JP3812125B2 - Armature coil manufacturing method and manufacturing apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an armature coil manufacturing method and manufacturing apparatus.
[0002]
[Prior art]
As a prior art, there is an armature coil manufacturing method described in Japanese Patent Laid-Open No. 9-182337. The armature coil includes a predetermined number of lower layer coil conductors and upper layer coil conductors. Each coil conductor includes a linear coil side inserted into a slot of the armature core, a pair of coil ends extending substantially perpendicularly from both ends of the coil side, and a tip of the coil end. It has a set of coil protrusions that are bent at a substantially right angle and protrude to the opposite side of the coil side.
In the manufacturing method described above, the lower layer coil conductor 4 and the upper layer coil conductor 5 are formed from rectangular wires. As shown in FIGS. 6A to 6C, first, a plurality of lower layer coil conductors 4 and upper layer coil conductors 5 are formed. A rectangular wire 10 having a length necessary for forming the unfolded body of the rectangular wire 10 is prepared, and then the cross-sectional area of the rectangular wire 10 is reduced at predetermined intervals in the longitudinal direction of the flat wire 10 to obtain the shaft details 10a. Form. Subsequently, a substantially central portion of each axial detail 10a is cut and divided into a plurality of lower layer coil conductors 4 and upper layer coil conductors 5 (coil material 11).
Thereafter, as shown in FIGS. 7A to 7E, both end portions of each developed body (coil material 11) are sequentially bent to form the lower layer coil conductor 4 and the upper layer coil conductor 5 having a predetermined shape. 6 and 7 show the manufacturing process of the lower layer coil conductor 4.
[0003]
[Problems to be solved by the invention]
In the above publication, preparing a plurality of types Although specific methods for performing the molding step shown in FIG. 7 (a) ~ (e) is not mentioned, generally performing respective molding the order of steps A method of manufacturing a final shape coil conductor by sequentially applying predetermined molding to each mold is conceivable. In this case, since it is necessary to sequentially attach and detach the processing material for each mold, in order to maintain high processing accuracy, it is necessary to position the processing material with high accuracy in each mold. In order to perform such high-precision positioning, high-precision molds are required, and the manufacturing cost is high. Moreover, since it is necessary to attach and detach processing materials for each mold in sequence, there is a problem that production efficiency is poor.
The present invention has been made based on the above circumstances, and its purpose is to reduce the manufacturing cost of high-precision armature coils (lower layer coil conductor and upper layer coil conductor) and realize high production efficiency. An object of the present invention is to provide a method and an apparatus for manufacturing an armature coil.
[0004]
[Means for Solving the Problems]
(Means of Claim 1)
A method of manufacturing a lower coil conductor or upper coil conductor through a plurality of molding process from the coil material of the flat wire, while maintaining the predetermined portion of the coil material to the pallet at a plurality of molds, respectively on type A predetermined molding process is sequentially performed simultaneously with the positioning of the pallet by the relative movement of the lower mold and the lower mold . According to this method, since the coil material of the final shape can be processed without removing the coil material from the pallet, high-speed processing is possible, and production efficiency can be improved.
[0005]
(Means of Claim 2)
The lower pallet is provided with the same width as the length between both end faces of the armature core and the thickness of the pair of first insulators, and receives a predetermined part of the coil material. Are provided in the entire width of the lower pallet, and the upper pallet has a width dimension between the lengths of both end faces of the armature core, a set of first insulators, and a set of lower coil ends. And the length of the set of second insulators are the same. Accordingly, the pallet can be used as a part of the mold, and when the portion corresponding to the lower coil end or the upper coil end of the coil material is bent, the position accuracy of the bent portion is improved.
Further, both side surfaces in the lateral width direction of the pallet are formed substantially at right angles to the bottom surface of the groove portion, and the height from the bottom surface of the groove portion to the bottom surface of the pallet is longer than the length of the lower layer coil end portion or the upper layer coil end portion. Therefore, a portion corresponding to the lower coil end or the upper coil end of the coil material can be bent and brought into contact with the side surface of the pallet. As a result, the bending angle of the bent portion can be processed at a substantially right angle by the corner of the pallet (the corner formed by the bottom surface of the groove and the side surface of the pallet).
[0006]
(Means of claim 3)
In the lower pallet, the corner portion (that is, the corner portion formed by the bottom surface of the groove and the side surface of the lower pallet) serving as a fulcrum when the portion corresponding to the lower coil end portion of the coil material is bent is the first insulation. R, which has a smaller radius of curvature than the corners of the body, is provided, and the upper pallet is a corner that serves as a fulcrum when bending the portion corresponding to the upper coil end of the coil material (that is, the bottom surface of the groove and the side surface of the upper pallet) R having a smaller radius of curvature than the corner of the second insulator is given. Thereby, since the lower layer coil conductor formed into a predetermined shape can form the corner (bending portion) between the lower coil side and the lower coil end with an R having a smaller radius of curvature than the corner of the first insulator, Since the said corner | angular part of a lower layer coil conductor does not contact | abut the corner | angular part of a 1st insulator when a lower layer coil conductor is assembled | attached to an armature core, a crack, a chip | tip, etc. of a 1st insulator can be prevented.
Similarly, since the corner (bending portion) between the upper layer coil side and the upper layer coil end can be formed with R having a smaller radius of curvature than the corner of the second insulator, when the upper layer coil conductor is assembled to the armature core Since the corner portion of the upper coil conductor does not hit the corner portion of the second insulator, it is possible to prevent the second insulator from being cracked or chipped.
[0007]
(Means of claim 4)
The lower pallet is provided with an R having a larger radius of curvature at the corner formed by the bottom and side surfaces of the groove than at the corner formed by the bottom and side surfaces of the slot of the armature core. As a result, when the lower coil side is inserted into the slot, the corner of the lower coil side does not hit the corner of the slot, so that the insulator for insulating the lower coil side and the wall surface of the slot is damaged. Can be prevented. The insulator may be a thin-film insulator (paper, resin, etc.) interposed between the lower coil side and the slot, or an armature core coated with an insulating coating such as powder.
[0008]
(Means of claim 5)
As positioning means for positioning the pallet and the lower mold or upper mold of the molding die, two or more positioning holes are provided at predetermined positions on the pallet, and positioning pins that fit into the positioning holes at predetermined positions on the lower mold or upper mold are provided. It may be provided. Alternatively, two or more positioning pins may be provided at predetermined positions on the pallet, and positioning holes that fit the positioning pins may be provided at predetermined positions on the lower die or the upper die. In this case, after the pallet is arranged at a predetermined position of the upper die or the lower die, the coil material can be processed simultaneously with the positioning of the pallet by moving the lower die or the upper die, so that high-speed machining is possible. .
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a plan view of the pallet.
An armature 1 that is an object of the present invention is used, for example, in a starter motor that starts an engine. As shown in FIGS. 3 and 4, a rotary shaft 2, an armature core 3, an armature coil (lower coil conductor) 4, an upper coil conductor 5), and a disk-shaped insulator (an inner disk-shaped insulator 6 as a first insulator and an outer disk-shaped insulator 7 as a second insulator). .
The rotating shaft 2 is rotatably supported via a bearing (not shown).
The armature core 3 is fitted into the outer periphery of the rotary shaft 2 in a press-fit state by superposing a plurality of disk-shaped core sheets. A predetermined number (for example, 25) of slots 3 a are recessed along the axial direction on the outer periphery of the armature core 3.
[0010]
The armature coil is composed of a lower layer coil conductor 4 and an upper layer coil conductor 5 made of pure copper or pure aluminum having a low electrical resistance, and the same number as the number of slots 3a is used. In addition, the manufacturing method of the lower layer coil conductor 4 and the upper layer coil conductor 5 is mentioned later.
The lower layer coil conductor 4 includes a linear lower layer coil side 4a, a set of lower layer coil ends 4b extending from both ends of the lower layer coil side 4a in a direction substantially perpendicular to the lower layer coil side 4a, It consists of a set of lower layer coil protrusions 4c protruding in the opposite direction from the lower coil side 4a at a substantially right angle from the tip of the coil end 4b. However, the pair of lower coil ends 4b are inclined at predetermined angles to opposite sides of the circumferential direction around the lower coil side 4a.
As shown in FIG. 3, the lower layer coil conductor 4 is assembled to the armature core 3 by inserting the lower layer coil side 4 a into the slot 3 a of the armature core 3. Note that the lower coil side 4a inserted into the slot 3a is insulated from the armature core 3 (wall surface of the slot 3a) by a lower layer slot insulator 8 (see FIG. 5) having a U-shaped cross section, for example. Yes. Alternatively, instead of using the lower layer slot insulator 8, an insulating tape or the like may be wound around the outer peripheral surface of the lower layer coil side 4a and inserted into the slot 3a.
[0011]
The upper layer coil conductor 5 is a pair of linear upper layer coil sides 5a provided slightly longer than the lower layer coil side 4a, and a set extending from both ends of the upper layer coil sides 5a in a direction substantially perpendicular to the upper layer coil sides 5a. The upper layer coil end portion 5b and a pair of upper layer coil protrusion portions 5c protruding in the direction opposite to the upper layer coil side 5a substantially perpendicularly from the tip of each upper layer coil end portion 5b. However, the pair of upper layer coil end portions 5b are inclined at a predetermined angle to opposite sides in the circumferential direction around the upper layer coil side 5a. On the other hand, the upper coil end portion 5b (on the right side in FIG. 3) is formed as a commutator side on which a brush (not shown) slides on its axial end surface.
As shown in FIG. 3, the upper layer coil conductor 5 is assembled to the armature core 3 by inserting the upper layer coil side 5a outside the lower layer coil side 4a in the slot 3a. The upper coil side 5a inserted into the slot 3a is insulated from the armature core 3 (the wall surface of the slot 3a) by an upper layer slot insulator 9 (see FIG. 5) having a U-shaped cross section, for example. Yes. Alternatively, instead of using the upper layer slot insulator 9, an insulating tape or the like may be wound around the outer peripheral surface of the upper layer coil side 5a and inserted into the slot 3a.
[0012]
As shown in FIG. 4, the disk-shaped insulator is interposed between the axial end surface of the armature core 3 and the lower coil end portion 4b, and a pair of inner disk-shaped insulators 6 that insulate the two. And a pair of outer disk-shaped insulators 7 interposed between the lower coil end 4b and the upper coil end 5b to insulate them.
The inner disk-shaped insulator 6 is formed by punching, for example, a resin plate having a predetermined thickness into an annular shape, and has a round hole 6a that can be fitted to the outer diameter of the rotary shaft 2 at the center. Yes. Before the lower coil conductor 4 is assembled to the armature core 3, the inner disk-shaped insulator 6 is mounted on the outer end face of the armature core 3 through the rotary shaft 2 through the round hole 6 a from the axial direction.
The outer disk-shaped insulator 7 is formed by punching, for example, a resin plate thicker than the inner disk-shaped insulator 6 into an annular shape, and can be fitted to the outer diameter of the lower coil protrusion 4c at the center. A hole 7a is opened. The outer disk-shaped insulator 7 is formed by assembling all the lower layer coil conductors 4 to the armature core 3 and then extending from the axial direction to the round holes 7a through the lower layer coil protrusions 4c to the outer side in the axial direction of the lower layer coil ends 4b. Installed.
[0013]
Next, the forming process of the armature coil (the lower layer coil conductor 4 and the upper layer coil conductor 5) will be described using the lower layer coil conductor 4 as an example.
A) Steps until a coil material used for the lower layer coil conductor 4 is formed.
a) First, as shown in FIG. 6A, a flat wire 10 having a length necessary for forming a developed body (coil material) of a plurality of lower layer coil conductors 4 is prepared. The flat wire 10 may be formed by forming a round wire with a roller or the like. Or you may punch from a flat plate.
b) Subsequently, as shown in FIG. 6B, the cross-sectional area of the flat wire 10 is reduced at predetermined intervals in the longitudinal direction of the flat wire 10 to form the shaft details 10a. In this case, the shaft details 10a can be formed by removing a part of the outer periphery of the flat wire 10 by punching or the like by pressing. Alternatively, the shaft detail 10a may be formed by plastically deforming a part of the outer periphery of the flat wire 10 with a roller.
c) Subsequently, the substantially central portion of each shaft detail 10a is cut and divided into a plurality of coil materials 11 (see FIG. 6C). Note that the step b) and the step c) may be interchanged. That is, after the rectangular wire 10 is cut into a plurality of coil materials 11, shaft details 10a are formed at both ends of the cut coil materials 11.
[0014]
B) A molding process until the final shape lower layer coil conductor 4 is formed from the coil material 11 by a manufacturing apparatus described later.
d) The portion corresponding to the lower layer coil protrusion 4c of the coil material 11 obtained in the steps (ac) is bent by approximately 90 degrees (see FIG. 7B).
e) Subsequently, the portion corresponding to the lower coil end 4b is inclined by a predetermined angle θ on the same plane of the coil material 11 (see FIG. 7C).
f) Subsequently, the portion corresponding to the lower coil protrusion 4c is twisted by 90 degrees with respect to the portion corresponding to the lower coil end 4b (see FIG. 7D).
g) Subsequently, the portion corresponding to the lower coil end portion 4b is bent 90 degrees with respect to the portion corresponding to the lower coil side 4a, and is formed to the final shape shown in FIG.
[0015]
Next, a manufacturing apparatus will be described.
The manufacturing apparatus holds a plurality of molds 12 that perform predetermined molding processes in the respective molding steps (d to g), and a coil material 11 during the molding process, and is used as a part of the mold. And a pallet 13.
(Configuration of mold 12)
Here, the mold 12 used in the step d) will be described as an example.
As shown in FIGS. 8 and 9, the molding die 12 includes a lower die 15 fixed to the lower plate 14, an upper die 17 fixed to the upper plate 16, a pallet receiver 18 for mounting the pallet 13, and the like. Composed.
[0016]
The lower plate 14 and the upper plate 16 are positioned by a plurality of guide bars 19, and the upper plate 16 is provided along the guide bars 19 so as to be movable in the vertical direction together with the upper mold 17.
The lower die 15 is divided into two parts and arranged on the lower plate 14 at a predetermined interval, and a molding recess 15 a for bending the end of the coil material 11 is formed.
The upper mold 17 is formed with a molding convex part 17 a corresponding to the molding concave part 15 a of the lower mold 15. The upper mold 17 is provided with two positioning pins 20 and a pallet presser 21. The positioning pin 20 is for positioning the pallet 13 with respect to the upper mold 17 and is provided so as to protrude downward from the upper mold 17. The pallet presser 21 presses the upper surface of the pallet 13 mounted on the pallet receiver 18 when the upper die 17 is lowered.
The pallet receiver 18 is disposed between one of the two lower molds 15 and the other lower mold 15 and is supported by a spring 22 with respect to the lower plate 14 so as to be movable in the vertical direction. The pallet receiver 18 is provided with a restricting means (not shown) for restricting the mounting position of the pallet 13.
[0017]
(Configuration of pallet 13)
The pallet 13 is provided with a lower layer side pallet 13 used when forming the lower layer coil conductor 4 and an upper layer side pallet (not shown) used when forming the upper layer coil conductor 5. Here, the lower layer side pallet 13 will be described as an example.
As shown in FIGS. 1 and 2, the pallet 13 is assembled with a workpiece receiver 23 and a clamper 24 for gripping (clamping) the coil material 11.
The workpiece receiver 23 is incorporated in a substantially central portion in the longitudinal direction of the pallet 13 over the entire lateral width direction (vertical direction in FIG. 1A) of the pallet 13. The width of the pallet 13, that is, the length of the work receiver 23, is set to be equal to the length obtained by adding the length between both end faces of the armature core 3 and the thickness of the pair of inner disk-shaped insulators 6. Yes.
As shown in FIG. 1B, the workpiece receiver 23 is formed with a recess 25 having a substantially L-shaped cross section for receiving the coil material 11 (setting the coil material 11) in the lateral width direction of the pallet 13. The depth of the recess 25 is set to be substantially the same as the thickness of the coil material 11. Further, the corner portions 25a formed on both sides of the bottom surface of the recess 25 are given R having a larger curvature radius than the corner portions 3b (see FIG. 5) formed by the bottom surface and the side surface of the slot 3a of the armature core 3. Yes. Furthermore, the corner 25b (see FIG. 2) formed by the bottom surface of the recess 25 and the side surfaces of the workpiece receiver 23 (left and right side surfaces in FIG. 2) has a smaller radius of curvature than the corner of the inner disk-shaped insulator 6. R is given.
[0018]
The clamper 24 is rotatably supported on the pallet 13 by the rotating shaft 26, and the urging force of the spring 28 is transmitted through the taper portion 27 a of the taper pin 27 incorporated in the pallet 13, so that the concave portion 25 of the work receiver 23. It is possible to clamp the coil material 11 set to the position with a predetermined clamping force. Accordingly, the coil material 11 can be unclamped (released) by pushing the taper pin 27 to eliminate the clamping force.
Two circular positioning holes 29 are formed in the pallet 13. As shown in FIG. 1B, the positioning hole 29 is provided penetrating in the height direction of the pallet 13 (vertical direction in FIG. 1B), and is provided in the above-described upper mold 17. 20 can be fitted. Both side surfaces of the pallet 13 in the lateral width direction are flat surfaces that are not stepped from the side surface of the work receiver 23 and are formed substantially perpendicular to the bottom surface of the recess 25 of the work receiver 23 (see FIG. 2). Further, the height from the bottom surface of the recess 25 of the work receiver 23 to the bottom surface of the pallet 13 is set to be equal to or longer than the length of the lower coil end 4b.
[0019]
Next, an example of this manufacturing apparatus will be described with respect to the step d) (step of bending a portion corresponding to the lower coil protrusion 4c from the coil material 11 by 90 degrees).
First, the coil material 11 cut to a predetermined length in the above-described steps (ac) is fixed to the pallet 13. Specifically, a predetermined portion of the coil material 11 is set in the recess 25 of the workpiece receiver 23 with the taper pin 27 pushed in, and then the taper pin 27 is released and the coil material 11 is clamped by the clamper 24. In addition, the predetermined site | part of the coil raw material 11 set to the recessed part 25 of the workpiece | work receiver 23 is between the site | parts corresponded to the lower layer coil edge part 4b of both sides. In other words, the portions corresponding to the lower layer coil end 4 b and the lower layer coil protrusion 4 c are in a state of protruding outward from the recess 25 of the workpiece receiver 23.
[0020]
Subsequently, the pallet 13 is mounted on the pallet receiver 18 of the mold 12 and the molding process is started. Here, the upper plate 16 is pressed downward by a press machine or the like (not shown), and the upper plate 16 is lowered along the guide bar 19. When the upper plate 16 is lowered, the positioning pins 20 provided on the upper die 17 are first fitted into the positioning holes 29 of the pallet 13 so that the pallet 13 is positioned relative to the lower die 15 and the upper die 17. Further, when the upper plate 16 is lowered, the lower surface of the pallet retainer 21 comes into contact with the upper surface of the pallet 13 and the upper surface of the coil material 11 and then presses the pallet 13 together with the pallet receiver 18 while compressing the spring 22. Thereafter, the end of the coil material 11 comes into contact with the molding recess 15a of the lower die 15, and the portion corresponding to the lower coil projection 4c is bent 90 degrees by the molding recess 15a of the lower die 15 and the molding projection 17a of the upper die 17. (See FIG. 10).
[0021]
Thus, the process of d) is completed, and the process proceeds to the next process e). At this time, the pallet 13 moves from the mold 12 used in the step d) to the mold used in the step e) while the coil material 11 is clamped.
In the above process, the lower coil conductor 4 is described as an example, but the upper coil conductor 5 is also formed through the same process. However, the upper pallet used in the forming process of the upper coil conductor 5 has a width of the pallet, that is, the length of the work receiver, the length between both end faces of the armature core 3 and a pair of inner disk-shaped insulators. 6, the thickness of the pair of lower coil ends 4 b, and the thickness of the pair of outer disk-shaped insulators 7 are set to be the same. Further, the corner formed by the bottom surface of the recess provided in the workpiece receiver and the side surface of the workpiece receiver is given R having a smaller radius of curvature than the corner of the outer disk-shaped insulator 7. Further, the height from the bottom surface of the concave portion of the workpiece receiver to the bottom surface of the pallet is set to be equal to or longer than the length of the upper coil end portion.
[0022]
(Effect of this embodiment)
In this embodiment, a predetermined forming process can be sequentially performed with the plurality of forming dies 12 while the predetermined portion of the coil material 11 is held on the pallet 13. According to this method, the lower layer coil conductor 4 and the upper layer coil conductor 5 having the final shape can be processed without removing the coil material 11 from the pallet 13. Further, the positioning of the pallet 13 with respect to the upper die 17 and the lower die 15 can be performed by fitting the positioning pins 20 provided on the upper die 17 with the positioning holes 29 provided on the pallet 13. In this case, the positioning of the pallet 13 and the processing of the coil material 11 can be continuously performed by the lowering of the upper die 17. As a result, high-speed machining becomes possible and production efficiency can be greatly improved.
[0023]
In the lower pallet 13 of this embodiment, the corners 25a formed on both sides of the bottom surface of the recess 25 of the workpiece receiver 23 are R-shaped, and the R is formed by the bottom surface and the side surface of the slot 3a of the armature core 3. Since the radius of curvature is larger than the radius R of the corner 3b, the lower coil conductor 4 manufactured through a predetermined molding process is assembled to the armature core 3, that is, when the lower coil side 4a is inserted into the slot 3a. Further, since the corner portion of the lower coil side 4a does not hit the corner portion of the slot 3a, the lower layer slot insulator 8 interposed between the lower coil side 4a and the slot 3a can be prevented from being damaged. Even when an insulating coating such as powder is applied to the armature core 3 instead of using the lower slot insulator 8, damage to the insulating coating can be similarly prevented.
Also, in the upper layer side pallet, the corners of the upper layer coil sides 5a can be formed into an R shape by forming the corners formed on both sides of the bottom surface of the concave portion of the workpiece receiving portion, so that the upper layer coil sides 5a are slotted. When inserted into 3a, damage to the upper slot insulator 9 or the insulating coating can be prevented.
[0024]
Furthermore, in the lower layer side pallet 13, a corner 25b formed by the bottom surface of the recess 25 of the workpiece receiver 23 and the side surface of the workpiece receiver 23 (a fulcrum when bending a portion corresponding to the lower coil end portion 4b of the coil material 11). Since the corner having a radius of curvature smaller than that of the corner of the inner disk-shaped insulator 6 is given, the corner (folded portion) between the lower coil side 4a and the lower coil end 4b is formed on the inner circle. It can be formed with R having a smaller radius of curvature than the corner of the plate-like insulator 6. Thereby, when the lower layer coil conductor 4 is assembled to the armature core 3, the corner portion (folded portion) of the lower layer coil conductor 4 does not hit the corner portion of the inner disk insulator 6. 6 can be prevented from cracking or chipping. Similarly, in the upper pallet, the corner portion serving as a fulcrum when the portion corresponding to the upper coil end portion 5b of the coil material 11 is bent is R having a smaller radius of curvature than the corner portion of the outer disk-shaped insulator 7. As a result, when the upper layer coil conductor 5 is assembled to the armature core 3, the corner portion (folded portion) of the upper layer coil conductor 5 does not hit the corner portion of the outer disk insulator 7, so that the outer disk insulator 7 can be prevented from cracking or chipping.
[0025]
In the above embodiment, the step of bending the end portion of the coil material 11 (the portion corresponding to the lower layer coil protruding portion 4c) by 90 degrees is described as an embodiment of the manufacturing apparatus, but the portion corresponding to the lower layer coil end portion 4b. Can be bent with the corner portion of the pallet 13 (the corner portion 25b formed by the bottom surface of the recess 25 and the side surface of the workpiece receiver 23) as a fulcrum, and the inner side surface of the bent portion. Is brought into contact with the side surface of the pallet 13 to improve the positional accuracy and bending angle (substantially right angle) of the bent portion.
In the above embodiment, as the positioning means for the pallet 13 with respect to the mold 12, the positioning pins 20 are provided in the upper mold 17 and the positioning holes 29 are formed in the pallet 13. That is, the positioning hole 29 may be formed in the upper mold 17 and the positioning pin 20 may be provided in the pallet 13. Further, the positioning hole 29 is not necessarily formed through the pallet 13.
[Brief description of the drawings]
FIG. 1A is a plan view of a pallet, and FIG. 1B is a cross-sectional view taken along line AA of the pallet shown in FIG.
FIG. 2 is a BB cross-sectional view of the pallet.
FIG. 3 is a half sectional view of an armature.
FIG. 4 is an exploded perspective view of an armature.
FIG. 5 is a cross-sectional view taken along the line CC of FIG.
FIG. 6 is a process diagram for forming a coil material.
FIG. 7 is a process diagram for forming a lower layer coil conductor.
FIG. 8 is a front view of the manufacturing apparatus.
FIG. 9 is a side view of the manufacturing apparatus.
FIG. 10 is a front view showing an operating state of the manufacturing apparatus.
[Explanation of symbols]
1 Armature 3 Armature core 3a Slot 4 Lower coil conductor (armature coil)
4a Lower coil side 4b Lower coil end 5 Upper coil conductor (armature coil)
5a Upper coil side 5b Upper coil end 6 Inner disk-shaped insulator (first insulator)
7 Outer disk-shaped insulator (second insulator)
11 Coil material 12 Mold 13 Pallet 15 Lower mold 17 Upper mold 20 Positioning pin 25 Recess (groove)
29 Positioning hole

Claims (5)

An armature core having a predetermined number of slots on the outer periphery;
A predetermined number of lower layers that have a lower layer coil side and a pair of lower layer coil ends extending substantially at right angles from both ends of the lower layer coil side, and are assembled to the armature core by inserting the lower layer coil side into the slot A coil conductor;
The armature core has an upper layer coil side and a pair of upper layer coil ends extending substantially at right angles from both ends of the upper layer coil side, and the upper layer coil side is inserted into the slot after the lower layer coil side. In an armature of a rotating electrical machine having a predetermined number of upper layer coil conductors assembled to
A rectangular wire coil material having a predetermined length necessary for manufacturing the lower layer coil conductor or the upper layer coil conductor is prepared, and the lower layer coil conductor or the upper layer coil conductor is formed from the coil material through a plurality of forming steps. A manufacturing method for manufacturing
Wherein each of a plurality of molding processes are used, a plurality of molds that have a and vertically relative movable upper and lower molds,
The plurality of molds are disposed between the upper mold and the lower mold, and are provided so as to be positioned at predetermined positions of the upper mold or the lower mold, and the coil material is molded by the mold. When performing, comprising a pallet that holds a predetermined portion of the coil material,
While maintaining the predetermined portion of the coil material in the pallet, said at a plurality of molds, the relative movement of each of the upper and lower molds, characterized in that simultaneously sequential predetermined molding the positioning of the pallet A method for manufacturing an armature coil. It is a manufacturing apparatus used for the manufacturing method of the armature coil described in Claim 1,
The pallet has a lower layer side pallet used when molding the lower layer coil conductor, and an upper layer side pallet used when molding the upper layer coil conductor,
The lower layer side pallet has a set of first widths whose width dimension is interposed between both end surfaces of the armature core and between the end surface of the armature core and the lower coil end portion and insulates both. A slot-shaped groove that is provided in the same length as the insulator plus a thickness, and that receives a predetermined portion of the coil material, is provided in the entire lateral width of the lower pallet, and both side surfaces in the lateral width direction of the groove It is formed substantially perpendicular to the bottom surface, and the height from the bottom surface of the groove portion to the pallet bottom surface is provided more than the length of the lower coil end,
The upper layer side pallet has a width dimension between a length between both end faces of the armature core, a thickness of the pair of first insulators, a thickness of the pair of lower layer coil ends, and a lower layer coil end part. A slot-shaped groove that is provided between the end of the upper layer coil and has the same length as the sum of the thickness of a pair of second insulators that insulate the two layers, and receives a predetermined portion of the coil material. Is provided on the entire lateral width of the upper pallet, and both side surfaces in the lateral width direction are formed substantially perpendicular to the bottom surface of the groove, and the height from the bottom surface of the groove to the pallet bottom is the height of the end of the upper coil. An apparatus for manufacturing an armature coil, wherein the apparatus is provided longer than the length. The lower pallet is
The corner portion serving as a fulcrum when bending the portion corresponding to the lower coil end of the coil material is given R having a smaller radius of curvature than the corner portion of the first insulator,
The upper pallet is
The corner portion serving as a fulcrum when the portion corresponding to the end portion of the upper layer coil of the coil material is bent is provided with an R having a smaller radius of curvature than the corner portion of the second insulator. Item 3. The armature coil manufacturing apparatus according to Item 2. In the lower pallet, the corner formed by the bottom surface and the side surface of the groove is provided with R having a larger radius of curvature than the corner formed by the bottom surface and the side surface of the slot of the armature core. The armature coil manufacturing apparatus according to claim 2 or 3, characterized in that: After placing the pallet in a predetermined position before Symbol upper mold or the lower mold, as a positioning means for positioning said lower mold or upper mold and its pallet,
Two or more positioning holes or positioning pins are provided at a predetermined position of the pallet, and positioning pins or positioning holes that are fitted to the positioning holes or positioning pins are provided at predetermined positions of the lower mold or the upper mold. The manufacturing apparatus of the armature coil in any one of Claims 2-4.

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