JP6111135B2 - Twist bending machine - Google Patents

Description

  The present invention relates to a twist bending apparatus, and more particularly to an apparatus for twisting and bending an end of a conductor when a rotating electrical machine is manufactured.

  Conventionally, an apparatus for twisting and bending an end portion of a conductor (coil segment) protruding from a slit formed side by side in the circumferential direction of the stator core has been proposed. For example, Patent Document 1 describes a device that holds a conductor end using a cylindrical jig (guide) and twists the conductor end by rotating the jig.

  In the apparatus described in Patent Document 1, the conductor end portion is inserted into the groove of the jig, and when the jig rotates in the circumferential direction, the conductor end is held in the groove by the circumferential thrust and the reaction force thereto.

JP-A-60-241748

  However, the position of the conductor end protruding from the slit of the stator core is not always at a predetermined position, and an inevitable error occurs. Therefore, it is conceivable to increase the size of the groove in order to ensure that the conductor end is inserted into the groove (holding part). However, in this case, there is a problem that the gap between the conductor and the inner wall surface of the groove is increased, and the shape of the end portion of the conductor is not predetermined.

  The present invention has been made in view of the above points, and an object of the present invention is to provide a twist bending apparatus in which a conductor end portion can be reliably inserted into a holding portion and a shape of the conductor end portion can be predetermined. .

The present invention provides an apparatus for bending Ri twisting the ends of the conductors protruding from the stator core slot in the rotary electric machine, the holding portion the ends of the conductors are inserted to hold is arranged in the circumferential direction, axial direction, and A cylindrical holding jig that is movable in the circumferential direction; and a driving means that moves the holding jig in the circumferential direction and the axial direction relative to the stator core, wherein the holding part includes an entrance portion, A rear portion and an intermediate portion located between the entrance portion and the back portion, and in the entrance portion, the drive means moves the holding jig in the circumferential direction relative to the stator core. The inner wall shape of the holding portion is different from the inner wall shape of the holding portion on the side opposite to the moving direction side, and the cross section of the back portion is in the traveling direction of the holding portion compared to the cross section of the intermediate portion. this width is large The features.

  According to the present invention, the inner wall shape of the holding portion on the moving direction side is different from the inner wall shape of the holding portion on the opposite side to the moving direction side. Thereby, the inner wall shape of a holding | maintenance part can be made into the shape suitable for each aptitude on the moving direction side and the opposite side to the moving direction side.

  When the holding jig is moved in the circumferential direction with respect to the stator core by the driving means, the inner wall on the side opposite to the moving direction side of the holding portion receives thrust, and the inner wall on the moving direction side of the holding portion receives reaction force. Therefore, for example, the inner wall on the side opposite to the moving direction side of the holding portion may have a shape that follows the shape of the conductor end after twisting so that the twisted bending shape of the conductor end can be obtained with high accuracy. . On the other hand, the inner wall on the moving direction side of the holding portion may have a portion that receives a reaction force and a shape that facilitates insertion of the conductor end portion into the holding portion.

  Specifically, in the present invention, the entrance portion of the holding portion on the moving direction side is tapered, and the entrance portion of the holding portion on the opposite side to the moving direction side has a plane parallel to the axial direction. You may have.

The perspective view which shows an example of the stator of the rotary electric machine manufactured using the twist bending apparatus of this invention. The perspective view which shows a coil segment. (A) is a perspective view which shows the protrusion part of a coil segment, (b) shows the part for one phase, respectively. The perspective view which shows the state which aligned the coil segment in the circumferential direction. The schematic cross section which shows the twist bending apparatus which concerns on this embodiment. The expanded sectional view which shows a holding | maintenance part. The enlarged view which shows the shape of a through-hole. The figure explaining drawing of the profile of a through-hole.

  First, an example of the structure of a rotating electrical machine manufactured using the twist bending apparatus of the present invention will be described with reference to FIGS.

  A rotating electrical machine such as an electric motor or a generator includes a stator 1 formed in a cylindrical shape and a rotor (not shown) that is rotatably disposed inside the stator 1.

  The stator 1 includes a stator core 2 and a coil 3. The stator core 2 has a cylindrical shape, and a plurality of slots 2a penetrating in the rotation axis direction are provided at intervals in the circumferential direction. Each slot 2 a is formed such that the radial cross-sectional shape of the stator core 2 extends radially from the center side of the stator core 2 toward the radial direction, and the inner periphery of the stator core 2 is formed through slits 2 b formed in the stator core 2. It communicates with the surface. The slit 2b may not be provided.

  The coil 3 is configured by inserting the coil segment 4 shown in FIG. 2 into the slot 2a from one side, and twisting and bending the protruding portion protruding from the other side of the slot 2a in the circumferential direction. A plurality of coil segments 4, in the embodiment, four conductors (rectangular wires) having a rectangular cross section are aligned in one row so that the wider surface faces each other, and are formed into one bundle in a U-shape. It is formed and comprises a pair of leg portions 4a, 4a and a head portion 4b that connects one end (the upper end in the figure) of both leg portions 4a, 4a.

  The coil segment 4 may be a bundle in which a plurality of rectangular wires are aligned in the width direction. For example, the coil segment 4 is an array in which a plurality of rectangular wires are aligned in a row so that the narrower surfaces face each other. There may be.

  At the center of the head 4b, an S-shaped portion 4c that is curved in an S-shape in the alignment direction of the rectangular wires is formed. The head 4b is inclined downward from the center (the center of the S-shaped portion 4c) toward both the leg portions 4a and 4a. The leg portions 4a of the coil segments 4 are inserted into the corresponding slots 2a from one side. The leg 4a of the coil segment 4 protrudes from the other side of the slot 2a.

  The protruding portion 4d of the leg 4a protruding from the other of the slot 2a is twisted and bent in the circumferential direction of the stator 1 as shown in FIG. 3A, and the tip portions 4e of the corresponding protruding portions 4d are TIG welded or the like. It is joined with. The coil 3 according to the present embodiment is a three-phase coil composed of a U phase, a V phase, and a W phase, and the leg portions 4a of the coil segments 4 inserted into the slots 2a have a U phase, They are arranged in the order of phase, V phase, V phase, W phase, and W phase. FIG. 3B shows only one-phase coil (for example, U-phase coil) of the three phases.

  Next, the manufacturing method of the coil segment 4 is demonstrated.

  First, a plurality of, in the embodiment, four rectangular wires are arranged in a row so that the wider surfaces face each other to form one bundle of rectangular wires. Next, the central portion of the flat wire bundle is bent into an S shape to form the S shape portion 4c. Next, it is necessary to bend the rectangular wire bundle along the circumferential direction of the stator core 2. This is because the slots 2a are arranged at intervals in the circumferential direction.

  Next, the flat wire bundle is curved so as to incline downward from the center (the center of the S-shaped portion 4c). Next, both ends of the flat wire bundle are bent downward to form the legs 4a, 4a. In this way, the coil segment 4 shown in FIG. 2 is formed.

  The coil segments 4 formed as described above are aligned so as to partially overlap in the circumferential direction corresponding to the positions of the slots 2a (see FIG. 4), and the leg portions 4a are inserted into the slots 2a of the stator core 2. Is done. The leg portion 4a is designed to protrude by a preset length below the slot 2a.

  The linear protruding portion 4d of the leg portion 4a protruding from the lower side of the slot 2a is twisted in the circumferential direction by the torsion bending apparatus 10 according to the embodiment of the present invention. The straight tip portion 4e of the projecting portion 4d twisted and bent is joined to the adjacent tip portion 4e by TIG welding or the like. In this way, the stator 1 in which eight layers (eight) of coil segments 4 are stacked in the radial direction is completed. Here, the layers are arranged in the order of one layer, two layers,..., Eight layers from the radially outer side to the inner side.

  Hereinafter, the twist bending apparatus 10 of the present invention will be described with reference to FIGS.

  The twist bending apparatus 10 is an apparatus for twisting and bending a protruding portion (hereinafter referred to as a coil end) 4d of the coil segment 4 protruding from the slot 2a. Note that the length of the coil end 4d, that is, the length of the linear protruding portion 4d before twisting, becomes longer as it goes outward in the radial direction.

The torsional bending apparatus 10 includes a support 11, two rotating bodies 12 and 13, a rotation driving unit 14, and holding jigs 15-1 to 15-4 and 16-1 to 16-4 corresponding to the coil ends 4 d of each layer. (Hereinafter, these are also simply referred to as “holding jigs 15 and 16”.) The support body 11 including the two connecting rods 17 and 18, the fixing rod 19, and the stator core holding body 21 has an upper end portion. Fixed to the ceiling, etc.

  The two rotators 12 and 13 are configured to be rotatable with respect to the support 11. Here, the inner rotating body 12 is rotatably provided with respect to the support body 11 and the outer rotating body 13 is rotatably provided with respect to the inner rotating body 12 via bearings.

  The rotation driving means 14 rotates the inner rotator 12 and the outer rotator 13 in opposite circumferential directions. Here, the rotation driving means 14 rotates the inner rotating body 12 clockwise and the outer rotating body 13 counterclockwise. The rotation driving means 14 is an electric motor, and rotates the inner rotator 12 and the outer rotator 13 via a gear train.

  The holding jigs 15 and 16 are four odd-layer holding jigs 15-1 to 15-4 respectively corresponding to a plurality of odd-numbered layers, here, one-layer, three-layer, five-layer, and seven-layer coil ends 4d. And four even layer holding jigs 16-1 to 16-4 respectively corresponding to the coil ends 4d of a plurality of even layers, here, 2, 4, 6 and 8 layers. . Each holding jig 15, 16 has a cylindrical shape with a step, and is arranged concentrically in the layer order.

  The odd layer connecting rod 17 is fixed to the outer rotating body 13 and connects the four odd layer holding jigs 15-1 to 15-4. Specifically, an elliptical through-hole with the axial direction of the outer rotating body 13 as the longitudinal direction is formed at the tip of the upper part of the odd layer holding jigs 15-1 to 15-4, One odd layer connecting rod 17 is inserted through all of these through holes. Accordingly, as the outer rotating body 13 rotates, the four odd-layer holding jigs 15-1 to 15-4 are independently movable in the axial direction and simultaneously rotate by the same angle.

  The leading end portions where the through holes of the odd layer holding jigs 15-1 to 15-4 are formed are located above the tips of the adjacent even layer holding jigs 16-1 to 16-4. The layer connecting rod 17 does not interfere with the even layer holding jigs 16-1 to 16-4.

  The even layer connecting rod 18 is fixed to the inner rotating body 12 and connects the four even layer holding jigs 16-1 to 16-4. Similarly to the odd-numbered layer connecting rod 17, the even-numbered layer connecting rod 18 is inserted through oval through holes formed in the upper ends of the even-numbered layer holding jigs 16-1 to 16-4. Yes. Thereby, with the rotation of the inner rotating body 12, the four even-layer holding jigs 16-1 to 16-4 are independently movable in the vertical direction and are simultaneously rotated by the same angle.

  The tip end portions in which the through holes of the even layer holding jigs 16-1 to 16-4 are formed are located above the tips of the adjacent odd layer holding jigs 15-1 to 15-4, and are even numbers. The layer connecting rod 18 does not interfere with the odd layer holding jigs 15-1 to 15-4. The holding jigs 15 and 16 may be formed with oval cutouts whose upper ends are opened with the axial direction as the longitudinal direction, instead of the oval through holes.

  As shown in FIG. 6, each holding jig 15, 16 has a holding portion 15 a, 16 a that is held by inserting the tip portion 4 e of the coil end 4 d into the lower end surface. The holding portions 15a and 16a are formed in the same number as the slot 2a and aligned in the circumferential direction.

  In addition, the lower end surfaces of the holding jigs 15 and 16 are positioned on the upper side of the holding jigs 15 and 16 positioned on the outer side in the radial direction in accordance with the length of the coil end 4d. Thereby, the length of the front-end | tip part 4e of the coil end 4d inserted in holding | maintenance part 15a, 16a becomes fixed.

  Each holding part 15 a, 16 a has a rectangular cross section in accordance with the rectangular cross section of the coil segment 4.

  However, the entrance portions of the holding portions 15 a and 16 a on the traveling direction side of the holding jigs 15 and 16 have a tapered portion 31. Thereby, the entrance part of holding | maintenance part 15a, 16a is expanded, and the front-end | tip part 4e of the coil end 4d becomes easy to enter. On the other hand, the entrance portions of the holding portions 15a, 16a opposite to the traveling direction side of the holding jigs 15, 16 are surfaces 32 that are parallel to, or perpendicular to, the axial direction.

  And the cross section is expanded in the inner part of holding | maintenance part 15a, 16a. Thereby, the back end of the intermediate part of holding part 15a, 16a becomes a supporting point of reaction force, and it is prevented that coil end 4d inserted in holding part 15a, 16a jumps out.

  The tapered portion 31 is linear in FIG. 6, but may be curved. Moreover, a vertical surface may exist in the entrance part of holding | maintenance part 15a, 16a by the side of the advancing direction of the holding jigs 15 and 16, and a taper part may be provided in the back.

  Furthermore, through holes 15b and 16b having different shapes as shown in FIG. 7 are formed on the outer peripheral surfaces of the holding jigs 15 and 16, respectively. The through holes 15b and 16b gradually extend in the axial direction toward the circumferential direction. A fixed bar 19 made of a round bar that passes through the through holes 15 b and 16 b is fixed to the support 11.

  The profiles of the through holes 15b and 16b formed in the holding jigs 15 and 16 are determined according to the shape of the coil end 4d that is twisted and bent by the holding jigs 15 and 16, respectively.

  Specifically, for example, as shown in FIG. 8, the coil ends 4d before twisting (straight), during twisting, and after twisting are plotted along the course of twisting, The movement locus L of the tip portion 4e of 4d is obtained. Then, the outer shape of the through hole 15b, 16b may be determined by drawing the outer shape in which the fixed rod 19 moves around the movement locus L thus obtained.

  The drawing is preferably set so that the tip surfaces of the tip portions 4e of the coil ends 4d of each layer after twist bending are flush with each other. With this setting, performance such as magnetic flux density of the rotating electrical machine is improved.

  When the rotating bodies 12 and 13 are rotated, the holding jigs 15 and 16 slide in the inner surfaces of the through holes 15b and 16b with respect to the fixed rod 19, respectively, so that the profiles of the through holes 15b and 16b are obtained. Move down by the amount you imitate.

  The innermost holding jig 15-1 has its inner peripheral surface restricted by the outer peripheral surface of the support 11 to move radially inward. As described above, the outer peripheral surface of the support 11 functions as a guide portion that guides the inside of the holding jigs 15 and 16.

  Further, the outermost holding jig 16-4 has its outer peripheral surface restricted by the inner peripheral surface of the annular guide body 22 fixed to the support body 11 and the fixing rod 19, and is restricted from moving radially outward. ing. Thus, the guide body 22 functions as a guide portion that guides the outside of the holding jigs 15 and 16.

  The stator core holding body 21 holds the stator core 2 in which the leg portions 4a of the coil segments 4 are inserted into the slots 2a. The stator core holder 21 is configured to be movable up and down with respect to the support 11 by lifting means (not shown).

  Hereinafter, a method for twisting and bending the coil end 4d using the twist bending apparatus 10 of the present invention will be described.

  First, the stator core 2 in which the leg 4a of the coil segment 4 is inserted into the slot 2a is held by the stator core holding body 21.

  Next, the stator core holding body 21 is raised by the elevating means, and the tip end portions 4e of the segment coils are inserted into the holding portions 15a and 16a of the holding jigs 15 and 16, respectively. Thereby, the front-end | tip part 4e of each segment coil is hold | maintained at holding | maintenance part 15a, 16a. The length of the tip portion 4e inserted into the holding portions 15a and 16a is constant regardless of the layer.

  Next, the rotation driving means 14 simultaneously rotates the inner rotary body 12 and the outer rotary body 13 in opposite circumferential directions. Here, the inner rotating body 12 is rotated counterclockwise, and the outer rotating body 13 is rotated clockwise. In addition, you may rotate the inner side rotary body 12 and the outer side rotary body 13 sequentially.

  As the outer rotating body 13 rotates clockwise, the four odd layer holding jigs 15-1 to 15-4 rotate clockwise by the same angle while following the profile of each through hole 15b. The holding jigs 15-1 to 15-4 move in the axial direction (downward). As a result, the coil ends 4d held by the holding portions 15a of the holding jigs 15-1 to 15-4 are twisted downward while being bent clockwise in accordance with the profiles of the respective through holes 15b.

  Further, as the inner rotating body 12 rotates counterclockwise, the four even-layer holding jigs 16-1 to 16-4 rotate counterclockwise by the same angle while changing the profile of each through hole 16b. Following this, each holding jig 16-1 to 16-4 moves in the axial direction (downward). As a result, the coil ends 4d held by the holding portions 16a of the holding jigs 16-1 to 16-4 are twisted downward while being bent counterclockwise following the profile of each through-hole 16b.

  In this manner, through holes 15b and 16b having different shapes are formed on the outer peripheral surfaces of the holding jigs 15 and 16, and the fixing rod 19 is inserted into the through holes 15b and 16b. As a result, when the rotary bodies 12 and 13 are rotated by the rotation driving means 14, the holding jigs 15 and 16 rotate in the circumferential direction and move downward along the profiles of the respective through holes 15b and 16b. To do.

  Therefore, by rotating the holding jigs 15 and 16 via the rotating bodies 12 and 13 by the rotation driving means 14, the holding jigs 15 and 16 can be moved by an appropriate axial distance to each layer, respectively. .

  When the holding jigs 15 and 16 rotate, the inner wall surfaces 33 of the holding portions 15a and 16a on the traveling direction side receive a reaction force with reference to FIG. As the reaction force is further away from the fulcrum A of the coil segment 4, the moment acting on the fulcrum A becomes larger, so even if the entrance portion has the tapered portion 31, the reaction force is not significantly affected.

  On the other hand, since the entrance portions of the holding portions 15a and 16a opposite to the traveling direction side are the vertical surfaces 32, the root portion of the tip portion 4e of the coil end 4d can be a starting point for twisting and bending. Moreover, since the cross section of the intermediate portion of the holding portions 15a and 16a is substantially the same as the cross section of the tip portion 4e and has a certain length, the tip portion 4e is within the holding portions 15a and 16a. Since it does not skew, the front-end | tip part 4e can be made into a linear shape.

  DESCRIPTION OF SYMBOLS 1 ... Stator, 2 ... Stator core, 2a ... Slot, 2b ... Slit, 3 ... Coil, 4 ... Coil segment, 4a ... Leg part, 4b ... Head part, 4d ... Projection part, Coil end, 4e ... Tip part, 10 ... Twisting and bending apparatus, 11 ... support, 12 ... rotating body, inner rotating body, 13 ... rotating body, outer rotating body, 14 ... rotation driving means (driving means), 15, 15-1 to 15-4 ... holding jig , Odd layer holding jig 16, 16-1 to 16-4 ... holding jig, even layer holding jig, 15a, 16a ... holding part, 15b, 16b ... through hole, 17 ... connecting rod, odd layer Connecting rod 18, connecting rod, even layer connecting rod 19 fixed rod 21 stator core holding body 22 guide body 31 tapered portion 32 vertical surface 33 inner wall surface

Claims (2)

An apparatus for bending Ri twisting the ends of the conductors protruding from the rotary electric machine stator core slots,
A cylindrical holding jig in which holding portions to which the end portions of the conductors are inserted and held are provided in the circumferential direction and are movable in the axial direction and the circumferential direction;
Drive means for moving the holding jig relative to the stator core in the circumferential direction and the axial direction;
The holding part is composed of an entrance part, a back part, and an intermediate part located between the entrance part and the back part,
In the entrance portion, the inner wall shape of the holding portion on the moving direction side that moves the holding jig in the circumferential direction with respect to the stator core by the driving means, and the inner wall of the holding portion on the opposite side to the moving direction side The shape is different ,
The torsional bending apparatus characterized in that the cross section of the inner part has a larger width in the traveling direction of the holding part than the cross section of the intermediate part .   The entrance portion of the holding portion on the moving direction side is tapered, and the entrance portion of the holding portion on the opposite side to the moving direction side has a plane parallel to the axial direction. The twist bending apparatus according to 1.