JP2016010217A - Coil molding device, and coil molding method employing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To mold a flat coil without disconnection, to shorten a coil molding time and to obtain a plurality of non-tabular coils while combining them so as to partially overlap them in a circumferential direction.SOLUTION: A coil molding device 10 is configured to mold a flat coil 12 including: a pair of linear parts 12a and 12b which are opposite to each other while interposing a predetermined interval therebetween; and a pair of connection line parts 12c and 12d connecting edges of the pair of linear parts. The coil molding device 10 includes: a core rod 16 of which the cross section is circular; axial alignment means 21 for axially aligning the one linear part 12 along an outer circumference of the core rod; and circumferential alignment means 31 for circumferentially aligning the pair of connection line parts along the outer periphery of the core rod. The axial alignment means and the circumferential alignment means are configured to provide a plurality of flat coils around the core rod. A molding method includes: overlapping other ends of the pair of connection line parts from the outside to the pair of connection line parts of the neighboring flat coil while making a length of the pair of connection line parts longer than a circumferential distance of the core rod supporting the one linear part 12a of the plurality of flat coils.

Description

  The present invention relates to an apparatus for manufacturing a coil having a non-flat shape such as a saddle shape used for a motor or the like by forming a flat coil. More specifically, the present invention relates to a coil forming apparatus that can be obtained by combining a plurality of non-flat coils obtained by simultaneously forming a plurality of flat coils, and a coil forming method using the same.

  Conventionally, as a method of manufacturing a coil having a non-flat shape such as a saddle type, a flat coil made of a wire wound using a winding core is used at a time using a press die made of a lower die and an upper die. A method of press molding has been proposed (for example, see Patent Document 1).

  The non-plate-like coil obtained by this manufacturing method has a pair of linear portions facing each other with a predetermined interval, and an arc portion connecting the ends of the pair of linear portions in an arc shape. It is said that it is a mold coil, and after winding using an adhesive copper wire having a fusion layer formed on the outer peripheral surface, the copper wire is energized to join the copper wires to obtain a flat coil first.

  After that, the flat coil thus obtained is press-molded. In the press molding, the copper wire is energized again to melt or soften the fusion layer again, and press molding is performed in that state.

Japanese Patent Publication No.58-32450

  However, in press molding using a press die, a flat coil to be press-molded couples a pair of linear portions facing each other at a predetermined interval and a pair of couplings connecting the respective edges of the pair of linear portions. And a line portion.

  And since the linear part and connecting wire part of a flat coil were simultaneously shape | molded at once, there existed a possibility that tensile stress might arise in a part of wire at the time of the press molding, and a disconnection might arise locally.

  In particular, in a coil used for a small coreless motor, since the wire used is relatively thin, when trying to obtain a non-planar coil having a bowl shape or the like by press molding, disconnection occurs during the press molding. It tends to occur relatively easily.

  In addition, when a motor using such a saddle-shaped non-flat coil is a three-phase synchronous motor that drives a rotor in three phases, a three-phase motor composed of a U phase, a V phase, and a W phase. The saddle coils for each phase are provided adjacent to each other so as to partially overlap in the circumferential direction.

  For this reason, when the saddle-shaped coils used in such a three-phase synchronous motor are separately molded, three coils are required for manufacturing one motor, which increases the coil manufacturing time. It was.

  Furthermore, as shown in FIG. 13, the three saddle coils used in such a three-phase synchronous motor have one linear portion 13 a of each saddle coil 13 below the other coil 13. A part of the saddle coils 13 is provided so as to be adjacent to each other in the circumferential direction so that the other straight line portion 13 b is on the upper side of the other coils 13. For this reason, when the saddle coil 13 for each phase is manufactured separately, it is necessary to assemble so that one linear portion 13a of each saddle coil is under the other coil 13, and assembling them. There were also problems that made it difficult to automate.

  The objective of this invention is providing the coil shaping | molding apparatus which can shape | mold a flat coil without breaking, and a coil shaping | molding method using the same.

  Another object of the present invention is to provide a coil forming apparatus capable of shortening the coil forming time by simultaneously forming a plurality of flat coils and simultaneously obtaining a plurality of non-plate coils, and a coil forming method using the same. It is in.

  Still another object of the present invention is to provide a coil forming apparatus and a coil forming method using the same, which can be obtained in a state where a plurality of non-flat coils are combined so as to partially overlap in the circumferential direction. is there.

  The coil forming apparatus of the present invention forms a flat coil having a pair of linear portions facing each other at a predetermined interval and a pair of connecting wire portions connecting the respective edges of the pair of linear portions.

  The characteristic configuration includes a core rod having a circular cross section, an axial direction means for axially extending one straight portion on the outer periphery of the core rod, and a pair of connecting wire portions on the outer periphery of the core rod in the circumferential direction. It is in the place provided with the circumferential direction alignment means.

  The axial direction alignment means is configured to align each linear portion of the two or more flat coils on the outer periphery of the core rod along the axial direction with a predetermined interval in the circumferential direction. The means is preferably configured so that the connecting wire portions of the two or more flat coils are arranged on the outer periphery of the core rod along the circumferential direction with a predetermined interval in the circumferential direction.

  In this case, the axial alignment means includes two or more axial pressing tools capable of pressing one linear portion on the outer periphery of the core rod, and two or more axial pressing tools on the outer periphery of the core rod. An axial pressing tool moving means that moves between a pressing position that is pressed and a spaced position that is spaced apart from the outer periphery of the core rod, and the circumferentially extending means includes both ends of one linear portion pressed against the outer periphery of the core rod Two or more circumferential pressing tools that can press one end of a pair of connecting line portions that are continuous with the core rod, and a pressing position that presses the two or more circumferential pressing tools against the outer periphery of the core rod are separated from the outer periphery of the core rod. Circumferential pressing tool moving means for moving between the spaced positions and rotating means for rotating two or more pressing tools around the core rod can be provided.

  On the other hand, the coil forming method of the present invention includes the above-described coil forming apparatus, and has a pair of linear portions facing each other at a predetermined interval and a pair of connecting line portions connecting the respective edges of the pair of linear portions. A plurality of flat coils are formed simultaneously.

  The characteristic point is that one linear portion of each of the plurality of flat coils is supported along the axial direction with a predetermined interval in the circumferential direction on the outer periphery of the core rod by the axial direction means. The circumferential pressing member in the adjusting means is pressed from the periphery of the core rod to each one end of a pair of connecting line portions that are continuous to both ends of one linear portion, and the pressed circumferential pressing tool is rotated around the core rod. A pair of connecting wire portions are sequentially arranged around the core rod.

  In this case, a pair of connecting wires are sequentially provided around the core rod by making the length of the pair of connecting wire portions longer than the circumferential distance of the core rod supporting one straight portion of each of the plurality of flat coils. It is preferable that the other end of the portion is overlapped with the pair of connecting wire portions of the adjacent flat coil from the outside.

  Further, the plurality of flat coils in this method are obtained by winding a wire having a fusion layer formed on the outer peripheral surface around a winding core, and molding the obtained adhesion layers of the plurality of flat coils in a melted or softened state. It is preferable to remove it from the core bar after curing.

  In the coil forming apparatus and the coil forming method using the same according to the present invention, the pressing of the straight portion of the flat coil to the mandrel and the forming of the connecting wire portion are performed separately, and the forming of the connecting wire portion is performed on the outer periphery of the core rod. It is done by following along. For this reason, unlike press molding in which these are simultaneously molded, it becomes possible to perform molding without causing tensile stress in a part of the wire, and it is possible to perform molding without disconnecting the flat coil.

  If the axially aligning means and the circumferentially aligning means are configured so that a plurality of flat coils are arranged around the core rod, a plurality of flat coils are simultaneously formed to simultaneously obtain a plurality of non-plate coils. Thus, the time required for forming a single coil can be shortened as compared with the prior art.

  In this case, if the length of the pair of connecting wire portions is made longer than the circumferential distance of the core rod that supports one straight portion of each of the plurality of flat coils, the pair of connecting wires that are sequentially arranged around the core rod The other end of the part overlaps with a pair of connecting wire parts of adjacent flat coils from the outside, and a plurality of non-plate coils can be molded into a combined state so as to partially overlap in the circumferential direction. Become.

It is a front view which shows the coil shaping | molding apparatus in this invention embodiment. It is a side view which shows the coil shaping | molding apparatus. It is the sectional view on the AA line of FIG. 2 which shows the upper surface of the axial direction alignment means. It is a side view which shows the axial direction alignment means. It is the BB sectional view taken on the line of FIG. 2 which shows the bottom face of the circumferential direction alignment means. It is a side view which shows the circumferential direction alignment means. It is a top view corresponding to FIG. 3 which shows the state by which the bobbin was inserted in the core rod. FIG. 8 is a top view corresponding to FIG. 7, showing a state in which one linear portion of a plurality of flat coils is provided around the core rod. It is a side view which shows the state which pressed the end of the connection line part which follows the one linear part against the core rod. It is a top view corresponding to FIG. 8 which shows the state which pressed the end of the connection line part against the core rod. It is a top view corresponding to FIG. 10 which shows the state which pressed all the connection line parts against the core rod. It is a perspective view which shows the state by which the flat coil is shape | molded by the non-plate-shaped coil. It is a perspective view which shows the stator with which the some non-plate-shaped coil was combined.

  Next, the best mode for carrying out the present invention will be described with reference to the drawings.

  1 and 2 show a coil forming apparatus 10 according to the present invention. The coil forming apparatus 10 forms a flat coil 12 (FIG. 12). As shown in FIG. 12A, the flat coil 12 has a pair of linear portions 12a, 12b and a pair of connecting line portions 12c and 12d connecting the respective end edges of the pair of linear portions 12a and 12b.

  Although not shown, the flat coil 12 can be obtained by rotating a winding core having a square cross section, winding the wire 11 around the outer periphery of the winding core, and winding multiple layers in the radial direction. Since such a winding machine for rotating the winding core is commercially available, the flat coil 12 used in the present invention can be obtained using such a commercially available winding machine. Therefore, the detailed description regarding this winding machine is abbreviate | omitted.

  In FIG.12 (b), the non-plate-shaped coil 13 obtained by the coil shaping | molding apparatus 10 of this embodiment is shown. The non-flat coil 13 includes a pair of linear portions 13a and 13b facing each other at a predetermined interval, and arc portions 13b and 13d that connect ends of the pair of linear portions 13a and 13b in an arc shape. Is a so-called saddle coil 13.

  The wire 11 constituting the flat coil 12 before molding and the non-flat coil 13 after molding has a circular cross section, and has a fusion layer formed on the outer peripheral surface that is melted or softened by hot air or a solvent. Conductive wire (so-called cement wire) is used.

  For this reason, the flat wire 12 before forming and the non-flat coil 13 after forming are adjacent to each other, and the adjacent wires 11 are in contact with each other, and the contacting wires 11 are fixed to each other by a fusion layer. Thus, the shapes of the flat coil 12 before molding and the non-flat coil 13 after molding are maintained.

  The coil forming apparatus 10 of the present invention for forming a flat coil 12 is configured to bend a pair of straight portions 12a and 12b of the flat coil 12 in the width direction and to bend the pair of connecting wire portions 12c and 12d in a longitudinal direction. It is.

  For this reason, as shown in FIGS. 1 and 2, the coil forming apparatus 10 of the present invention includes a core rod 16 having a circular cross section and an axial direction in which one linear portion 12 a is aligned along the outer periphery of the core rod 16. The alignment means 21 and the circumferential alignment means 31 are provided on the outer periphery of the core rod 16 to align the pair of connecting line portions 12c and 12d in the circumferential direction.

  In this embodiment, in order to obtain three saddle-shaped coils 13 (FIG. 12) used for a three-phase synchronous motor at the same time, it is possible to place three flat coils 12 around the core rod 16 at the same time. The case where the axial direction alignment means 21 and the circumferential direction alignment means 31 are provided is shown.

  As shown in FIGS. 3 and 4, the axially aligning means 21 is a 3 for pressing one straight portion 12 a (FIG. 12) of each of the three flat coils 12 to the outer periphery of the core rod 16. Between the three axial pressing tools 24, the pressing position where the three axial pressing tools 24 are pressed against the outer periphery of the core rod 16, and the spaced position away from the outer periphery of the core rod 16. And an axial pressing tool moving means 23 to be moved.

  In this embodiment provided with three axial pressing tools 24, the case where the three axial pressing tools 24 are provided in a radial manner is illustrated, and the axial pressing tool moving means 23 has a main body 23d as a base. It is fixedly provided on 10a (FIGS. 1 and 2).

  The axial pressing tool moving means 23 is a fluid pressure cylinder 23 that moves the axial pressing tool 24 by fluid pressure, and a horizontal table 23c is provided above the main body 23d.

  At the center of the table 23c, a fixture 23e to which the lower end of the core rod 16 is attached is provided, and the core rod 16 extends vertically upward through the fixture 23e so as to be detachable from the fixture 23e. Is done.

  In the core rod 16 in this embodiment, the first step portion 16a (FIG. 4) with which the lower end of the bobbin 14 (FIG. 7) fitted from the upper end abuts, and one linear portion 12a extends along the outer periphery of the bobbin 14. The thing in which the 2nd step part 16b (FIG. 4) with which the lower edge of the flat coil 12 contact | abuts was formed is illustrated.

  On the upper surface of the table 23c in the axial pressing tool moving means 23, three support rails 23a are provided radially about the central portion of the table 23c, that is, the core rod 16, every 120 degrees.

  The three support rails 23a are each provided with a support slider 23b movably provided by fluid pressure, and an axial pressing tool 24 is attached to each of the support sliders 23b.

  The three axial pressing tools 24 press the one linear portion 12a against the outer periphery of the core rod 16 by approaching the core rod 16 and reducing the interval between them, and the placement portion placed on the support slider 23b 24 a, a standing part 24 c standing on the mounting part 24 a, and a side of the standing part 24 c that faces the core rod 16, and when the interval between them is narrowed, A contact portion 24b that actually presses the straight portion 12a.

  And this axial direction pressing tool moving means 23 is comprised so that the three axial direction pressing tools 24 can be moved radially via the slider 23b by supply of the compressed air to the main-body part 23d, and it moves radially. Thus, the three axial pressing tools 24 are configured to increase the distance between each other as indicated by the broken line arrows in FIG. 3 or to reduce the distance from each other as indicated by the solid line arrows in FIG. 3.

  As shown in FIG. 2, a support member 26 is erected on the base 10 a adjacent to the axial alignment means 21, and an elevating air cylinder 27 is attached to the support member 26. The elevating air cylinder 27 has a main body portion 27b attached to the support member 26, and a movable slider 27a attached to the main body portion 27b so as to be movable up and down by supplying compressed air, and is attached to the movable slider 27a. Member 28 is attached. And the means 31 along the circumferential direction is attached to this attachment member 28.

  As described above, the circumferentially aligning means 31 is attached to the upper side of the axially aligning means 21 via the lifting / lowering air cylinder 27, and the lifting / lowering air cylinder 27 moves the movable slider 27a up and down to move along the circumferential direction. 31 is configured to be vertically movable above the means 21 along the axial direction.

  As shown in FIGS. 5 and 6, the circumferentially aligning means 31 includes three circumferential pressing tools 34, a circumferential pressing tool moving means 32 that moves the circumferential pressing tool 34, and its circumferential pressing. Rotating means 41 for rotating the tool 34 around the core rod 16 is provided.

  In this embodiment including three circumferential pressing tools 34, the case where three circumferential pressing tools 34 are provided in a radial manner is illustrated, and the circumferential pressing tool moving means 32 includes three circumferential pressing tools. The operating tool 33 is provided so that 34 can be moved radially, and an air cylinder 36 (FIG. 2) that operates the operating tool 33 to move the circumferential pressing tool 34 by fluid pressure.

  The operating tool 33 is provided with a cylindrical portion 33e with its axis in the vertical direction at the upper center of the main body portion 33d. The cylindrical portion 33e is attached to the mounting member 28 via a bearing 29 so that the axial center of the cylindrical portion 33e coincides with the axial center of the core rod 16 (FIG. 2).

  Three grip rails 33a are provided on the lower surface of the main body portion 33d of the operation tool 33 radially from the central portion every 120 degrees centering on the axial center of the cylindrical portion 33e, that is, the axial center of the core rod 16. (FIG. 6), gripping sliders 33b (FIG. 5) are movably provided on these gripping rails 33a. The circumferential pressing tool 34 is attached to each gripping slider 33b.

  When the elevating air cylinder 27 shown in FIGS. 1 and 2 is lowered along with the movable slider 27a along the circumferential direction means 31 as indicated by the solid line arrow, as shown in FIG. The individual circumferential pressing tools 34 are adjusted so as to be positioned around the core rod 16.

  As shown in FIGS. 1 and 2, when the circumferentially extending means 31 is lifted together with the movable slider 27a as indicated by the broken arrow, the three circumferential pressing members 34 in the circumferentially aligned means 31 are also raised. Then, a work space is formed between the core rod 16 and the circumferentially extending means 31, and an operator can place one of each of the three flat coils 12 by the axially aligned means 21 through the work space. The linear portion 12a is supported on the outer periphery of the core rod 16, or the molded saddle coil 13 supported by the axially aligning means 21 can be removed from the axially aligning means 21. . Here, an adjusting screw for adjusting the rising position of the movable slider 27a is shown by reference numeral 27c in FIGS.

  As shown in FIGS. 5 and 6, the operating tool 33 in the circumferentially aligning means 31 of this embodiment is provided with operating protrusions 33 f for moving three circumferential pressing tools 34 on the upper part of the cylindrical portion 33 e. Commercially available products are used.

  The operation projection 33f is pressed from above to move the gripping slider 33b along the gripping rail 33a together with the circumferential pressing tool 34, and as shown in FIG. 10, the three circumferential pressing tools 34 are connected to each other. By shortening the interval and pulling back the pressed operation projection 33f, as shown in FIGS. 5 and 6, it is configured to increase the interval between the three circumferential pressing members 34 together with the grip slider 33b. The

  The operation tool 33 is attached to the mounting member 28 so that the cylindrical portion 33e can rotate about the vertical center axis through the bearing 29, and the center axis that is the center of rotation is the center of the core rod 16. Mounted to match the axis.

  As shown in FIGS. 9 and 10, the circumferential pressing tool 34 has one end of each of a pair of connecting line portions 12 c and 12 d continuous with both ends of one linear portion 12 a pressed against the outer periphery of the core rod 16. It is pressed against the rod 16. That is, the three axial pressing tools 24 are configured to press one end of each of the pair of connecting line portions 12c and 12d against the outer periphery of the core rod 16 by approaching the core rod 16 and reducing the interval between them.

  As shown in FIG. 5, the three circumferential pressing tools 34 include a placement portion 34d placed on the gripping slider 33b, a hanging portion 34a provided hanging from the placement portion 34d, The abutting portion 34b that is formed on the center side of the hanging portion 34a facing the core rod 16 and that actually presses one end of each of the pair of connecting line portions 12c and 12d against the outer periphery of the core rod 16 when the interval between the core rods 16 is narrowed. , 34c.

  As shown in FIGS. 9 and 10, the contact portions 34 b and 34 c in the circumferential pressing tool 34 are provided so as to sandwich the contact portion 24 b of the axial pressing portion 24. As a result, the circumferentially-aligning means 31 in the lowered state reduces the distance between the three circumferential pressing members 34 located around the core rod 16, thereby reducing the contact portion 24 b of the axial pressing portion 24. On both sides, the contact portions 34 b and 34 c are brought into contact with the pair of connecting wire portions 12 c and 12 d, and the pair of connecting wire portions 12 c and 12 d are arranged along the outer periphery of the core rod 16.

  As shown in FIGS. 1 and 2, the operation air cylinder 36 that presses or pulls back the operation protrusion 33 f in the operation tool 33 is provided on the movable slider 27 a in the lift air cylinder 27.

  And this air cylinder 36 which comprises the circumferential direction pressing tool movement means 32 presses the circumferential direction pressing tool 34 against a pair of connection line part 12c, 12d on the outer periphery of the core bar 16 by pressing the operation protrusion 33f. By moving back to the pressing position, and conversely, pulling back the operation projection 33f, each circumferential pressing tool 34 is separated from the outer periphery of the core rod 16 and moved to the separated position.

  On the other hand, the rotating means 41 rotates the circumferential pressing tool 34 at the pressing position around the core rod 16. The driven pulley 42 provided on the cylindrical portion 33 e of the operation tool 33 and the cylindrical portion 33 e are used as bearings. An electric motor 43 provided on the mounting member 28 supported via 29, and a belt 46 stretched between a driving pulley 44 on a rotating shaft 43a of the electric motor 43 and a driven pulley 42 provided on the cylindrical portion 33e. Have

  When the electric motor 43 is driven and the rotation shaft 43a rotates forward or backward, the drive pulley 44 also rotates forward or backward. The rotation is transmitted to the driven pulley 42 via the belt 46, and the circumferential pressing tool 34 is moved. The provided operating tool 33 is configured so as to rotate forward or reverse together with the circumferential pressing tool 34 around the center axis of the core rod 16 as a rotation center.

  As shown in FIGS. 1 and 11, a plurality of circumferentially extending means 31 are provided at one end of the pair of connecting wire portions 12 c and 12 d of the flat coil 12 supported by the axial pressing tool 24 of the axially extending means 21. When the plurality of circumferential pressing tools 34 are in contact with each other, and the plurality of circumferential pressing tools 34 are rotated about the core bar 16 as indicated by solid arrows, the plurality of circumferential pressing tools 34 are rotated. A pair of connecting wire portions 12c and 12d in the flat coil 12 having no gap are sequentially pressed against the outer periphery of the core rod 16 in the circumferential direction.

  Further, since the circumferentially aligning means 31 in this embodiment moves the plurality of circumferentially pressing members 34 radially by the air pressure supplied to the air cylinder 36, the pair of connecting wire portions 12c and 12d are connected to the core rod. When the outer periphery of 16 is sequentially pressed in the circumferential direction, the connecting wire portions 12c and 12d ride on the connecting wire portions 12c and 12d of the adjacent flat coil 12, and the core rod 16 pressed by the circumferential pressing tool 34 is centered. When the radii of the connecting line portions 12c and 12d are enlarged, the intervals between the plurality of circumferential pressing tools 34 are increased against the air pressure of the compressed air, and the radius is allowed to be increased.

  Returning to FIG. 1, the coil forming apparatus 10 includes a controller 51 that controls the axial direction alignment means 21 and the circumferential direction alignment means 31. The control output of the controller 51 is a support valve 52 for supplying compressed air to the fluid pressure cylinder 23 in the axial direction aligning means 21, a contact valve 53 for supplying compressed air to the operation tool 33 in the circumferential direction aligning means 31, It is connected to an elevating valve 54 and an electric motor 43 that supply compressed air to an elevating air cylinder 27 that moves the circumferentially aligning means 31 up and down.

  Here, reference numeral 56 in FIG. 1 denotes a compressed air source 56 that supplies compressed air to the axially aligning means 21, the operation air cylinder 36, and the elevating air cylinder 27, and reference numeral 57 denotes the coil forming apparatus 10. Is an operation switch 57 for driving.

  Next, the coil shaping | molding method in this invention using the coil shaping | molding apparatus mentioned above is demonstrated.

  In this coil forming method, one linear portion 12a of each of the plurality of flat coils 12 is supported along the axial direction with a predetermined interval in the circumferential direction on the outer periphery of the core rod 16 by the axially aligning means 21. The coil supporting step and the pressing tool pressing step for pressing the circumferential pressing tool 34 in the circumferential alignment means 31 from the periphery of the core rod 16 to one end of the pair of connecting wire portions 12c and 12d that are continuous from both ends of the one linear portion 12a. And rotating the pressed circumferential pressing tool 34 around the core rod 16 so that the pair of connecting line portions 12c and 12d run around the core rod 16 in the circumferential direction; The connecting wire portions 12c and 12d are curved around the core rod 16 along the circumferential direction, and a removal step of removing the plurality of non-plate-like coils 13 obtained thereby from the core rod 16 is included.

  Below, each process is explained in full detail.

<Coil support process>
In this step, one linear portion 12a of each of the plurality of flat coils 12 is supported along the axial direction at a predetermined interval in the circumferential direction on the outer periphery of the core rod 16 by the axial direction aligning means 21. Therefore, first, a plurality of flat coils 12 are prepared.

  Although not shown, the flat coil 12 is manufactured using a commercially available winding machine, and the wire 11 having a fusion layer formed on the outer peripheral surface is heated by rotating a winding core having a square cross section. On the other hand, the flat coil 12 as shown in FIG. 12 (a) can be obtained by winding around the outer periphery of the core and further winding in multiple layers in the radial direction.

  In a state before the flat coil 12 is supported, the circumferentially extending means 31 is raised as shown by the broken line arrow in FIG. 2 to form a work space above the axially aligned means 21, and FIG. As shown by the solid line arrow, the plurality of axial pressing tools 24 in the axial alignment means 21 are separated from each other and away from the core rod 16.

  As shown in FIG. 13, in this embodiment, a case where a plurality of non-planar coils 13 obtained around the bobbin 14 are assembled will be described. As shown in FIG. 7, the bobbin 14 is arranged along the axial direction. The upper end 21 is fitted into the core 16 from the work space from above, and the lower end thereof is brought into contact with the first step portion 16a (FIG. 4) for positioning.

  Here, this bobbin 14 exemplifies one having a cylindrical portion 14a fitted into the core rod 16 and a plurality of radially provided ribs 14b extending in the axial direction from the periphery of the cylindrical portion 14a.

  As shown in FIG. 8, the plurality of flat coils 12, in this embodiment, the three flat coils 12, have a predetermined interval in the circumferential direction around one linear portion 12 a on the outer periphery of the core rod 16. Open it along the axis.

  In this embodiment, since the bobbin 14 is used, each one linear part 12a is made to follow the cylinder part 14a between the rib 14b of the bobbin 14 and the rib 14b every 120 degree | times. Then, the lower edge of the flat coil 12 along which the one linear portion 12a extends along the outer periphery of the bobbin 14 is brought into contact with the second step portion 16b (FIG. 4) of the core rod 16 to perform positioning.

  Thereafter, the operation switch 57 is operated to supply or discharge the compressed air to or from the main body 23d of the axially aligning means 21 through the support valve 52 according to a command from the controller 51, as indicated by a solid line arrow in FIG. The plurality of axial pressing tools 24 are moved radially to reduce the interval between them, and the contact portion 24b of the axial pressing tool 24 contacts one linear portion 12a of the flat coil 12 as shown in FIG. Let

  In this manner, one linear portion 12a of each of the three flat coils 12 is supported along the axial direction at predetermined intervals (every 120 degrees) in the circumferential direction on the outer periphery of the core rod 16. Then, by pressing against the cylindrical portion 14a of the bobbin 14 fitted in the core rod 16, one linear portion 12a of each flat coil 12 is curved in the width direction along the cylindrical portion 14a.

<Pressing tool pressing process>
In this step, the circumferential pressing tool 34 in the circumferential direction aligning means 31 is pressed from the periphery of the core rod 16 to one end of a pair of connecting line portions 12c and 12d that are continuous to both ends of one linear portion 12a. In other words, the plurality of circumferential pressing tools 34 radially provided around the core rod 16 are reduced in distance from each other, and the plurality of circumferential pressing tools 34 are brought into contact with one ends of the pair of connecting line portions 12c and 12d, respectively. .

  Specifically, in order to bring the plurality of circumferential pressing tools 34 into contact with each other, the circumferentially aligning means 31 is lowered. This lowering is performed by operating the elevating valve 54 by the controller 51, supplying or discharging compressed air to the elevating air cylinder 27, and lowering the movable slider 27a as shown by a solid line arrow in FIG. Accordingly, a plurality of circumferential pressing tools 34 in the circumferential direction alignment means 31 are arranged around the core rod 16.

  Next, the controller 51 operates the contact valve 53 and pushes the operation protrusion 33f in the circumferentially extending means 31 by projecting the retracting rod 36a (FIGS. 1 and 2) of the operation air cylinder 36. As shown by the solid line arrows in FIG. 6, the intervals between the plurality of circumferential pressing tools 34 are reduced. As a result, as shown in FIGS. 9 and 10, one end of a pair of connecting line portions 12c and 12d continuous to both ends of one linear portion 12a of the three flat coils 12 supported by the axially aligning means 21. The abutting portions 34b and 34c of the plurality of circumferential direction pressing tools 34 are pressed against each other.

<Processing along connecting lines>
In this step, the pressed circumferential pressing tool 34 is rotated around the core rod 16, and the pair of connecting wire portions 12 c and 12 d are arranged around the core rod 16 in the circumferential direction. The rotation of the circumferential pressing tool 34 around the core rod 16 is performed by driving the electric motor 43 shown in FIG. 1, and the belt 46 is driven by the rotation of the drive pulley 44 provided on the rotation shaft 43a. The operating tool 33 as the circumferentially aligning means 31 is rotated around the center axis of the core rod 16 together with the driven pulley 42 through the shaft.

  Here, since the flat coil 12 supported by the axial pressing tool 24 in the axial alignment means 21 has one linear portion 12a pressed against the core rod 16, the flat coil 12 does not rotate. .

  For this reason, a pair of connecting line parts 12c and 12d which are connected to both ends of one straight line part 12a of the flat coil 12 with which a plurality of circumferential pressing tools 34 in the circumferentially extending means 31 are in contact are indicated by solid line arrows in FIG. When the plurality of circumferential pressing members 34 are rotated, the pair of connecting line portions 12c and 12d that do not rotate are sequentially pressed against the core rod 16 from one end side thereof, and the pair of connecting line portions are 12c and 12d are sequentially arranged along the outer periphery of the core rod 16 in the circumferential direction.

  The other straight line portion 12 b (FIGS. 9 and 12) is along the core rod 16 in a state where all of the pair of connecting line portions 12 c and 12 d are pressed against the core rod 16.

  Then, the pair of opposing linear portions 12a and 12b (FIG. 12A) of the flat coil 12 remain along the longitudinal direction of the core rod 16, and a pair of continuous connections between both ends of the pair of linear portions 12a and 12b. Since the line portions 12c and 12d are curved along the circumferential direction of the core rod 16, as shown in FIG. 12 (b), the pair of straight portions 12a and 12b is a pair of straight portions facing each other at a predetermined interval. 13a and 13b, and the pair of connecting line portions 12a and 12b are curved to form arc portions 13b and 13d that connect the edges of the pair of straight portions 13a and 13b in an arc shape. As a result, a plurality of so-called saddle-shaped non-plate coils 13 can be obtained simultaneously.

  Thus, in the coil shaping | molding apparatus 10 of this invention and the coil shaping | molding method using the same, the pressing of the straight part 12a of the flat coil 12 to the mandrel 16 and shaping | molding of the connecting wire parts 12c and 12d are performed separately.

  Further, the connecting wire portions 12 c and 12 d are formed by sequentially following the outer periphery of the core rod 16. For this reason, unlike conventional press molding in which these are simultaneously molded, it is possible to mold without causing tensile stress in a part of the wire 11, and it is possible to mold without breaking the flat coil 12.

  Since the axially-aligning means 21 and the circumferentially-aligning means 31 are arranged around the core rod 16 so that the plurality of flat coils 12 are arranged around the core rod 16, the plurality of flat coils 12 are simultaneously formed. Thus, a plurality of non-plate coils 13 can be obtained at the same time, and the time for forming a single coil can be shortened as compared with the prior art.

  Here, when the length W (FIG. 12 (a)) of the pair of connecting wire portions 12c and 12d is made longer than the circumferential distance of the core rod 16 that supports one straight portion 12a of each of the plurality of flat coils 12. As shown in FIG. 11, the pair of connecting line portions 12 c and 12 d that sequentially follow the periphery of the core rod 16 by the rotation of the circumferential pressing tool 34 around the core rod 16 are adjacent to each other. The pair of connecting wire portions 12c and 12d of the flat coil 12 overlap from the outside.

  In this way, when the connecting line portions 12c and 12d ride on the connecting line portions 12c and 12d of the adjacent flat coil 12 and overlap with each other from the outside, the connecting line portions centering on the core rod 16 pressed by the circumferential pressing tool 34. The radii of 12c and 12d are enlarged. However, since the circumferentially aligning means 31 in this embodiment moves the plurality of circumferential pressing tools 34 radially by the air pressure supplied to the air cylinder 36 (FIGS. 1 and 2), the compressed air It is possible to increase the distance between the plurality of circumferential pressing tools 34 against the pressure, and an increase in the radius thereof is allowed.

  Therefore, by making the length of the pair of connecting wire portions 12c and 12d longer than the circumferential distance of the core rod 16 that supports one straight portion 12a of each of the plurality of flat coils 12, the core rod 16 is surrounded by the length thereof. The other ends of the pair of connecting line portions 12c and 12d that are sequentially lined overlap with the pair of connecting line portions 12c and 12d of the adjacent flat coil 12 from the outside, and as shown in FIG. It becomes possible to mold into a combined state so as to partially overlap in the direction.

<Removal process>
In this step, the pair of connecting wire portions 12c and 12d are curved by being circumferentially arranged around the core rod 16, and the plurality of non-plate coils 13 obtained in this way are removed from the core rod 16. .

  In this embodiment in which the wire 11 having an adhesion layer on the surface is used, the support of one linear portion 12a in the coil support step, the pressing tool pressing step, and the connecting wire portion alignment step are performed by melting the fusion layer or Performed in a softened state.

  That is, in the case where the fusion layer is melted or softened by hot air, a hot air generator (not shown) is provided, and hot air generated from the hot air generator is blown to each flat coil 12, thereby The fused layer of the wire 11 constituting the coil 12 is melted or softened.

  And in that state, the support of one linear part 12a in the coil support process, the pressing tool pressing process, and the connecting line part alignment process are performed.

  Further, when the fusion layer is melted or softened by a solvent, the fusion layer of the wire 11 constituting the flat coil 12 is melted or softened by a solvent applied, immersed or dispersed, and the state Thus, the support of one linear portion 12a, the pressing tool pressing step, and the connecting line portion alignment step in the coil supporting step are performed.

  And after obtaining the non-plate-like coil 13 by them, the fusion | melting layer of the wire 11 is solidified, the wires 11 are mutually adhere | attached, and the shape of the non-plate-like coil 13 which comprises the saddle shape obtained by shaping | molding is maintained. It is assumed that the non-flat coil 13 obtained in this way is in a state where the shape can be maintained, and this removal step is performed thereafter.

  A specific procedure in this detaching process is that the controller 51 operates the abutment valve 53 to immerse the retracting rod 36a (FIGS. 1 and 2) of the operating air cylinder 36 and operate the circumferentially aligning means 31. The projection 33f is pulled back, and the intervals between the plurality of circumferential pressing members 34 are increased as indicated by broken line arrows in FIG. Thereby, the several circumferential direction pressing tool 34 which contact | abutted to the outer periphery of the flat coil 12 is spaced apart from the outer periphery.

  Thereafter, the controller 51 operates the lift valve 54 to raise the movable slider 27a in the lift air cylinder 27. As shown by the broken arrow in FIG. A work space is formed above the axial alignment means 21.

  At the same time or thereafter, the controller 51 operates the support valve 52 to move the plurality of axial pressing members 24 in the axially aligning means 21 radially as shown by solid arrows in FIG. The axial pressing tool 24 that presses one linear portion 13a of the non-flat coil 13 forming the saddle shape against the core rod 16 is separated from the linear portion 12a.

  An operator or a take-out robot (not shown) is pressed by the axial direction means 21 through a work space formed above the flat coil 12 and between the flat coil 12 and the circumferential direction means 31. The plurality of non-planar coils 13 that have been moved are moved upward together with the bobbin 14 and removed from the core rod 16.

  As a result, the production of the series of non-plate-like coils 13 is finished, and the production of the next non-plate-like coil 13 is started again from the coil support step described above. If it does in this way, it will become possible to obtain the non-plate-like coil 13 which has a desired shape continuously.

  And since the length of a pair of connecting wire part 12c, 12d was made longer than the circumferential direction distance of the core rod 16 which supports each one linear part 12a of several flat coil 12, three removed As shown in FIG. 13, the non-planar coil 13 has one linear portion 13 a of each non-planar coil 13 below the other coil 13 and the other linear portion 13 b of each non-planar coil 13. A part of the circumferential direction is overlapped so as to be on the upper side of the adjacent non-flat coil 13 and is provided adjacent to the circumferential direction.

  Therefore, in the coil shaping | molding apparatus 10 of this invention, and the coil shaping | molding method using the same, it becomes possible to shape | mold the some non-plate-shaped coil 13 in the state combined so that one part may overlap in the circumferential direction. .

  In the above-described embodiment, although the electric motor 43 is used as the rotating means 41 that rotates the circumferential pressing tool 34 around the core rod 16 in the circumferentially aligning means 31, the rotating means 41 is electrically driven. Instead of the motor 43, a fluid pressure cylinder or a fluid pressure motor may be used.

  In the above-described embodiment, the three flat coils 12 are supported around the bobbin 14 fitted into the core rod 16. However, the bobbin 14 is not always necessary, and the number of the flat coils 12 is three. It is not limited. Therefore, two, four, or five or more flat coils 12 may be supported around the core rod 16 without providing the bobbin 14. Even if it does in this way, it becomes possible to shape | mold the some flat coil 12 simultaneously, and to obtain the some non-plate-like coil 13 simultaneously, and can shorten the time concerning a single coil shaping | molding conventionally.

  Further, in the above-described embodiment, the wire 11 having a round cross section has been described. However, the wire 11 may be a so-called square wire having a square cross section.

DESCRIPTION OF SYMBOLS 10 Coil forming apparatus 12 Flat coil 12a, 12b Straight line part 12c, 12d Connecting wire part 16 Core rod 21 Axial direction alignment means 23 Axial direction pressing tool movement means 24 Axial direction pressing tool 31 Circumferential direction alignment means 32 Circumferential direction pressing tool Moving means 34 Circumferential pressing tool 41 Rotating means

Claims (6)

A flat type having a pair of linear portions (12a, 12b) facing each other with a predetermined interval and a pair of connecting line portions (12c, 12d) connecting the respective edges of the pair of linear portions (12a, 12b) In the coil forming apparatus for forming the coil (12),
A core rod (16) having a circular cross section;
Axial alignment means (21) for axially aligning one linear portion (12a) on the outer periphery of the core rod (16),
A coil forming apparatus comprising: a circumferential direction aligning means (31) for aligning the pair of connecting wire portions (12c, 12d) in the circumferential direction on an outer periphery of the core rod (16). The axially-aligning means (21) is arranged along the axial direction with a predetermined interval in the circumferential direction between each linear portion (12a) of the two or more flat coils (12) on the outer periphery of the core rod (16). Configured to
Circumferentially extending means (31) is configured to circulate the connecting wire portions (12c, 12d) of the two or more flat coils (12) on the outer periphery of the core rod (16) with a predetermined interval in the circumferential direction. The coil forming apparatus according to claim 1, wherein the coil forming apparatus is configured to follow the direction. The axial alignment means (21) includes two or more axial pressing tools (24) capable of pressing one linear portion (12a) to the outer periphery of the core rod (16) and two or more axial pressing tools ( 24) Axial pressing tool moving means (23) for moving between a pressing position for pressing the one linear portion (12a) on the outer periphery of the core rod (16) and a spaced position spaced from the outer periphery of the core rod 16. )
The circumferential alignment means (31) has one end of a pair of connecting wire portions (12c, 12d) continuous to both ends of the one straight portion (12a) pressed against the outer periphery of the core rod (16). Two or more circumferential pressing tools (34) that can be pressed against the rod (16), two or more circumferential pressing tools (34) against the outer circumference of the core rod (16), and the core rod (16 ) And a rotating means for rotating the two or more circumferential pressing tools (34) around the core rod (16). (41) The coil forming device according to claim 2 characterized by things. Using the coil forming apparatus (10) according to claim 3, the edges of the pair of linear portions (12a, 12b) and the pair of linear portions (12a, 12b) facing each other with a predetermined interval are connected. A coil forming method for simultaneously forming a plurality of flat coils (12) having a pair of connecting wire portions (12c, 12d),
By means of the axial alignment means (21), one linear portion (12a) of each of the plurality of flat coils (12) is aligned in the axial direction with a predetermined interval in the circumferential direction on the outer periphery of the core rod (16). And support
The pair of connecting line portions (12c, 12d) that are connected to both ends of the one linear portion (12a) from the periphery of the core rod (16) with the circumferential direction pressing tool (34) in the circumferential direction alignment means (31) Press against one end of each
The circumferential pressing tool (34) that is pressed is rotated around the core rod (16) so that the pair of connecting wire portions (12c, 12d) are sequentially placed around the core rod (16). A coil forming method.   The length of the pair of connecting wire portions (12c, 12d) is made longer than the circumferential distance of the core rod (16) that supports one straight portion (12a) of each of the plurality of flat coils (12), The other end of the pair of connecting wire portions (12c, 12d) that are sequentially arranged around the core rod (16) is overlapped from the outside with a pair of connecting wire portions (12c, 12d) of adjacent flat coils. Coil forming method.   The plurality of flat coils (12) is obtained by winding a wire (11) having a fusion layer formed on the outer peripheral surface thereof around a winding core having a square cross section, and the obtained flat coils (12) The coil forming method according to claim 4 or 5, wherein the adhering layer is formed in a melted or softened state and is cured and then removed from the core rod (16).

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