JP2020025381A - Device and method for winding edge-wise coil - Google Patents

Abstract

To improve the quality of an edge-wise coil in a device for manufacturing the edge-wise coil by bending a flat wire in an edge-wise direction.SOLUTION: This edge-wise coil winding device includes a bending unit that bends a flat wire in an edge-wise direction and a feeding mechanism for feeding the flat wire to the bending unit, and manufactures an edge-wise coil. The bending unit comprises a bending post against which the inner edge of the bent part of the flat wire abuts, an outer diameter holding part that holds the outer edge of the bent part of the flat wire, and turns around the bending post while being pressed toward the bending post, and bends the bent part, a turntable that moves the outer diameter holding part in a turning direction, and a radial moving mechanism for moving the outer diameter holding part in a radial direction during the turning movement of the outer diameter holding part.SELECTED DRAWING: Figure 1

Description

  An embodiment of the present invention relates to a winding device and a winding method of an edgewise coil.

  For example, it is known that there is an edgewise coil as a coil for a motor, which can increase the space factor, and is compact and has high performance. This edgewise coil is formed by bending a rectangular wire in the edgewise direction and overlapping it in the thickness direction while forming a quadrangle. As an edgewise coil winding device for manufacturing this kind of edgewise coil, there is one described in, for example, Patent Document 1. This edgewise coil winding device includes a winding mechanism and a feed mechanism for feeding a flat wire toward the winding mechanism. The winding mechanism includes a fulcrum roller that supports the inner end of the flat wire, a bender that turns around the fulcrum roller while pressing the flat wire against the fulcrum roller and bends the flat wire, and compresses the flat wire along the fulcrum roller. It is configured with a press mechanism.

JP 2007-74881 A

  However, in the conventional edgewise coil winding device described above, swelling and crushing in the outer peripheral portion of the bent portion of the flat wire are apt to occur, and the winding and loosening of the edgewise coil occur, resulting in a sufficient quality of the edgewise coil. Was not improved.

  In view of the above, in a device for manufacturing an edgewise coil by bending a rectangular wire in the edgewise direction, a winding device and a winding method for an edgewise coil capable of improving the quality of the edgewise coil are provided.

  The winding device for an edgewise coil according to the embodiment includes a bending section configured to bend a flat wire in an edgewise direction, and a supply mechanism that supplies the flat wire to the bending section to manufacture an edgewise coil. Wherein the bent portion holds a bending post to which an inner edge of the bent portion of the flat wire is abutted, and holds an outer edge of the bent portion of the flat wire, and presses the bent portion toward the bending post. An outer diameter holding portion that turns around the bending post to bend the bending portion, a turntable that moves the outer diameter holding portion in a turning direction, and the outer diameter holding portion when the outer diameter holding portion turns. A radial moving mechanism for sliding in the radial direction.

  The method for winding an edgewise coil according to the embodiment is a method for winding an edgewise coil for manufacturing an edgewise coil by bending a rectangular wire in an edgewise direction, wherein an outer edge of a bent portion of the rectangular wire is formed. While holding the outer diameter holding portion, and pressing the inner edge of the bent portion of the flat wire against the bending post, while rotating the outer diameter holding portion around the bending post, and moving the outer diameter holding portion through the turning movement. In synchronization with this, a bending operation is performed on the bent portion of the flat wire while sliding in a radial direction in a predetermined pattern.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows one embodiment, and is a longitudinal sectional view illustrating a main configuration of a winding device. The perspective view which shows the principal part structure of a winding apparatus schematically. Plan view schematically showing the state during bending work FIG. 4 is a plan view schematically showing a configuration of a cam portion of the second turntable. Block diagram schematically showing the electrical configuration of the winding device A perspective view showing the appearance of an edgewise coil.

  Hereinafter, an embodiment applied to manufacture of a rectangular edgewise coil used for a motor or the like will be described with reference to the drawings. FIG. 6 shows the appearance of the edgewise coil 1 to be manufactured in the present embodiment. The edgewise coil 1 is formed by bending a rectangular wire 2 made of, for example, copper or the like and having a rectangular cross section with a flat R in the edgewise direction, with a slight R at each corner, at an angle of 90 degrees. It is configured by stacking and winding in a stacked state.

  The winding device 11 according to the present embodiment is for manufacturing the edgewise coil 1 described above. Hereinafter, the configuration of the winding device 11 will be described with reference to FIGS. The winding device 11 includes a bending portion 12 (see FIGS. 1 to 3) for bending and forming the rectangular wire 2 in an edgewise direction, and a bending portion 12 provided on the right side of the bending portion 12 for bending the rectangular wire 2. And a supply mechanism 13 (see FIG. 5) for supplying to the forming section 12.

  Although not shown or described in detail, the supply mechanism 13 sends out the flat wire 2 from a supply source configured by winding the long flat wire 2 around a drum, and corrects the bending habit of the fed flat wire 2. Then, a well-known configuration is provided in which the workpiece is straightened and supplied to the processing position of the bending section 2 by a predetermined amount, that is, by a predetermined length. In this case, as partially shown in FIG. 2, the supply mechanism 13 includes a supply nozzle 14 that is located on the right side of the bending section 12 and that horizontally feeds the flat wire 2 to the left in the figure. The flat wire 2 is supplied to the processing position of the bending section 12 from the tip of the supply nozzle 14. The feed amount of the flat wire 2 by the supply mechanism 13 and the timing of the supply operation are controlled by a control device described later.

  As shown in FIG. 2, the bent portion 12 includes a horizontal base 15 having a base shape, and a box-shaped cover 16 having an open lower surface that covers the upper surface of the base 15. A circular opening 16a is provided at a substantially central portion of the cover 16, and the circular opening 16a is a processing position where the flat wire 2 is bent. On the upper surface of the cover 16, a first mounting plate 17 that is located on the right side of the processing position and is long in the left-right direction is provided horizontally. At the same time, on the upper surface of the cover 16, a second mounting plate 18 that is long in the left-right direction is provided horizontally at a position slightly behind the first mounting plate 17.

  On the first mounting plate 17 and the second mounting plate 18, a portion to be wound after the bending of the flat wire 2 is finished is sent and mounted. The first mounting plate 17 has a slit 17a extending in the entire left-right direction, and the flat wire 2 sent from the tip of the supply nozzle 14 passes through the slit 17a to the right. Is supplied horizontally to the processing position.

  As shown in FIG. 1 and the like, the bending portion 12 holds a bending post 19 with which the inner edge of the bent portion of the flat wire 2 abuts at a processing position, and an outer edge of the bent portion of the flat wire 2. An outer diameter holding portion 20 for turning the bending portion by an angle of 90 degrees around the bending post 19 and bending the bent portion while pressing against the bending post 19, and a turntable for moving the outer diameter holding portion 20 in the turning direction. A first turntable 21 and the like are provided. In the present embodiment, a radial moving mechanism 22 is provided for sliding the outer diameter holding unit 20 in the radial direction (the direction of arrow C) when the outer diameter holding unit 20 is turned.

  As shown in FIG. 1, on the base portion 15, a cylindrical support tube portion 23 is provided to extend right above the circular opening 16a. A small diameter portion 23 a is provided at the upper end of the support cylinder 23. The bending post 19 has a cylindrical shape that is long in the vertical direction, and is provided so as to vertically penetrate a hollow portion in the support cylindrical portion 23. The upper portion of the bending post 19 protrudes upward from the small-diameter portion 23a and is located at the circular opening 16a, and a large-diameter circular flange portion 19a is provided at the upper end thereof. In the present embodiment, the center of the support cylinder 23 and the bending post 19 is the center axis O extending in the vertical direction, and is the center of rotation of the turntable 21 and rotation of the outer diameter holding unit 20.

  The flat wire 2 supplied to the processing position has its inner edge, that is, the rear side in the figure, abutted against the outer peripheral portion of the bending post 19, and in this state, the lower surface of the circular flange portion 19a and the support It is vertically sandwiched between the upper end surface of the small diameter portion 23a of the cylindrical portion 23. At this time, although not shown in detail, the bending post 19 is provided so as to be vertically movable with respect to the support cylinder portion 23, and is pulled downward by the cylinder 24 (shown only in FIG. The attachment power is obtained.

  The outer diameter holding portion 20 is disposed on the outer peripheral side (on the near side in FIG. 1 and the like) of the upper end of the bending post 19 and the small diameter portion 23a of the support cylindrical portion 23. The outer diameter holding portion 20 is configured to rotatably rotate a roller 20c in a horizontal direction along a vertical axis via a bearing between a rectangular lower block 20a and an upper surface plate 20b disposed above the lower block 20a. Have. The outer edge of the flat wire 2 is pressed against the bending post 19 while the outer edge of the flat wire 2 is pressed against the lower surface of the upper surface plate 20b while the outer edge of the flat wire 2 is pressed. It is supposed to be.

  A lower portion of the outer diameter holding portion 20 on the outer peripheral side of the lower block 20a is attached to an upper end of a support block 25 having an L-shaped side surface. Here, the first turntable 21 is formed in a disk shape having a circular hole at the center, and is rotatable in a horizontal direction via a bearing 26 on an outer peripheral portion of an intermediate portion in the vertical direction of the support cylindrical portion 23. Is provided. Although not shown in detail, the first turntable 21 is driven to rotate around the support cylinder 23 at an arbitrary angle by a rotation drive mechanism using a first servomotor 27 (see FIG. 5) as a drive source. It has become.

  The support block 25 is formed in an L-shape extending outside the support cylinder portion 23 and then extending in the outer peripheral direction, and is supported by the first turntable 21. At this time, the inner diameter side portion of the lower end of the support block 25 is supported on the upper surface of the first turntable 21 by the guide portion 28 so as to be slidable in the radial direction (the direction of arrow C). At the same time, the lower end of the outer peripheral end of the support block 24 is connected to the upper end of a round drive shaft 29. The first turntable 21 has an elongated hole 21a extending in the radial direction. The width of the elongated hole 21a corresponds to the outer diameter of the turning drive shaft 29, and the turning drive shaft 29 extends vertically so as to pass through the elongated hole 21a. A cam follower 30 is provided at the lower end of the turning drive shaft 29.

  Thus, when the first turntable 21 is rotated around the support cylinder 23, the support block 25, and thus the outer diameter holding unit 20, rotates around the support cylinder 23. In this case, as shown in FIG. 3, the outer circumference of the bending post 19 is viewed from above from the initial position on the near side of the bending post 19 to the bending position on the left side in the drawing of the bending post 19, as shown in FIG. It turns around 90 degrees. Thus, the work of bending at an angle of 90 degrees with respect to the flat wire 2 is performed by the cooperation of the outer diameter holding portion 20 and the bending post 19. Also, at this time, the rotation drive shaft portion 29 relatively moves in the elongated hole 21a in the radial direction, so that the support block 25 and thus the outer diameter holding portion 20 have a fixed length in the radial direction with respect to the first turntable 21. Displacement is allowed.

  In the present embodiment, the radial moving mechanism 22 that slides the outer diameter holding unit 20 in the radial direction is configured as follows. That is, as shown in FIG. 1, on the outer peripheral portion of the support cylinder portion 23, a second rotary table is coaxially disposed with the first rotary table 21 under the first rotary table 21. 31 is provided rotatably in the horizontal direction via a bearing 32. The second turntable 31 is formed in a disk shape having a circular hole in the center, and the periphery of the support cylinder portion 23 is rotated by a rotation drive mechanism using a second servomotor 33 (see FIG. 5) as a drive source. It is driven to rotate at any angle.

  As shown in FIG. 4, a concave portion 31a is provided on the front side of the upper surface portion of the second turntable 31, and a rectangular shape slightly longer in the radial direction is fitted so as to fit in the concave portion 31a. A cam plate 34 is provided. A cam groove 34a slightly inclined with respect to the radial direction is formed on the upper surface of the cam plate 34, and the cam follower 30 at the lower end of the turning drive shaft portion 29 is engaged in the cam groove 34a. . Thus, a cam mechanism 35 is provided between the second turntable 31 and the outer diameter holding unit 20 for converting the rotational movement of the second turntable 31 into the radial movement of the outer diameter holder 20. Have been.

  In the cam mechanism 35, when the first turntable 21 and the second turntable 31 are integrally rotated while keeping the same phase, the outer diameter holding unit 20 does not move in the radial direction. On the other hand, when the phase of the second turntable 31 is shifted forward in the clockwise direction relative to the first turntable 21, the outer diameter holding unit 20 moves to the inner circumference side, that is, the side closer to the bending post 19. . Conversely, when the phase of the second turntable 31 is delayed with respect to the first turntable 21 in the clockwise direction, the outer diameter holding unit 20 moves to the outer side, that is, the side away from the bending post 19. .

  FIG. 5 schematically shows an electrical configuration of the winding device 11 of the present embodiment. As shown in FIG. 5, the winding device 11 is provided with a control device 36 for controlling the whole. The control device 36 is mainly composed of a computer, and controls the supply mechanism 13, the cylinder 24, the first servomotor 27, and the second servomotor 33. Thus, the control device 36 can rotate the second turntable 31 with respect to the first turntable 21 so as to have an arbitrary phase.

  The control device 36 automatically executes the winding operation of the edgewise coil 1 based on a preset control program. In this winding operation, first, the feeding mechanism 13 feeds the flat wire 2 toward the processing position by a predetermined amount, and holds both side edges of the flat wire 2 between the bending post 19 and the outer diameter holding portion 20. I do. Next, the first rotary table 21 is rotated by the first servomotor 27 to rotate the outer diameter holding unit 20 from the initial position to the bending position, and the flat wire 2 is bent at an angle of 90 degrees in the edgewise direction. Thereafter, the outer diameter holding unit 20 is turned in the reverse direction to return to the original initial position, and the feeding mechanism 13 repeats feeding the rectangular wire 2 by a predetermined amount.

  At this time, in this embodiment, during the bending operation of the flat wire 2, the control device 36 rotates the first turntable 21 at a predetermined speed to rotate the outer diameter holding unit 20 at a constant speed. In the control program, a pattern of the rotation phase of the second turntable 31 with respect to the rotation phase of the first turntable 21 is set, and the second servomotor 33 is controlled according to the pattern. For example, the relationship between the rotation phases of the two turntables 21 and 31 is such that when the first turntable 21 is rotated by 30 degrees from the reference position, the second turntable 31 is rotated by 31 degrees from the reference position. This is a pattern representing.

  In this case, as described above, the phase shift between the first turntable 21 and the second turntable 31 causes the outer diameter holding unit 20 to slide in the radial direction by the action of the cam mechanism 35. be able to. When the outer diameter holding portion 20 is moved in the outer diameter direction, that is, in a direction away from the bending post 19, the pressing force of the flat wire 2 against the bending post 19 can be reduced, and conversely, the outer diameter holding portion 20 can be moved in the inner diameter direction. That is, when the flat wire 2 is moved in the direction approaching the bending post 19, the pressing force of the flat wire 2 against the bending post 19 can be increased.

  Therefore, the outer diameter is held so that the force acting on the flat wire 2 in the width direction, that is, the pressing force of the outer diameter holding portion 20 against the bending post 19 is an appropriate force that does not cause swelling or collapse. An appropriate radial position, that is, a movement pattern at each angle during the turning of the unit 20 is previously obtained experimentally, theoretically, or empirically by an operator or the like. Then, the data of the appropriate pattern is set in the control device 36. Accordingly, the outer diameter holding unit 20 performs a bending operation on the flat wire 2 while sliding in a radial direction (direction of arrow C) in a predetermined pattern in synchronization with the turning movement.

  Next, a manufacturing process of the edgewise coil 1 in the winding device 11 having the above configuration, that is, a winding method according to the present embodiment will be described. As described above, an appropriate pattern of the rotation phase of the second turntable 31 with respect to the rotation phase of the first turntable 21 in the bending process is set in the control device 36 before the operation is started. The winding operation of the edgewise coil 1 is executed by the control device 36 as follows.

  That is, first, the supply mechanism 13 executes a supply step of feeding the rectangular wire 2 by a predetermined amount from the supply source toward the processing position of the bending section 12. As shown by the solid line in FIG. 3, the bent portion of the flat wire 2 is located at the processing position, and both side edges of the bent portion of the flat wire 2 are formed between the outer diameter holding portion 20 and the bending post 19 located at the initial position. It is held between the front and rear. Next, a bending process is performed in which the outer diameter holding portion 20 is turned around the central axis O and the flat wire 2 is bent in the edgewise direction while the inner edge of the bent portion of the flat wire 2 is pressed against the bending post 19. Is done.

  This bending process is performed by rotating the first turntable 21 clockwise (in the direction of arrow A) by 90 degrees by the first servomotor 27 as shown by the imaginary line in FIG. This is done by turning 20 to the bending position. At this time, in synchronization with the rotation of the first turntable 21, the second turntable 31 is rotationally driven by the second servomotor 33 in a predetermined pattern. Thus, the outer diameter holding unit 20 is slid in the radial direction (direction of arrow C) in a predetermined pattern during the turning movement at an angle of 90 degrees by the action of each mechanism 35 in synchronization with the turning movement. Become like

  At this time, in a place (angle) where the pressing force of the flat wire 2 against the bending post 19 is likely to be too strong, the outer diameter holding portion 20 is moved in a direction radially away from the bending post 19 and the pressing force is suppressed to a small value. . Further, in a place (angle) where the pressing force of the flat wire 2 against the bending post 19 may be too weak, the pressing force is increased by moving the flat wire 2 in a direction approaching the bending post 19 in the radial direction. Thus, the force acting in the width direction of the bent portion of the flat wire 2 is equalized at each angle (phase) when the outer diameter holding portion 20 turns.

  When the bending of the rectangular wire 2 is completed, the outer diameter holding unit 20 bends by rotating the first turntable 21 and the second turntable 31 in the opposite directions in a state where the flat wire 2 is released. It turns from the position in the direction of arrow B and returns to the initial position. Thereafter, the feeding mechanism 13 again feeds the rectangular wire 2 from the supply source toward the processing position of the bending portion 12 by a predetermined amount, in this case, a length corresponding to the width of one side of the edgewise col 1. Is performed, and the above-described bending process is repeated. As a result, the flat wire 2 is sequentially bent and formed at an angle of 90 degrees, and the formed portions are placed on the first mounting plate 17 and the second mounting plate 18 in order. The work is completed when the edgewise coil 1 having the predetermined number of turns is obtained.

  According to the winding device 1 and the winding method of the present embodiment, the following operations and effects can be obtained. That is, in the present embodiment, the radial moving mechanism 22 that slides the outer diameter holding unit 20 in the radial direction when the outer diameter holding unit 20 that bends the rectangular wire 2 is turned is provided. Then, in the bending process, the outer diameter holding portion 20 is turned while the inner edge of the bent portion of the flat wire 2 is pressed against the bending post 19, and, in synchronism with the turning movement, in the radial direction in a predetermined pattern. Made to slide.

  With this configuration, at a position (phase) where the pressing force on the rectangular wire 2 becomes too large, the outer diameter holding portion 20 is slid to a position radially away from the bending post 19, and the pressing force on the rectangular wire 2 decreases. In an excessive position (phase), the outer diameter holding portion 20 can be slid to a position radially approaching the bending post 19. Thereby, the force acting in the width direction of the bent portion of the flat wire 2 is suppressed from being uneven at each angle (phase) when the outer diameter holding portion 20 turns, and the outer periphery of the bent portion of the flat wire 2 is suppressed. It is possible to suppress the occurrence of swelling or crushing in the part, and to perform a high-quality bending operation.

  As a result, according to the present embodiment, in manufacturing the edgewise coil 1 by bending the rectangular wire 2 in the edgewise direction, an excellent effect that the quality of the edgewise coil 1 can be improved can be achieved. Obtainable. In particular, in the present embodiment, the radial moving mechanism 22 is configured by the second turntable 31, the cam mechanism 35, and the like. In this way, a radial movement pattern for the turning operation of the outer diameter holding unit 20 is determined in advance so that an appropriate operation is performed, and control by the control device 36 is performed to obtain the movement pattern. You can get the action.

  In the above-described embodiment, the configuration using the second turntable 31 and the cam mechanism 35 is employed as the radial moving mechanism 22, but the outer diameter holding unit 20 can be freely moved in the radial direction. If so, various configurations can be adopted. For example, it is also possible to adopt a configuration in which a linear moving mechanism using a servomotor and a ball screw mechanism is provided on the first turntable 21. In addition, various modifications can be made to, for example, the configuration of details of the bent portion.

  The embodiments described above have been presented by way of example, and are not intended to limit the scope of the invention. These new embodiments can be implemented in other various forms, and various omissions, replacements, and changes can be made without departing from the spirit of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are also included in the invention described in the claims and their equivalents.

  In the drawings, 1 is an edgewise coil, 2 is a flat wire, 11 is a winding device, 12 is a bending section, 13 is a supply mechanism, 19 is a bending post, 20 is an outer diameter holding section, and 21 is a first turntable. , 22 is a radial moving mechanism, 23 is a support cylinder, 25 is a support block, 27 is a first servomotor, 29 is a turning drive shaft, 30 is a cam follower, 31 is a second turntable, and 33 is a 2 is a servo motor, 34 is a cam plate, 34a is a cam groove, 35 is a cam mechanism, and 36 is a control device.

Claims (3)

A bending device for bending a flat wire in the edgewise direction, and a supply mechanism for supplying the flat wire to the bending portion, a winding device for an edgewise coil for manufacturing an edgewise coil,
The bending section,
A bending post against which the inner edge of the bent portion of the flat wire abuts,
An outer diameter holding portion that holds an outer edge portion of the bent portion of the flat wire, and turns around the bending post while bending toward the bending post to bend the bent portion,
A turntable for moving the outer diameter holding unit in a turning direction,
An edgewise coil winding device comprising: a radial direction moving mechanism that slides the outer diameter holding portion in the radial direction when the outer diameter holding portion turns. The radial movement mechanism,
A second turntable provided coaxially with the turntable,
A cam mechanism that is provided between the second turntable and the outer diameter holding unit and converts a rotational movement of the second turntable into a radial movement of the outer diameter holding unit;
The winding device for an edgewise coil according to claim 1, further comprising: a control device configured to rotate the second turntable so as to have an arbitrary phase with respect to the turntable. An edgewise coil winding method for manufacturing an edgewise coil by bending a rectangular wire in an edgewise direction,
While holding the outer edge of the bent portion of the flat wire with an outer diameter holding portion, and pressing the inner edge of the bent portion of the flat wire against a bending post, while rotating the outer diameter holding portion around the bending post,
An edgewise coil winding method for performing a bending operation on a bent portion of the flat wire while sliding the outer diameter holding portion in a predetermined pattern in a radial direction in synchronization with the turning movement.

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