end of the substantially hexagonal flat rectangular conductor 28 in which a plurality of conductors are laminated by moving the inner mold 42 and the outer mold 44 constituting the molding device 40 by stroke. Crank forming, arc forming, and edgewise forming can be performed on the corresponding portion, and as a result, a plurality of coil end portions 34 and 36 in which a plurality of conductive wires are laminated are formed in different non-linear shapes. The substantially hexagonal concentric winding coil 14 can be formed.

  In such a configuration, when the coil end portions 34 and 36 of the substantially hexagonal concentric winding coil 14 are formed into a plurality of different non-linear shapes from the substantially hexagonal flat wire 28, the inner mold of the molding apparatus 40 is used. It is sufficient to move 42 and the outer mold 44 in the first direction X by one stroke. In addition, the conductors at each stage in the stacking direction of the coil end portions 34 and 36 of the concentric winding coil 14 can be formed into a plurality of different non-linear shapes substantially simultaneously, and each of the conductors is different from each other. In forming a non-linear shape, it is sufficient to move the inner mold 42 and the outer mold 44 of the molding apparatus 40 in the first direction X by one stroke.

  That is, in each step of moving the inner die 42 and the outer die 44 of the molding apparatus 40 by one stroke in the first direction X, each step in the stacking direction of the coil end corresponding portion of the substantially hexagonal rectangular wire 28 is obtained. By bending the conductive wires collectively, it is possible to realize a plurality of different non-linear shapes of the coil end portions 34 and 36 of the substantially hexagonal concentric coil 14 in which a plurality of conductive wires are laminated. .

  In this regard, according to the forming method by the forming apparatus 40 of this embodiment, the substantially hexagonal concentric winding in which the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes from the substantially hexagonal flat wire 28. In forming the coil 14, it is not necessary to prepare separate molds and jigs for forming each of these non-linear shapes (specifically, a crank shape, an arc shape, and a bent shape). Therefore, it is not necessary to provide a plurality of steps and to separately provide a transfer facility between the steps.

  For this reason, according to the present embodiment, the number and cost of facilities such as molds and jigs increase when the coil end portions 34 and 36 of the concentric winding coil 14 are formed into a plurality of different non-linear shapes. Can be prevented, and an increase in installation space of equipment can be prevented. Therefore, according to the present embodiment, the concentric winding coil 14 in which the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes can be realized with a simple configuration.

  In addition, according to the present embodiment, the coil end portions 34 and 36 of the concentric winding coil 14 can be formed into a plurality of different non-linear shapes at substantially the same time. Therefore, when forming the concentric winding coil 14 in which the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes, the processing time of the rectangular conductor 28 to be formed can be shortened.

  Further, according to the forming method by the forming apparatus 40 of the present embodiment, the coil end portions 34 and 36 in which a plurality of conductive wires are laminated from the substantially hexagonal flat rectangular wire 28 that is wound a plurality of turns are different from each other. In order to form the substantially hexagonal concentric winding coil 14 formed in a linear shape, it is not necessary to bend the conducting wires at each stage in the stacking direction one by one. For this reason, when shaping | molding the concentric winding coil 14 with which several conducting wire is laminated | stacked, the processing time of the flat conducting wire 28 of shaping | molding object can be shortened.

  Furthermore, according to the shaping | molding method by the shaping | molding apparatus 40 of a present Example, both the coil end parts 34 and 36 of the concentric winding coil 14 can be shape | molded to several different non-linear shape substantially simultaneously. For this reason, when forming both the coil end portions 34 and 36 of the concentric winding coil 14 into a plurality of different non-linear shapes, the processing time of the rectangular wire 28 to be formed can be shortened, and both coils It is possible to suppress deformation of the slot portions 30 and 32 that connect both the coil end portions 34 and 36 due to the molding of the end portions 34 and 36 being performed at different timings.

  As described above, according to this embodiment, when forming the substantially hexagonal concentric winding coil 14 in which a plurality of conductive wires are laminated and the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes. The processing time for the flat rectangular wire 28 to be molded can be greatly shortened. Therefore, the concentric winding coil 14 can be formed in a short time, and the productivity of the concentric winding coil 14 can be improved.

  Further, according to the present embodiment, in the process of forming the substantially hexagonal concentric winding coil 14 in which the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes from the substantially hexagonal flat conductor 28, It is not necessary to repeat attachment / detachment of the flat conducting wire 28 to be formed from a mold or a jig between forming steps of a plurality of different non-linear shapes. For this reason, it is possible to prevent the flat rectangular wire 28 to be molded from being easily damaged due to repeated attachment / detachment from the mold or jig, and as a result, the quality of the concentric winding coil 14 is deteriorated. Can be suppressed.

  In this embodiment, the lead wires of each step at the coil end corresponding portion of the flat lead wire 28 enter between the fins 62 and the fins 84 of the outer mold 44 first. It starts when the approximate center of the two directions Y enters the gap 64 of the fin 62 and the gap 86 of the fin 84. Then, the approach is performed so as to enter the gap between the fins 62 and the gap between the fins 84 in order from the approximate center in the second direction Y to both outer sides.

  In such a configuration, the bending process of the portion corresponding to the coil end of the flat wire 28 proceeds from the center side in the second direction Y of the portion corresponding to the coil end toward both outer sides. For this reason, according to the present embodiment, unlike the configuration in which the bending process of the flat wire 28 described above proceeds from both outer sides in the second direction Y of the coil end corresponding portion toward the center side, the flat wire 28 corresponds to the coil end. It is possible to prevent excessive conductors from gathering in forming a desired crank shape at substantially the center in the second direction Y of the part. Therefore, when forming the coil end portions 34 and 36 of the concentric winding coil 14 into a plurality of different non-linear shapes, the forming accuracy can be improved.

  In the present embodiment, the edge-wise forming of the coil end portions 34 and 36 of the concentric winding coil 14 is performed after the crank forming and the arc forming, and the flat conductors 28 at the respective stages in the stacking direction are the fins 62, It is performed in a state sandwiched between 84. In this respect, it is possible to suppress the deformation of the coil portion in which the crank forming and the arc forming have been completed particularly during the edgewise forming, so that the concentric winding coil 14 can be formed with high accuracy.

  In this embodiment, the substantially hexagonal concentric coil 14 is formed from the substantially hexagonal rectangular conductor 28 by moving the inner mold 42 and the outer mold 44 of the molding apparatus 40 by one stroke. In the process, first, the approximate center in the second direction Y of the lead wire of each step at the coil end corresponding portion of the flat lead wire 28 is the gap 64 between the fin 62-1 and the fin 62-2 of the outer mold 44 and the fin 84-. Crank forming that is bent into a crank shape so that a step is formed in the third direction Z at the approximate center in the second direction Y of the coil end corresponding portion by fitting into the gap 86 between the first and fins 84-2. Is done.

  Then, after the above crank forming is started, the lead wires of the respective stages of the coil end corresponding portions are finned in order from the substantially center in the second direction Y to the both outer sides as the stroke movement of the inner mold 42 and the outer mold 44 proceeds. By entering and fitting into the gap between 62 and the gap between the fins 84, the entire coil end corresponding portion is formed into an arc shape so as to curve in the third direction Z in accordance with the arc of the annular stator core 12. Arc forming to be bent is performed.

  Next, after the arc forming is started, the short side of the cross section of the coil end corresponding portion is moved to the processing surface 46 of the inner die 42 and the outer die 44 by the progress of the stroke movement of the inner die 42 and the outer die 44. By being sandwiched between 50, 54, and 58, edgewise forming is performed in which the entire coil end corresponding portion is bent into a bent shape in the XY plane orthogonal to the third direction Z.

  In this embodiment, the tips of the fins 62 and 84 attached and fixed to the outer mold 44 in the first direction X side are the end portions of the outer mold 44 on the inner mold 42 side (that is, the concave surfaces 56, 60 and the entire processing surface 54, 58 are positioned closer to the inner mold 42 than the entire inner mold 42 side end). According to such a structure, the difference between the start timings of the crank forming and the arc forming of the coil end portions 34 and 36 of the concentric winding coil 14 and the start timing of the edgewise forming is widened, that is, the crank forming and the arc forming respectively. The time from the start to the start of edgewise molding can be earned. For this reason, according to the present embodiment, the crank forming and arc forming processes can be further advanced before the start of edgewise forming, and the shape of the portion corresponding to the coil end of the flat wire 28 at the start of the edgewise forming can be determined. It can be made closer to the desired crank shape and arc shape.

  In this embodiment, the edge-wise forming of the coil end portions 34 and 36 of the concentric winding coil 14 is performed after the crank forming and the arc forming are started and after both the crank forming and the arc forming are completed. Be started. Specifically, the distance (width) between the slot-corresponding portions on both sides of the flat conductor 28 is determined by the crank forming and the arc forming of the coil end corresponding portion of the flat conductor 28 to the slots on both sides of the concentric winding coil 14 after the forming is completed. After substantially matching the distance (width) between the portions 30 and 32, the coil end corresponding portion of the flat wire 28 is brought into contact with the processed surfaces 54 and 58 of the concave surfaces 56 and 60 of the outer mold 44, so that both processed surfaces 54 , 58 is started and edgewise molding is started.

  According to such a configuration, the slots on both sides of the rectangular conductor 28 when the edge-wise forming is started when the portions corresponding to the coil ends of the rectangular conductor 28 are brought into contact with the processed surfaces 54 and 58 of the concave surfaces 56 and 60 of the outer mold 44. The distance (width) between the corresponding parts is made as small as possible with respect to the distance (width) between the slot corresponding parts on both sides of the flat rectangular wire 28 before the start of molding, specifically, the concentric coil after the completion of molding. 14 can be made substantially equal to the distance (width) between the slot portions 30 and 32 on both sides.

  The concave portion of the outer mold 44 has a width that imitates the shape of the coil end portions 34 and 36 of the concentric coil 14 after completion of molding and the slot portions 30 and 32 on both sides accommodated in the status lot (ie, The distance between the both side walls in the second direction Y of the concave surfaces 56, 60 is formed so as to be substantially equal to the distance between the outer ends of the slot portions 30, 32 on both sides after the molding is completed.

  Therefore, according to the present embodiment, when the substantially hexagonal concentric coil 14 is formed from the substantially hexagonal rectangular conductor 28, when the rectangular conductor 28 is fitted into the recess of the outer mold 44, the rectangular Prevents the short cross-sectional side of the outer peripheral side of the shoulder near the boundary between the coil end corresponding portion of the conductive wire 28 and the slot portions on both sides from coming into contact with the side walls and corners of the concave surfaces 56 and 60 of the outer mold 44 easily. It is possible to suppress contact between the outer peripheral side of the shoulder portion of the flat wire 28 and the outer mold 44 with an excessive force. For this reason, according to the present embodiment, during molding from the flat conducting wire 28 to the concentric winding coil 14, it is possible to prevent film peeling and damage of the shoulder portion of the flat conducting wire 28 due to contact with the outer mold 44. Can do.

  Furthermore, in the present embodiment, when the flat conducting wire 28 is bent using the outer mold 44 and the inner mold 42, the ends of the both end portions 28a and 28b of the flat conducting wire 28 are gripping members 112 and 114, respectively. The both end portions 28a and 28b are fixed to the base 98 by being gripped by. At this time, both end portions 28a and 28b of the flat conducting wire 28 are respectively gripped and fixed independently from the outer mold 44 and the inner mold 42 that are stroke-moved during molding.

  In such a structure, both end portions 28a and 28b from the coil end corresponding portion to both ends of the flat wire 28 are brought together with the bending deformation portion as a base point during the bending of the coil end corresponding portion during forming of the flat wire 28. It is prevented from moving. For this reason, according to the present embodiment, it is possible to avoid contact between both ends 28a, 28b and the dies 42, 44 due to the accompanying movement of both ends 28a, 28b of the flat wire 28. It is possible to prevent the film peeling and damage of the both end portions 28a and 28b.

  Further, in the present embodiment, the flat conductive wire 28 is gripped by the gripping members 112 and 114 at the ends of both end portions 28a and 28b protruding outside from the take-out holes 70 and 72 of the first outer mold 44-1. Thus, the base 98 is fixed. The gripping members 112 and 114 can swing around the first direction X with respect to the base 98 while gripping the flat conducting wire 28, and the flat conducting wire 28 is bent during the molding ( In particular, when the arc forming and edgewise forming bending process proceeds after the crank forming), when the first direction X is rotated about the axis along with the bending deformation, it swings following the rotation. .

  For this reason, according to the present embodiment, when the concentric winding coil 14 is completely formed, the shape of each of the slot portions 30 and 32 is twisted about the first direction X as an axis center compared to the desired shape. Therefore, it is possible to accurately form the rectangular conductor wire 28 to the concentric winding coil 14.

  Further, in the present embodiment, the gripping of the both end portions 28a and 28b of the flat wire 28 by the gripping members 112 and 114 is realized by gripping the both end portions 28a and 28b on the long side of the cross section. In such a structure, the gripping area per unit length of both end portions 28a, 28b of the flat conducting wire 28 by the gripping members 112, 114 can be increased as compared with the configuration of gripping on the short side of the cross section. Therefore, according to the present embodiment, the gripping members 112 and 114 can stably grip both ends 28a and 28b of the flat conductor 28 on the short side of the cross section, and the flat conductor It is possible to reliably ensure the prevention of the accompanying movement of the both end portions 28a and 28b during molding from 28 to the concentric coil 14.

  In the above-described embodiment, the inner mold 42 and the outer mold 44 are the “mold” described in the claims, the coil end portions 34, 36 of the concentric winding coil 14 of the flat conductor 28. Corresponding coil end corresponding portions correspond to “corresponding portions” described in the claims, and the moving mechanisms 100, 102, 104, and 106 correspond to “mold moving mechanisms” described in the claims, respectively. .

  By the way, in the above-described embodiment, in the process of forming the substantially hexagonal concentric winding coil 14 in which the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes from the substantially hexagonal flat wire 28, The first inner mold 42-1 and the first outer mold 44-1 are moved closer to each other so as to sandwich the lead-side coil end corresponding portion of the flat rectangular wire 28 in the first direction X (inside and outside). The coil is moved toward one direction X (normal direction), and the second inner mold 42-2 and the second outer mold 44-2 are moved closer to each other so that the non-lead-side coil of the rectangular conductor 28 is obtained. The stroke is moved in the first direction X (normal direction) so as to sandwich the end corresponding part in the first direction X (inside and outside). Further, the first outer mold 44-1 and the second outer mold 44-2 are moved by stroke at substantially the same time.

  In the above process, the first outer mold 44-1 and the second outer mold 44-2 are stroke-moved in the normal direction of the first direction X by the moving mechanisms 100 and 106 so as to approach each other. When such stroke movement is made, the coil end corresponding portions on both sides of the flat wire 28 are located between the fins 62 attached to the first outer mold 44-1 and the fins 84 attached to the second outer mold 44-2. As a result of bending and fitting between them, crank forming is performed at the center in the second direction Y of the lead wire of each step for each of the coil end corresponding portions on both sides of the flat lead wire 28, and arc forming is performed. Is called.

  As described above, at the time of crank forming and arc forming using the fins 62 and 84, the coil end corresponding portions on both sides of the flat wire 28 are placed in the first direction X so as to approach each other due to friction with the outer fins. It is pressed toward. When the coil end corresponding portions on both sides of the flat conducting wire 28 are thus pressed, the slot corresponding portions sandwiched between the coil end corresponding portions on both sides of the flat conducting wire 28 may be deformed in the second direction Y and swell. is there.

  On the other hand, in the above-described embodiment, the first outer mold 44-1 and the second outer mold 44-2 are directed inward in the first direction X by the moving mechanisms 100 and 106 so as to approach each other. The strokes are moved toward the outside in the first direction X so that the first inner mold 42-1 and the second inner mold 42-2 are separated from each other by the moving mechanisms 102 and 104 at the same time. Moved.

  If the inner molds 42-1 and 42-2 are stroked so that the outer molds 44-1 and 44-2 are moved so as to approach each other, both sides of the flat wire 28 are formed. Coil end corresponding parts (particularly, approximately the center in the second direction Y) and slot corresponding parts (particularly, near the boundary with the coil end corresponding part) are the machining surfaces 46, 47 of the inner molds 42-1, 42-2. , 50, 51 while being in contact with each other, the coil end corresponding portions on both sides of the flat wire 28 are extended outward in the first direction X so as to be separated from each other. For this reason, according to such a configuration, it is possible to prevent the slot corresponding portions sandwiched between the coil end corresponding portions on both sides of the flat conductor 28 from being deformed in the second direction Y and bulging during crank forming or arc forming. .

  Here, since the rectangular conducting wire 28 having a rectangular cross section is not curved toward the stacking direction of each step conducting wire before the start of arc forming, the conducting wires at each step corresponding to the slot corresponding portions on both sides are in the second direction Y. However, since arc bending starts toward the stacking direction of the respective step conductors, the conductors at the respective steps corresponding to the slots on both sides are inclined with respect to the second direction Y. It will be a thing. That is, when the rectangular conducting wire 28 having a rectangular cross section is formed into an arc shape, the rectangular conducting wire 28 is moved from the state in which the conducting wires at the respective stages corresponding to the slots on both sides are kept horizontal with respect to the second direction Y. It moves slightly in the direction Z and deforms into a tilted state.

  However, during the arc forming process of the flat conducting wire 28, the inner molds 42-1 and 42-2 are separated from each other, that is, approach the paired outer molds 44-1 and 44-2 from the start to the completion thereof. Assuming that the movement of the stroke continues toward the outside, the following inconvenience occurs. Specifically, the deformation of the flat wire 28 due to the above-described arc forming causes the coil end corresponding portions and the slot corresponding portions on both sides of the flat wire 28 to be processed surfaces 46, 47, 50 of the inner molds 42-1, 42-2. , 51 while being stretched outward in the first direction X. For this reason, during the deformation, the inner peripheral side of the flat conducting wire 28 is the processed surfaces 46, 47, 50, 51 of the inner molds 42-1 and 42-2 (particularly the coil end corresponding portion and the slot corresponding portion of the flat conducting wire 28). The rectangular conductor 28 is damaged and the film is peeled off by the relative movement in the third direction Z and the rubbing against corners formed in the vicinity of the corners (ie, the corners of the fin-like portions 83 and 97). May occur.

  Therefore, in the molding apparatus 40 of this modification, stroke movement is performed such that the inner molds 42-1 and 42-2 are separated from each other, that is, approach the paired outer molds 44-1 and 44-2. Outer mold 44 that makes the inner molds 42-1 and 42-2 approach each other, that is, is paired at an intermediate timing from the start to the completion of arc forming of the flat lead wire 28. A stroke movement (backward movement) in the direction opposite to the normal direction is performed, such as being separated from −1, 44-2. In addition, when the stroke movement in the direction opposite to the normal direction of the inner molds 42-1 and 42-2 is performed as described above, the first such that the outer molds 44-1 and 44-2 approach each other. The stroke movement in the direction X may be continued as usual.

  The movement amount of the stroke movement in the opposite direction described above is sufficient if at least the contact between the inner molds 42-1 and 42-2 and the flat wire 28 is eliminated. Further, the midway timing at which the stroke movement in the opposite direction is started after the slot-corresponding portion sandwiched between the coil end corresponding portions on both sides of the flat wire 28 is prevented from being deformed and bulging in the second direction Y, The flat conductor 28 may be at any timing as long as the conductors at the respective stages corresponding to the slots on both sides are deformed from a state in which the conductor is kept horizontal with respect to the second direction Y, and is more preferably inclined. The timing is most likely to cause deformation.

  In the configuration of such a modification, the flat rectangular wire 28 is inclined in the third direction Z from the state in which the conductive wires at the respective stages of the slot-corresponding portions on both sides are kept horizontal with respect to the second direction Y during arc forming. Even if the inner peripheral side of the flat conducting wire 28 is in contact with the corners near the processed surfaces 46, 47, 50, 51 of the inner molds 42-1 and 42-2 immediately before being deformed into the state, When deformation (arc forming) is performed, the inner peripheral side of the flat rectangular wire 28 and the processing surfaces 46, 47, 50, 51 of the inner molds 42-1 and 42-2 can be separated from each other. It is possible to avoid rubbing the inner peripheral side in contact with the corners near the processed surfaces 46, 47, 50, 51 of the inner molds 42-1, 42-2. Therefore, according to the configuration of this modification, the flat conductor 28 is prevented from being damaged or peeled off due to rubbing against the corners of the inner molds 42-1 and 42-2 when the flat conductor 28 is formed into an arc. Can do.

  The stroke movement in the opposite direction described above may be temporary. In this case, after the stroke movement in the opposite direction is completed, the inner molds 42-1 and 42-2 are again separated from each other, that is, approach the paired outer molds 44-1 and 44-2. Such stroke movement in the normal direction may be performed. In the arc forming, after the flat conductor 28 is deformed from the state in which the conductors at the respective steps corresponding to the slots on both sides are kept horizontal with respect to the second direction Y, or after the deformation is substantially completed, the inner metal If the stroke movement in the normal direction such that the molds 42-1 and 42-2 are separated from each other, that is, approaches the paired outer molds 44-1 and 44-2, is resumed, the rectangular conductor 28 and the inner mold Although the molds 42-1 and 42-2 come into contact with each other, the flat conductor 28 is hardly deformed due to the arc forming thereafter, so that the flat conductor 28 is prevented from being damaged or peeled off. Edgewise molding and the like can be performed appropriately.

  Further, in the above-described embodiment, the gripping members 112 and 114 that grip the flat conducting wire 28 as a molding target are arranged outside the first direction X of the first outer mold 44-1, and the gripping members 112 are arranged. , 114 is held at the tips of both end portions 28a, 28b of the flat conducting wire 28. However, the present invention is not limited to this, and as shown in FIG. 12, the holding members 120 and 122 for holding the flat conducting wire 28 as the molding object are respectively connected to the first inner mold 42-1 and the second inner mold. It is good also as arrange | positioning between the type | molds 42-2 and holding | grip the slot corresponding | compatible part extended substantially linearly from the coil end corresponding | compatible part of the flat conducting wire 28 by those holding members 120,122. Also in this case, the holding members 120 and 122 respectively hold and fix the end portions 28a and 28b of the flat wire 28 independently from the outer mold 44 and the inner mold 42 that are moved by stroke during molding.

  In addition, the holding | grip of the edge parts 28a and 28b of the flat conducting wire 28 by the holding members 120 and 122 shall be maintained until the holding | maintenance by the 1st and 2nd outer side metal molds 44-1 and 44-2 is cancelled | released, What is necessary is just to cancel | release after holding | maintenance cancellation | release. According to such a configuration, the flat rectangular wire 28 after molding is formed into a die by friction with the fins 62 and 84 when the flat rectangular wire 28 after molding is released by the first and second outer molds 44-1 and 44-2. It is possible to prevent deformation of the flat conducting wire 28 after being formed due to being pulled by 42 and 44.

  In the above modification, each of the gripping members 120 and 122 may be configured to collectively grip the slot corresponding portions of each step of the flat wire 28, or only the slot corresponding portions connected to both ends of the flat wire 28. It is good also as what grasps. Further, in the structure in which the gripping members 120 and 122 collectively grip the slot-corresponding portions of each step of the flat wire 28, the gripping members 120 and 122 are held in the second direction Y of the two plate members 120a, 120b, 122a, and 122b. The flat conductive wires 28 are formed on the surface facing the second direction Y of one of the two plate members 120a, 120b, 122a, 122b of the gripping members 120, 122. It is also possible to form a plurality of grooves that can accommodate the slot-corresponding portions of each stage. Each of the grooves may be formed in a rectangular shape having a cross-sectional area slightly larger than the cross-sectional area of the flat conducting wire 28. Further, the two plate members 120a, 120b, 122a, 122b of the holding members 120, 122 may be fastened to each other by bolts 124, 126.

  Further, in the above-described embodiment, each of the holding members 112 and 114 is held by holding the rectangular conducting wire 28 by bolting together the surfaces of the two flat plates 112a, 112b, 114a, and 114b. However, the present invention is not limited to this, and the flat conductive wire 28 may be gripped by displacing the two flat plates 112a, 112b, 114a, 114b with hydraulic pressure, air pressure, an electric motor, or the like. In this modification, it is only necessary to continuously hold the flat wire 28 from the start to the completion of forming from the flat wire 28 to the concentric coil 14.

10 Stator 12 Stator Core 14 Stator Coil (Concentric Winding Coil)
28 Flat rectangular wire 30, 32 Slot portion 34, 36 Coil end portion 40 Molding device 42, 42-1, 42-2 Inner die 44, 44-1, 44-2 Outer die 62, 62-1, 62-2 , 84, 84-1, 84-2 Fins 46, 50, 54, 58 Work surface 98 Base 100, 102, 104, 106 Moving mechanism 110 Controller 112, 114, 120, 122 Holding member

Claims (9)

A forming method of forming a concentric winding coil having a plurality of different non-linear shapes with a coil end portion protruding from an end surface in the axial direction of the stator core from a rectangular wire wound around a predetermined number of turns,
A die formed by imitating the shape of the coil end portion of the concentric winding coil is moved in a predetermined direction with respect to the set rectangular conductor wire in one step, and the rectangular conductor wire, A corresponding portion corresponding to the coil end portion is bent toward the stacking direction by inserting it between a plurality of fins that are attached to the mold and arranged in the stacking direction of the flat wire to be set. Processing and bending toward the orthogonal direction by pressing with a processing surface facing the orthogonal direction orthogonal to the laminating direction of the flat wire to be set of the mold,
When bending the corresponding portion of the flat wire, the flat wire is used independently of the mold that is moved by stroke so that both ends of the flat wire do not move in the predetermined direction using a gripping member. A method for forming a concentric winding coil, characterized by gripping both ends of the coil.   The gripping of the both ends of the rectangular conducting wire by the gripping member is released after the mold is moved in a direction opposite to the predetermined direction in order to remove the concentric coil after the concentric coil is formed. The method for forming a concentric coil according to claim 1.   3. The method for forming a concentric coil according to claim 1, wherein both ends of the flat wire held by the holding member are ends of straight portions extending linearly from the corresponding portion.   4. The method of forming a concentric coil according to claim 1, wherein both ends of the flat wire are each gripped by the gripping member on the long side of the cross section.   The both ends of the said flat conducting wire are each hold | gripped by the said holding member which can be rock | fluctuated in the linear part extended linearly from the said corresponding | compatible part, The same as described in any one of Claim 1 thru | or 4 characterized by the above-mentioned. A method for forming a core-wound coil. A forming apparatus for forming a concentric winding coil having a plurality of different non-linear shapes with a coil end portion protruding from an axial end surface of a stator core from a rectangular wire wound around a predetermined number of turns,
A plurality of fins that are formed to imitate the shape of the coil end portion of the concentric winding coil and are arranged side by side in the stacking direction of the flat wire to be set, and the stacking direction of the flat wire to be set A mold having a machining surface oriented in an orthogonal direction perpendicular to
A mold moving mechanism for moving the mold in a predetermined direction with respect to the set flat wire, and
The mold is bent toward the stacking direction by inserting a corresponding portion of the flat conductor wire corresponding to the coil end portion between the plurality of fins by a stroke movement by the mold moving mechanism. And while bending to the orthogonal direction by pressing on the processing surface,
When bending the corresponding portion of the flat wire by the mold, both ends of the flat wire are not moved in the predetermined direction. An apparatus for forming a concentric coil, comprising gripping members for gripping both ends.   The concentric winding coil forming apparatus according to claim 6, wherein the gripping member grips an end of a straight portion that linearly extends from the corresponding portion as an end of the flat wire.   The concentric winding coil forming apparatus according to claim 6 or 7, wherein the gripping member grips both ends of the rectangular conducting wire on the long side of the cross section. The concentric winding coil forming apparatus according to any one of claims 6 to 8, wherein the gripping member is swingable in a state where both ends of the flat wire are gripped.