JP5436397B2 - Winding end forming apparatus and method - Google Patents

Description

  The present invention relates to an apparatus and method for forming an end of a winding, and more particularly to an apparatus and method for forming an end of a winding of a coil member using a rectangular wire.

  Conventionally, a brushless motor in which a plurality of divided cores each having a conducting wire wound around a winding frame are arranged in an annular shape is known. When the conducting wire is a flat wire, when the conducting wire is bent to be crimped to the electrode after the winding process, it is necessary to grip the end of the conducting wire and move it with a complicated operation.

  For example, Patent Document 1 discloses that a nozzle that grips an end of a conducting wire is rotated to twist the conducting wire, bent in a twisted state, and pushed into the groove of the electrode. Specifically, after the winding process is completed, the nozzle for supplying the conductor is moved in the lateral direction without cutting the winding termination of the conductor, and then the nozzle is rotated to twist the winding termination of the conductor. . Next, the nozzle is moved to the lower side of the winding frame in the rotated position, and the winding end portion of the conducting wire twisted in the vicinity of the groove of the winding frame is hooked on the end portion of the groove and bent. Thereby, the conducting wire enters the inside of the groove of the reel. Next, the nozzle is moved to the outer peripheral surface side of the winding frame, and the conducting wire is pushed into the groove of the winding frame.

JP 2007-250801 A

  However, in the method described in Patent Document 1, there is a step of twisting the conducting wire. Therefore, the operation | movement which twists conducting wire is needed, and while the time which winding end part shaping | molding becomes long, the subject that size reduction and simplification of an apparatus become difficult occurs.

  In view of the above, an object of the present invention is to provide a winding end portion forming method and apparatus in which the time required for forming a winding end portion is shortened and the apparatus can be downsized and simplified.

  In the winding end forming method of the present invention, the end of the wire having a rectangular cross section wound around the winding frame is inserted into the recess of the electrode so that the wide surface side is the outer peripheral surface side of the winding frame. A forming method, the step of gripping the wide surface of the end portion of the conducting wire from both sides so that the gripped conducting wire is rotatable within the wide surface, and the winding portion of the winding portion of the conducting wire. In the state of pressing to the outer peripheral surface side of the frame, the step of causing the end portion of the gripped lead wire to rotate in the wide surface direction, and the portion adjacent to the end portion of the winding portion of the lead wire in the narrow surface direction A step of moving the end portion of the lead wire raised so as to be bent, and inserting the end portion of the lead wire into the concave portion of the electrode.

  According to the method for forming a winding end of the present invention, the winding end portion is twisted as a result without including a step of positively twisting the conducting wire by rotating about the axis in the direction in which the conducting wire extends (axis perpendicular to the rectangular cross section). A conducting wire can be inserted into the recess of the electrode. Therefore, compared with the method described in the cited document 1, it is possible to shorten the time required for forming the winding end.

  The winding end forming apparatus according to the present invention includes a winding end portion that inserts an end portion of a conducting wire having a rectangular cross section wound around the winding frame into a recess of the electrode so that the wide surface side is the outer peripheral surface side of the winding frame. A molding apparatus, a gripping part for gripping the wide surface of the end of the conductive wire from both sides so that the gripped conductive wire is rotatable within the wide surface, a moving unit for moving the gripping part, A pressing portion that presses and holds the conducting wire to the outer peripheral surface side of the winding frame; and a control portion that controls the moving portion and the pressing portion, and the control portion includes a winding portion of the conducting wire. In a state where the terminal portion is pressed, the end portion of the conducting wire gripped by the gripping portion is rotated and raised in the wide surface direction, and then a portion adjacent to the terminal end portion of the winding portion of the conducting wire is formed in the narrow surface direction. The moving part and the pressing part are controlled so that the grip part moves so as to be bent That.

  According to the winding end portion forming device of the present invention, the winding end forming apparatus includes the gripping portion that grips the wide surface of the end portion of the conducting wire from both sides so that the conducting wire can rotate within the wide surface. It is possible to bend the conducting wire by moving the gripping portion with the moving portion while the end portion of the conducting wire rotates freely within the wide surface.

  Therefore, since a mechanism for twisting the lead wire by rotating it around the axis in the direction in which the lead wire extends is not required, the apparatus is smaller than the case described in the cited document 1 that requires such a mechanism. And simplified.

The front view of the coil components used by embodiment of this invention. The front view which shows roughly the state which extended the winding termination | terminus part of the conducting wire wound by the winding frame in the horizontal direction. The front view which shows schematically the state which rotated the winding termination | terminus part of the conducting wire shown in FIG. 2 to the near side. FIG. 4 is a front view schematically showing a state in which a winding end of the conducting wire shown in FIG. 3 is rotated downward and pushed into a recess. The schematic perspective view which shows the coil | winding edge part shaping | molding apparatus which concerns on embodiment of this invention. The perspective view which shows the holding part of a coil | winding edge part shaping | molding apparatus.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  The winding end portion forming method of this embodiment is for forming the winding end portion of the coil component 10 shown in FIG. For example, the coil component 10 is a divided core that is arranged in a ring shape and constitutes a stator of a rotating electrical machine such as a hybrid vehicle or an electric vehicle.

  The coil component 10 includes a winding frame 11 formed of an assembly of a laminated steel plate (not shown) in which a plurality of substantially T-shaped steel plates are integrated and an insulating bobbin (insulator) externally fitted to the laminated steel plate, It has a conducting wire (winding) 12 wound around a winding frame 11 and metal electrodes (terminals) 13 and 14.

  The conducting wire 12 is a rectangular wire having a substantially rectangular cross section covered with an insulating coating, and has a wide surface corresponding to the long side of the rectangular cross section and a narrow surface corresponding to the short side. The conducting wire 12 is wound around the winding frame 11 so that the wide surface side is on the winding frame 11 side.

  On the reel 11, a lower flange 15 and an upper flange 16 are formed at the lower end and the upper end of the body part around which the conducting wire 12 is wound. Each of the flanges 15 and 16 is formed with grooves (slits) 15a and 16a for drawing out the winding end portion 12a and the winding start end portion 12b of the conducting wire 12 from the body side.

  The lower electrode 13 is located below the lower flange 15, and a recess 13a (see FIG. 2) in which the winding terminal portion 12a of the conducting wire 12 enters and is fixed is formed directly below the groove 15a. The conducting wire 12 has its winding end portion 12 a inserted into the recess 13 a of the lower electrode 13 via the groove 15 a and is caulked to be connected to the lower electrode 13.

  The upper electrode 14 is located above the upper flange 16, and a recess 14a (see FIG. 2) in which the winding start end portion 12b of the conducting wire 12 enters and is fixed is formed directly above the groove 16a. The conducting wire 12 has its winding start end portion 12 b squeezed into the concave portion 14 a of the upper electrode 14 via the groove 16 a and is connected to the upper electrode 14.

  Hereinafter, the winding edge part shaping | molding method which concerns on embodiment of this invention is demonstrated.

  First, as shown in FIG. 2, in the first step, after the winding of the conducting wire 12 around the winding frame 11 is completed, the conducting wire 12 is temporarily cut at a position away from the outer peripheral surface of the winding frame 11. Thereby, the winding termination | terminus part 12a which is an edge part by the side of the winding end of the conducting wire 12 is formed.

  Next, in the second step, rotation around the center of the gripping portion is performed by sandwiching the wide surface of the winding terminal portion 12a of the conductive wire 12 from both sides so that the gripped conductive wire 12 can rotate within the wide surface. The conducting wire 12 is grasped by the grasping portion 40 (see FIG. 5) in the permitted state.

  Next, in the third step, the gripping portion 40 is moved while maintaining the state where the winding end portion 12a is gripped, and the lead wire 12 is linearly stretched by pulling in the lateral direction so that the lead wire 12 is tensioned. Then, the winding end portion of the conducting wire 12 is pressed against the reel 11 side.

  Next, as shown in FIG. 3, in the fourth step, the terminal portion of the winding portion of the conducting wire 12 is pressed against the outer peripheral surface side of the winding frame 11 by the pressing jig (pressing portion) 21. The pressing jig 21 is formed of a moderately hard material, but the corners are rounded so that the insulating coating is not damaged even if it contacts the conductor 12. And the holding | grip part 40 is rotated only 90 degree | times centering on the winding end part of the conducting wire 12 to the near side. Thereby, the conducting wire 12 is raised 90 degrees in the wide surface direction (the front side of the drawing) with the portion adjacent to the portion pressed by the pressing jig 21 as the root portion, and the root portion of the conducting wire 12 is the corner of the pressing jig 21. It will be in the state bent with the small curvature radius along the part.

  Next, as shown in FIG. 4, in the fifth step, the grip portion 40 is rotated by 90 degrees in the narrow surface direction (lower side of the drawing) around the root portion of the conducting wire 12. At this time, the linear portion of the conducting wire 12 is rotated while being pulled so that the conducting wire 12 is tensioned so that the straight line state is maintained. As a result, the portion of the conducting wire 12 adjacent to the end portion of the winding portion is twisted as a result, the winding end portion 12a of the raised conducting wire 12 bends 90 degrees downward, and the conducting wire 12 becomes the groove 15a. Get inside. In other words, the pressing jig 21 is pressed against the conductor 12 at a position where the conductor 12 bent downward enters the groove 15a.

  At this time, the conducting wire 12 that has entered the groove 15 a is pushed into the outer peripheral surface of the winding frame 11 by the pushing jig 22. Thereby, the conducting wire 12 enters to the back of the recess 13 a of the lower electrode 13.

  Thereafter, although not shown, in the sixth step, the lower electrode 13 is crimped using a caulking tool such as pliers, and the conducting wire 12 is fixed to the lower electrode 13. Thereby, the conducting wire 12 is connected to the lower electrode 13. Thereafter, in a seventh step, the winding end portion 12a is cut at a predetermined position using a cutting tool such as a nipper. Thereby, the shaping | molding of the coil | winding end part 12a is completed.

  Further, the winding start end portion 12b is also molded at the end portion in the same manner as the winding end portion 12a. However, since the winding start part 12b of the conducting wire 12 is covered with the conducting wire 12 wound on the outside, it is not necessary to press the pressing jig 21. Thereby, winding end part shaping | molding is all completed and the coil component 10 shown in FIG. 1 is completed.

  As described above, according to the winding end portion forming method according to the present embodiment, as a result, the method does not include the step of positively twisting the lead wire 12 by rotating it around the axis in the direction in which the lead wire 12 extends. The conducting wire 12 can be inserted into the recess 13a of the lower electrode 13 through the groove 15a. Therefore, compared with the method described in the cited document 1, it is possible to shorten the time required for forming the winding end.

  Further, unlike the method described in the cited document 1, it is not necessary to bend the conductor 12 while it is hooked on the end of the groove, and the conductor 12 is held in the gripper 40 in a state where rotation around the center of the gripper is allowed. (See FIG. 5), it is possible to eliminate the risk of the insulating coating being damaged.

  Hereinafter, the winding edge part shaping | molding apparatus 30 which concerns on embodiment of this invention is demonstrated.

  Although not shown in detail, the winding end forming apparatus 30 is included in, for example, a station core manufacturing apparatus disclosed in Japanese Unexamined Patent Application Publication No. 2009-99908. The station core manufacturing apparatus has four stations obtained by dividing the process required for winding, and can manufacture the coil component 10 shown in FIG. 1 at a high speed.

  Although not shown, the station core manufacturing apparatus causes the reel 11 to be gripped by the reel gripping jig, the coil 12 is wound around the reel 11, and the coil is a finished product in which the end of the conductor 12 has been formed. An attachment / detachment station ST1 that removes the component 10 from the reel holding jig, a winding station ST2 that winds the conductor 12 around the reel 11 to form a winding, a winding terminal end 12a and a winding start end of the wound conductor 12 The end forming station ST3 for inserting the portion 12b into the recesses 13a and 14a of the electrodes 13 and 14 and the winding end portion 12a and the winding start end portion 12b of the conducting wire 12 are caulked and fixed to the electrodes 13 and 14, respectively. And an end connection station ST4 for cutting off an excessive end of the conducting wire 12.

  The station core manufacturing apparatus includes a table having a reel holding jig for gripping the reel 11 corresponding to each station provided concentrically and spaced apart by a predetermined angular interval.

  At the attachment / detachment station ST1, the reel 11 is gripped by the reel gripping jig. The reel 11 gripped by the reel gripping jig rotates the table and reaches the winding station ST2.

  At the winding station ST2, the conducting wire 12 is fed out from the nozzle, and the reel 11 is rotated integrally with the reel gripping jig. Thereby, the conducting wire 12 is wound around the winding frame 11.

  When the conducting wire 12 is wound around the reel 11, the table is rotated again, and the reel 11 held by the reel holding jig reaches the end forming station ST3.

  At the end forming station ST3, the winding end portion 12a and the winding start end portion 12b of the conducting wire 12 are inserted into the recesses 13a and 14a of the electrodes 13 and 14, respectively, using the winding end forming device 30. Then, the table is rotated again, and the reel 11 around which the conducting wire 12 is wound reaches the end connection station ST4.

  A crimping tool and a cutting tool are disposed at the end connection station ST4. Using a caulking tool, the winding end portion 12a and the winding start end portion 12b of the conducting wire 12 are caulked to the electrodes 13 and 14, respectively. Next, the winding end portion 12a and the winding start end portion 12b of the conducting wire 12 are cut using a cutting tool.

  Thereafter, the table is rotated again, and the coil component 10 formed with the winding end reaches the attachment / detachment station ST1. Then, the coil component 10 is taken out from the reel gripping jig.

  As shown in FIG. 5, the gripping unit 40 is attached to the tip of a robot hand 31 that is a moving unit. Here, the robot is a four-axis robot installed in the vicinity of the table, and is configured to be capable of three-axis rotational movement and one-axis linear movement. This robot can only perform movement control of the robot hand 31 and cannot perform posture control.

  The winding end forming device 30 includes a control unit (not shown) including a CPU, a ROM, a RAM, an I / O, and the like. The control unit performs movement control of the robot hand 31, and The advance / retreat control of the pressing jig 21 (see FIGS. 3 and 4) is performed.

  As shown in FIG. 6, the gripping part 40 grips by holding the attachment part 50 attached to the tip of the robot hand 31 (see FIG. 5) and the winding terminal part 12 a (see FIGS. 1 to 4) of the conducting wire 12. The holding part 60 which guides, and the guide part 70 which guides the conducting wire 12 are provided.

  The attachment portion 50 is composed of two attachment members 51 and 52 that sandwich the tip of the robot hand 31 from the outside. The gripping portion 40 is fixed to the tip of the robot hand 31 by tightening these mounting members 51 and 52 sandwiching the tip of the robot hand 31 with a bolt 53.

  The holding portion 60 is configured such that the interval (wide or narrow) can be changed by a holding interval setting unit 62 that changes the interval between the pair of holding members 61 and 61 so that the conducting wire 12 can be held. The front end of each clamping member 61 has a rotatable rotating member 63 facing the other rotating member 63 so that the clamped conducting wire 12 can rotate within the wide surface. The rotating member 63 is configured by, for example, a disc-shaped rubber having a rough surface being pivotally supported by the holding member 61.

  The clamping interval setting unit 62 changes the interval between the pair of clamping members 61 and 61. Here, the interval is changed by the cam follower.

  Specifically, a member 64 to which each clamping member 61 is fixed is configured to be slidable along the guide rail 60. And the cam member 66 fixed to the front-end | tip of a piston moves up and down by the up-and-down movement of the piston (not shown) of the cylinder 65. FIG. The cam member 66 is provided with a pair of holes 66a inclined so as to spread outward in the downward direction, and each clamping member 61 is connected to the other end of a rod-shaped follower member (not shown) whose one end enters the holes 66a. The member 64 fixed to is fixed. Thereby, when the piston moves up, the interval between the clamping members 61 becomes narrow, and when the piston moves down, the interval between the clamping members 61 becomes wide.

  The guide unit 70 guides the conducting wire 12 to a position suitable for gripping by the gripping unit 60. The guide portion 70 includes a guide plate 71 having a tip 71a cut out in a triangular shape. The guide unit 70 moves the guide plate 71 down by the guide plate moving unit 72 that moves the guide plate 71 up and down, and positions the conductor 12 at the top of the notch. 12 is guided.

  The guide plate moving unit 72 moves the guide plate 71 up and down by a cylinder 74. Specifically, a cylinder 74 is fixed to a member 75 fixed to the mounting member 52, and a guide plate 71 is fixed to a member 76 to which a piston (not shown) of the cylinder 74 is fixed.

  Further, the pressing jig 22 is attached to the grip portion 40. Thus, in the fifth step, the pushing jig 22 contacts the conductor 12 in the process of rotating the grip 40 in the narrow surface direction and bending the winding end portion 12a of the conductor 12 downward 90 degrees. In contact therewith, the conducting wire 12 is pushed into the outer peripheral surface side of the reel 11.

  As described above, in the winding end portion forming device 30, the rotating member 63 is attached to the tip of each gripping member 61, and the gripping portion is rotated while rotating the rotating member 63 in contact with the winding terminal portion 12 a of the conducting wire 12. It is possible to bend the conducting wire 12 by moving 40.

  For this reason, the winding end forming device 30 does not have a mechanism for twisting the conducting wire 12 so as to rotate around the axis in the direction in which the conducting wire 12 extends, and cannot control the posture of the robot hand 31 4. It can be composed of an axis robot. Therefore, the winding end forming device 30 is reduced in size and simplified as compared with the case where a 6-axis robot for controlling the position and orientation of the nozzle as described in the cited document 1 is necessary.

  Further, unlike the device described in the cited document 1, it is not necessary to bend the conductor 12 in a state where it is hooked on the end of the groove, and the gripping section 40 so that the sandwiched conductor 12 can be rotated within a wide surface. Since the lead wire 12 is gripped, the risk of the insulating coating being damaged can be eliminated.

  Although the embodiment of the present invention has been described above with reference to the drawings, the present invention is not limited to this.

DESCRIPTION OF SYMBOLS 10 ... Coil component, 11 ... Winding frame, 12 ... Conductor, 12a ... Winding terminal part (end part), 13 ... Lower electrode (electrode), 13a ... Recessed part, 14 ... Lower flange, 14a ... Groove, 21 ... Pressing Jig (pressing part), 22 ... Pushing jig, 30 ... Winding end forming device, 31 ... Robot hand (moving part), 40 ... Gripping part, 60 ... Holding part, 61 ... Holding member, 63 ... Rotating member 70 ... Guide part.

Claims (2)

A winding end forming method for inserting an end of a rectangular conductor wire wound around the winding frame into a recess of an electrode so that the wide surface side is the outer peripheral surface side of the winding frame,
Gripping the wide surface of the end of the conductive wire from both sides so that the gripped conductive wire is rotatable within the wide surface;
In a state where the end of the winding portion of the conducting wire is pressed against the outer peripheral surface side of the winding frame, the end of the gripped conducting wire is rotated in the wide surface direction, and is caused to occur,
The end portion of the lead wire is moved so that the portion adjacent to the end portion of the winding portion of the lead wire is bent in the narrow surface direction, and the end portion of the lead wire is inserted into the concave portion of the electrode. A winding end forming method comprising the steps of: A winding end forming device for inserting the end of a rectangular conductor wire wound around the winding frame into the recess of the electrode so that the wide surface side is the outer peripheral surface side of the winding frame,
A gripping part for gripping the wide surface of the end of the conductive wire from both sides so that the gripped conductive wire is rotatable within the wide surface;
A moving unit for moving the gripping unit;
A pressing portion that presses and holds the conducting wire against the outer peripheral surface side of the winding frame; and
A control unit for controlling the moving unit and the pressing unit,
The control unit is configured to cause the end portion of the conducting wire gripped by the gripping portion to rotate in the wide surface direction while the pressing portion presses the terminal end portion of the winding portion of the conducting wire, and then raises the conducting wire. A winding end forming apparatus, wherein the moving portion and the pressing portion are controlled so that the gripping portion moves so as to bend a portion adjacent to a terminal portion of the winding portion in a narrow surface direction. .

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