JP6881732B2 - Coil manufacturing method and coil manufacturing equipment - Google Patents

Description

The present invention relates to a coil manufacturing method and a coil manufacturing apparatus.

The larger the space factor, which is the ratio of the actual cross-sectional area of the strands to the cross-sectional area when the coil is cut on the plane orthogonal to the direction of electricity flow, the larger the current can flow and the motor output. Can be improved.
It is known that the space factor can be improved as compared with the case where a round wire is spirally wound by using a wire having a quadrangular cross section, bending it, and winding it in a spiral shape.
In particular, a flat wire with a rectangular cross section and a flat plate shape is bent with the wide side surface perpendicular to the center line of the coil, and the coil is spirally wound and laminated to further improve the space factor. it can.

In a conventional coil using a wire rod having a quadrangular cross section, such as a coil for a stator core of a motor used in home appliances and automobiles, as described above, it is bent and wound to form a spiral as a whole and laminated. However, as shown in FIG. 11, a gap S1 is generated in the coil center line L direction (stacking direction).
In FIG. 11, reference numeral 100 indicates a stator, 101 indicates a slot, 102 indicates a square coil inserted into the slot 101, and Wa indicates a wire rod having a square cross section.

Explaining the generation of the gap S1 with a flat wire Ws, as shown in FIG. 12A, a compressive force F1 acts on the inner diameter side of the bent portion and a tensile force F2 acts on the outer diameter side when bending. Is. As shown in FIG. 12B, since the inner diameter side of the bent portion is raised by the compressive force, swelling We is generated on the upper and lower surfaces. The bulge We acts as a spacer and a gap S1 is generated.

Even if the square wound shapes formed by bending are laminated, the layers do not adhere to each other due to the gap S1, and the gap S1 is accumulated according to the number of layers, so that the space factor decreases. For example, the height of the bulge due to one bending is about 0.1 mm, but when this is accumulated, it may be about 1 mm as a whole.

In order to deal with this problem, in Patent Document 1, as shown in FIGS. 7 (D) to 7 (F), the movement of the side surface on the inner diameter side to the bending center side is restricted, and the vertical direction on the inner diameter side is restricted. A configuration is disclosed in which a dent is formed before bending by pressing with a pressing member. After forming the dent, the vertical protrusion formed on the edge of the dent is cut by passing it through a die.

JP-A-2007-36056

As described above, when bending a flat wire, a compressive force acts on the inner diameter side of the bent portion, and a tensile force acts on the outer diameter side. Patent Document 1 proposes a method of suppressing only the bulge generated on the inner diameter side of the bent portion, but the outer diameter side of the bent portion becomes thin due to the tensile force.
As shown in FIG. 13, the thin-walled portion Wg on the outer diameter side accumulates in the stacking direction, although it is not as much as the effect of the bulge generated on the inner diameter side during bending, and the space factor of the entire coil is reduced.
In other words, even if the swelling on the inner diameter side during bending is well suppressed, it cannot be said that it is sufficient from the viewpoint of improving the space factor of the entire coil.
In FIG. 13, reference numeral Ws-1 indicates a core wire made of a copper material, and Ws-2 indicates an insulating layer coated on the surface of the core wire (hereinafter, the same applies).
No measures have been taken to reduce the wall thickness on the outer diameter side because it is more difficult to increase the thickness than to form a dent.

The present invention was devised in view of such a current situation, and is capable of suppressing a change in thickness during bending of a flat wire to further improve the space factor, and manufactures a coil that contributes to higher efficiency of the motor. It is an object of the present invention to provide a method and a coil manufacturing apparatus.

In order to achieve the above object, the present invention relates to a coil manufacturing method in which a flat wire having an insulating layer coated on the surface of a core material is bent along a plane orthogonal to the thickness and spirally wound. It is characterized in that the thickness on the inner diameter side of the bent portion is reduced and at the same time the thickness on the outer diameter side is increased during bending.
By doing so, it is possible to absorb the bulge that occurs on the inner diameter side during bending, suppress the thinning that occurs on the outer diameter side, and minimize the change in thickness before and after bending.

By pressing and deforming both planes of the flat wire, the thickness on the inner diameter side may be reduced and at the same time the thickness on the outer diameter side may be increased.

The flat wire may be pressed in a state where the movement of at least one of the inner diameter side side surface and the outer diameter side side surface is restricted.
Since the escape of the wire rod due to pressing can be regulated, the thickness change before and after the bending process can be suppressed with high accuracy.

Both planes of the flat wire are pressed by one flat surface, and each flat surface first comes into contact with the inner diameter side from a state of being obliquely opposed to both planes, and then falls to the outer diameter side. It may be pressed against.
The plastic flow inside the wire can be effectively generated from the inner diameter side to the outer diameter side.

An inclined portion that bends in the thickness direction of the flat wire may be formed at the same portion of each wound layer. The space factor can be further improved in combination with the effect of suppressing the occurrence of swelling on the inner diameter side and thinning on the outer diameter side.

Further, in order to achieve the above object, the present invention is a coil manufacturing apparatus in which a flat wire having an insulating layer coated on the surface of a core material is bent along a plane orthogonal to the thickness and spirally wound. Therefore, a pressing deformation portion that presses and deforms both planes of the flat wire to reduce the thickness on the inner diameter side and at the same time increase the thickness on the outer diameter side at the bending portion during bending, and the flat angle. It is characterized by having a winding portion in which a wire is bent and wound in a spiral shape.
It is possible to absorb the bulge that occurs on the inner diameter side during bending, suppress the thinning that occurs on the outer diameter side, and minimize the change in thickness before and after bending.

The coil manufacturing apparatus may have a regulating means for restricting the movement of at least one of the inner diameter side side surface and the outer diameter side side surface of the flat wire, and may press the flat wire in a regulated state by the regulating means. ..
Since the escape of the wire rod due to pressing can be regulated, the thickness change before and after the bending process can be suppressed with high accuracy.

In the coil manufacturing apparatus, the pressing and deforming portion is provided with flat surfaces that are obliquely opposed to both planes of the wire rod, and the pair of flat surfaces are first in contact with the inner diameter side from a state in which they are obliquely opposed to each other, and the outside You may press it so that it falls to the radial side.
The plastic flow inside the flat wire can be effectively generated from the inner diameter side to the outer diameter side.

The coil manufacturing apparatus may have an inclined portion forming portion that is located at the same portion of each winding layer and forms an inclined portion that bends in the thickness direction of the flat wire.
The space factor can be further improved in combination with the effect of suppressing the occurrence of swelling on the inner diameter side and thinning on the outer diameter side.

According to the present invention, it is possible to provide a coil manufacturing method and a coil manufacturing apparatus that can suppress a change in thickness during bending of a flat wire and further improve the space factor, and contribute to high efficiency of the motor.

It is a schematic block diagram of the coil manufacturing apparatus which concerns on one Embodiment of this invention, (a) is a plan view, (b) is a side view. It is a perspective view which shows the main part of the pressing deformation part. In the cross-sectional view showing the deformation operation by the pressing deformation portion, (a) is a diagram showing a state in which the flat wire can be fed, (b) is a diagram showing a state in which the movement of the flat wire is restricted, and (c) is a diagram showing a state in which the movement of the flat wire is restricted. It is a figure which shows the state which the pressure deformation was made. In the cross-sectional view showing the details of the deformation operation by the pressing deformation portion, (a) is a view showing the initial pressing state in which the flat surfaces 20a and 22a are in contact with the upper and lower surfaces of the flat wire, and (b) is the flat surface 20a. It is a figure which shows typically the state which plastic flow occurs in the inside of a flat wire by the bending movement of 22a. It is a figure which shows the difference between the cross section of a flat wire after a pressing deformation by a pressing deformation part, and the shape before a deformation. It is a figure which shows the operation of bending in a winding part, (a) is a plan view which shows the state which the flat wire to which the pressure deformation was applied reached the position which performs bending, (b) is X-X-ray of (a). It is an enlarged sectional view by X-ray. It is a figure which shows the operation of the bending process in a winding part, (a) is a plan view which shows the state in the process of bending process, (b) is the enlarged sectional view by XX line of (a). It is a figure which shows the operation of the bending process in a winding part, (a) is a plan view which shows the state of the completion stage of a bending process, (b) is the enlarged sectional view by XX line of (a). It is a main part perspective view which shows the process of forming a short side cloth. It is a perspective view which shows the winding state by the flat wire which formed the short side cross in advance. It is a main part plan view which shows the gap at the time of winding a wire rod having a quadrangular cross section in the conventional. It is a figure which shows the bulge which occurs on the inner diameter side of the bent part when a flat wire is bent, (a) is the perspective view for demonstrating the principle that bulge occurs, and (b) is the perspective view which shows the bulge of the bent part. .. It is a figure which shows the thin-walled state which occurs on the outer diameter side of the bent part at the time of bending a flat wire, and is the cross-sectional view of a part of a laminated structure.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
1A and 1B are views showing an outline configuration of a coil manufacturing apparatus according to the present embodiment, where FIG. 1A is a plan view and FIG. 1B is a side view.
The coil manufacturing apparatus 1 clamps a roller group 2 that takes in a flat wire Ws as an example of a wire material supplied from the outside and removes bending and twisting in the feed direction (Z direction), and a flat wire Ws having a rectangular cross section. It has a wire rod feeding means 3 for feeding, and a winding portion 7 that is bent into a flat wire Ws and spirally wound (laminated).
The winding portion 7 in the present embodiment has a configuration of forming a square coil having a long side portion and a short side portion.

On the upstream side of the winding portion 7 in the wire feeding direction, there is a bulge on the inner diameter side (inside) and an outer diameter side (outside) when the flat wire Ws is bent along a plane orthogonal to the thickness direction of the flat wire Ws. ) Is provided with a pressing deformation portion 4 for imparting deformation for suppressing the thinning.
"Along a plane orthogonal to the thickness direction" means that the wide surface is perpendicular to the centerline of the coil.
The pressing deformation portion 4 is adapted to impart deformation that exerts the above-mentioned suppressing function to the upper and lower surfaces (both sides) of the flat wire Ws before the winding portion 7 bends the flat wire Ws.
An inclined portion is formed on the upstream side of the winding portion 7 in the wire feeding direction and on the downstream side of the pressing deformation portion 4 to preform an inclined portion (short side cross) described later on the short side portion of the flat wire Ws. The part 5 is arranged. That is, the inclined portion forming portion 5 is adapted to form the inclined portion Wi on the flat wire Ws before the winding portion 7 bends the flat wire Ws.

The inclined portion forming portion 5 may be arranged on the upstream side of the pressing deformation portion 4. That is, since the position where the pressing deformation is applied and the position where the inclined portion Wi is formed are different, there is no limitation on the positional relationship between the pressing deformation portion 4 and the inclined portion forming portion 5 in the feeding direction of the wire rod.
A stopper 6 is arranged between the winding portion 7 and the inclined portion forming portion 5 to stop the feeding of the wire rod and fix the position at the time of bending at the winding portion 7.

The roller group 2 is composed of a plurality of rollers 2a arranged on both sides of the flat wire Ws in the feeding direction.
The wire rod feeding means 3 includes a feed screw mechanism 8 and a gripping unit 9 that moves in the wire rod feeding direction by driving the feed screw mechanism 8. The feed screw mechanism 8 includes a feed screw 10 and a motor 11 or the like which is a drive source for rotating the feed screw 10.

The gripping unit 9 is synchronously moved by a unit main body 12 that meshes with the feed screw 10 and a drive source (not shown) housed in the unit main body 12, and a pair of clamps 13a that grip the flat wire Ws from the vertical direction (thickness direction). , 13b and. By moving the gripping unit 9 by the feed screw mechanism 8 while the flat wire Ws is gripped by the clamps 13a and 13b, the flat wire Ws is fed to the winding portion 7.
The gripping unit 9 is returned to the upstream side by rotating the motor 11 in the reverse direction in a state where the gripping by the clamps 13a and 13b is released. By the reciprocating operation of the gripping unit 9, the flat wire Ws can be intermittently sent to the winding portion 7 side.

The pressing deformation portion 4 includes a housing 14 extending in the vertical direction, feed screws 15A and 15B rotatably supported by the housing 14, a motor 16 as a drive source for rotationally driving the feed screws 15A and 15B, and a feed. It has an upper press unit 17 and a lower press unit 18 that rotate in the vertical plane in synchronization with the rotation of the screw 15.

The upper press unit 17 is detachably (replaceable) fixed to the unit body 19 by fastening means such as bolts so as to diagonally face the upper surface of the flat wire Ws with the unit body 19 that meshes with the feed screw 15A. It has a mold 20 and.
The lower press unit 18 is detachably (replaceable) fixed to the unit body 21 by fastening means such as bolts so as to diagonally face the lower surface of the flat wire Ws with the unit body 21 that meshes with the feed screw 15B. It has a mold 22 and.
By pressing with the upper press die 20 and the lower press die 22, the upper and lower surfaces of the flat wire Ws are deformed to suppress swelling on the inner diameter side and thinning on the outer diameter side when bending. The details of this deformation imparting operation will be described later.

The inclined portion forming portion 5 includes a housing 23 extending in the vertical direction, feed screws 24A and 24B rotatably supported by the housing 23, and a motor 25 as a drive source for rotationally driving the feed screws 24A and 24B. It has an upper press unit 26 and a lower press unit 27 that approach and separate in the vertical direction in synchronization with the rotation of the feed screws 24A and 24B.
The upper press unit 26 has a unit main body 28 that meshes with the feed screw 24A, and an upper press mold 29 that is detachably fixed to the unit main body 28 by a fastening means such as a bolt so as to face the upper surface of the flat wire Ws. ing.
The lower press unit 27 has a unit main body 30 that meshes with the feed screw 24B, and a lower press mold 31 that is detachably fixed to the unit main body 30 by a fastening means such as a bolt so as to face the lower surface of the flat wire Ws. ing.
By pressing with the upper press die 29 and the lower press die 31, an inclined portion (short side cross) Wi bent in the vertical direction (stacking direction) is formed on the flat wire Ws.

The stopper 6 has a main body portion 32 and a pair of clamps 33a and 33b that are synchronously approached and separated from each other in the vertical direction by a drive source (not shown) in the main body portion 32.
Bending is performed by the winding portion 7 in a state where the flat wire Ws is gripped and fixed by the clamps 33a and 33b. When the bending operation of the winding portion 7 is completed, the gripping by the clamps 33a and 33b is released, and the flat wire Ws can be fed.

The winding portion 7 supports the base 34, the columnar reference shaft 35 provided on the base 34, the columnar rotating shaft 36 rotatably provided about the reference shaft 35 as a fulcrum, and the base 34. It has a drive mechanism 37 that displaces the base 34 in the vertical direction, a holding jig 38, and the like. The reference shaft 35 and the rotating shaft 36 may have a roller configuration capable of reducing friction during bending.
The drive mechanism 37 includes a base 39, a feed screw 40 that rotates by a drive source (not shown) in the base 39, a frame 41 that moves up and down by the rotation of the feed screw 40, and a support shaft 42 fixed to the frame 41. Etc.

When the right angle line Ws is sent and the predetermined bending position reaches the position of the reference shaft 35, the movement of the right angle line Ws is fixed by the stopper 6, and the rotation shaft 36 rotates from the P1 position to the P2 position in this state. As a result, the flat wire Ws is bent at a substantially right angle. When the bending process at one position is completed, the rotating shaft 36 is returned to the P1 position, which is the home position, in preparation for the next bending process.
The long side portion and the short side portion are distinguished by changing the feed amount of the flat wire Ws, and by repeating this bending process, the square winding shapes are laminated to finally form a square coil.

When laminating the second and subsequent layers, the drive mechanism 37 lowers the bending position slightly with respect to the wire rod supply path, and the wire rod is pressed by the presser jig 38 so that it does not rise. It is possible to wind the lower layer so as to cover the bending of the next layer in the height direction.
That is, the winding portion 7 has a configuration capable of performing bending at a lower position deviated from the position of the flat wire Ws entering the winding portion 7 in the stacking direction (center direction of the coil). doing.
As a result, springback (return due to elasticity) remains in the direction in which the layers are in close contact with each other, and the adhesion between the layers in the stacking direction is improved.

As described with reference to FIG. 12, when bending is performed, swelling We is generated by the action of compressive force if no measures are taken on the inner diameter side of the bending portion. On the other hand, as shown in FIG. 13, a thin portion Wg is generated on the outer diameter side of the bent portion due to the action of the tensile force.
When the bulge We and the thin portion Wg are generated, a gap is formed between the winding layers as described above, and the space factor of the coil is lowered.

Patent Document 1 discloses measures for suppressing swelling on the inner diameter side during bending, but no measures are taken for thinning the outer diameter side.
Therefore, in the present invention, it is determined that the swelling on the inner diameter side and the thinning on the outer diameter side at the bending portion are suppressed at the same time, and the decrease in the space factor is suppressed with high accuracy.
Specifically, as shown in FIG. 2, before the bending process is performed, the upper and lower surfaces of the portion where the flat wire Ws is bent are simultaneously pressed by the upper press die 20 and the lower press die 22 to be deformed. , It suppresses the swelling that occurs on the inner diameter side and the thinning that occurs on the outer diameter side when bending.
That is, by forming in advance a thin portion capable of absorbing the bulge on the inner diameter side and a thick portion capable of compensating for the thinning on the outer diameter side on both sides of the flat wire Ws, the bulge We and the thin portion Wg at the time of bending are formed. It is based on the idea of canceling the outbreak.
The corners of the surfaces of the upper press mold 20 and the lower press mold 22 facing the flat wire Ws are curved surfaces so as not to damage the insulating layer of the flat wire Ws.

The deformation imparting operation by the upper press die 20 and the lower press die 22 will be described with reference to FIGS. 3 to 5. In FIG. 5, the insulating layer Ws-2 is omitted for the sake of clarity.
As shown in FIG. 3A, the upper press die 20 and the lower press die 22 have flat surfaces 20a and 22a as pressing surfaces, respectively, and the flat surfaces 20a and 22a are oblique to the upper and lower surfaces of the flat wire Ws. They are arranged so as to face each other.
Although not shown, the unit body 19 of the upper press unit 17 has an arcuate screw that meshes with the feed screw 15A and rotates around the axis, whereby the flat surface 20a has a flat wire Ws. Displace (move) so as to draw a curved locus from the state of diagonally facing the upper surface (plane) of.
The lower press unit 18 has the same configuration except that the direction of the flat surface with respect to the flat wire Ws is opposite.

When the feeding of the flat wire Ws is completed, as shown in FIG. 3 (b), the inner press mold 43 provided in the pressing deformation portion 4 presses the side surface on the inner diameter side of the flat wire Ws, and at the same time, the outer press mold 44 presses. The flat wire Ws is fixed by pressing the side surface on the outer diameter side. The inner press mold 43 and the outer press mold 44 constitute the regulatory means (omitted in FIGS. 1 and 2). The regulating means may regulate at least one of the inner diameter side and the outer diameter side side surface.
The lead screws 15A and 15B rotate in a state where the flat wire Ws is fixed, that is, in a state where the side surface on the inner diameter side and the side surface on the outer diameter side of the flat wire Ws are restricted so as not to move. As shown in FIG. 3C, the upper press die 20 and the lower press die 22 are displaced and approach each other so as to draw a curved locus, and simultaneously press the upper surface and the lower surface of the flat wire Ws.
By this pressing, the thickness t1 on the inner diameter side of the flat wire Ws becomes smaller than the original thickness t0, and the thickness t2 on the outer diameter side becomes larger than the original thickness t0.
The thickness t3 of the inner press die 43 is set smaller than the thickness t1 on the inner diameter side so as not to hinder the pressing operation of the upper press die 20 and the lower press die 22.

The pressing operation by the upper press die 20 and the lower press die 22 will be described in detail with reference to FIG. As shown in FIG. 4A, the flat surface 20a of the upper press mold 20 and the flat surface 22a of the lower press mold 22 first abut on the inner diameter side to start pressing. Since the flat surfaces 20a and 22a are pressed so as to fall toward the outer diameter side, as shown in FIG. 4B, plastic flow is generated inside the flat wire Ws, and the meat on the inner diameter side moves toward the outer diameter side. To do.
Since the flat surfaces 20a and 22a are displaced so as to draw a curved (isolated) locus, the plastic flow is transmitted to the outer diameter side.
As a result, as shown in FIG. 5, on the inner diameter side of the flat wire Ws, the amount of flesh corresponding to the blank portion E between the two-dot chain line showing the original shape of the flat wire Ws and the solid line showing the deformed line is reduced. To do. On the outer diameter side, the amount of fleshing corresponding to the built-up portion M between the two-dot chain line showing the original shape and the solid line showing the deformed state increases.

Therefore, on the inner diameter side of the flat wire Ws, the bulge generated during bending is absorbed by the blank portion E, and on the outer diameter side, the thinning caused during bending is suppressed by the build-up portion M.
As a result, the influence at the time of bending is almost suppressed, the adhesion between layers is enhanced, and the space factor is improved.
The degree of the blank portion E and the build-up portion M is adjusted by the inclination angles θ of the flat surfaces 20a and 22a with respect to the flat line Ws (see FIG. 3A) and the amount of biting of the flat surfaces 20a and 22a with respect to the plane of the flat line Ws. can do.
For example, the flat wire Ws is actually bent to generate a bulge We, the bulge We is measured by a three-dimensional measuring device, and a blank portion E that can be canceled is determined based on the measurement data. The capacities of the blank portion E and the build-up portion M are about the same.

When the materials of the flat wire Ws are different, the above parameters may be optimized for each material. A plurality of types of upper press dies 20 and lower press dies 22 having different inclination angles of flat surfaces may be prepared and replaced according to changes in the material.
The degree of thinning on the outer diameter side that occurs during bending is less than that on the inner diameter side. This is because the inner diameter side is compressed in a narrow range, while the outer diameter side is stretched in a wide range.
When the deformation is completed in the pressing deformation portion 4, the feed screws 15A and 15B rotate in the reverse direction, and the upper press die 20 and the lower press die 22 are separated from the flat wire Ws.

The bending operation in the present embodiment will be described with reference to FIGS. 6 to 8.
FIG. 6A shows a state in which the flat wire Ws is sent to a position where bending is performed, and FIG. 6B is an enlarged cross-sectional view taken along line XX of FIG. 6A.
In FIG. 6A, the reference numeral AP indicates a region where deformation is applied by the pressing deformation portion 4, and corresponds to a bending portion.
The cross-sectional shape of the flat wire Ws shown in FIG. 6 (b) is the same as the cross-sectional shape shown in FIG. 3 (c), and shows the cross-sectional shape before bending.

FIG. 7 shows a state in which the rotation shaft 36 rotates from the P1 position to the P2 position and the bending progresses. When the bending process is started, as shown in FIG. 7A, a compressive force acts on the inner diameter side and a tensile force acts on the outer diameter side.
As shown in FIG. 7 (b), the inner diameter side bulges due to the internal strain, and the blank portion E shown in FIG. 5 decreases. On the other hand, on the outer diameter side, an inward force is generated, and the build-up portion M shown in FIG. 5 decreases.

As shown in FIG. 8A, the bending process is completed when the rotating shaft 36 reaches the P2 position. Until the bending process is completed, the inner diameter side is continuously bulged from the state shown in FIG. 7 due to the compressive force, but is absorbed by the rest of the blank portion E.
On the other hand, an inward force is continuously generated on the outer diameter side, but it is replenished by the rest of the build-up portion M.
As a result, the swelling on the inner diameter side and the thinning on the outer diameter side are canceled by the deformation previously applied by the pressing deformation portion 4, and the upper and lower surfaces of the bent portion of the flat wire Ws become substantially flat.

By giving the flat wire Ws a deformation that can cancel the swelling on the inner diameter side and the thinning on the outer diameter side at the same time before bending in this way, it is possible to form a coil with a high space factor in a simple process. it can.
If the winding portion 7 is bent so as to cause springback as described above, the adhesion between the laminated surfaces is further enhanced, and the space factor can be further improved.

In the winding shape of the conventional coil, as shown in FIG. 11, it is unavoidable that a gap S2 is formed in the innermost part of the slot 101, and in combination with the above-mentioned gap S1, the space factor is lowered and the space factor of the motor is reduced. There was a problem that efficiency did not increase.
As a method for eliminating the gap S2 formed at the innermost part of the slot, a so-called short-side cross method is used in which a square coil is formed by a round wire in which the wire runs diagonally only on the short-side side.
However, it has been difficult to use a short-sided cloth because the wire rod Wa having a quadrangular cross section has anisotropy in bendability and twists.

In the above description, the example in which the short side cloth is not provided has been described, but as described with reference to FIG. 1, the coil manufacturing apparatus 1 of the present embodiment has the inclined portion forming portion 5 for forming the short side cloth.
As shown in FIG. 1, the upper press mold 29 of the inclined portion forming portion 5 has a step shape, and the lower press mold 31 has a step shape along the step shape.
As shown in FIG. 9, by simultaneously pressing from above and below by the upper press mold 29 having the inclined surface 29a and the lower press mold 31 having the inclined surface 31a, the inclined portion Wi as a short side cross is formed on the flat line Ws. It is formed.
In FIG. 9, reference numerals 29b and 31b indicate bolt insertion holes.

As shown in FIG. 10, the inclined portion Wi is formed on the short side portion Wm of the square winding shape having the long side portion Wn and the short side portion Wm, and the winding shapes are laminated. As a result, the problem related to the gap S2 described with reference to FIG. 11 can be solved, and the space factor can be further improved in combination with the effect of suppressing the occurrence of swelling on the inner diameter side and thinning on the outer diameter side. ..

In the present embodiment, the upper press die 29 and the lower press die 31 are synchronously moved and pressed, but one of them may be fixed and pressed.
Further, a plurality of sets of upper press dies 29 and lower press dies 31 having different angles of inclined surfaces may be arranged and replaced depending on changes in conditions such as the material of the wire rod.

Since the inclined portion Wi is formed before the winding portion 7 is bent, interference between the configuration of the winding portion 7 and the configuration for forming the inclined portion Wi does not occur, and a short side cloth is incorporated. The coil can be easily manufactured.

In the above embodiment, the flat wire is illustrated, but the same can be applied to a wire having a cross-sectional shape (polygonal shape) in which swelling on the inner diameter side and thinning on the outer diameter side occur when bent.
Further, although the square coil has been described in the above embodiment, the coil shape is not limited to this.

In the above embodiment, the pressing deformation portion 4 and the inclined portion forming portion 5 are arranged on the upstream side of the winding portion 7 and preformed before the flat wire Ws is bent. Not limited to.
In the process of the winding portion 7, the pressing deformation or the like may be performed in preference to the bending process. That is, the timing of press deformation and the like may be before the bending process, and there is no positional limitation. A coil may be formed by using a wire rod that has been pressed and deformed in advance outside the apparatus.
Further, although the material of the wire is copper in the above embodiment, other materials may be used.

Although the preferred embodiment of the present invention has been described above, the present invention is not limited to such a specific embodiment, and unless otherwise specified in the above description, the present invention described in the claims. Various modifications and changes are possible within the scope of the purpose.
The effects described in the embodiments of the present invention merely exemplify the most preferable effects arising from the present invention, and the effects according to the present invention are limited to those described in the embodiments of the present invention. is not it.

1 Coil manufacturing equipment 4 Pressing deformation part 5 Inclined part forming part 7 Winding part 43 Inner press type as regulating means 44 Outer press type as regulating means t0 Original thickness t1 Inner diameter side thickness t2 Outer diameter side thickness Wi tilt Flat wire as part Ws wire

Claims (6)

In a coil manufacturing method in which a flat wire having an insulating layer coated on the surface of a core material is bent along a plane orthogonal to the thickness and spirally wound.
The flat wire of the both planes pressed with a flat surface of the respective one, first in the inner diameter side contact from a state in which the respective flat surface facing diagonally, respectively to the both planes, to fall on the outer diameter side by pressing, the flat wire pressed by deforming the both planes of the coil manufacturing method characterized by increasing the thickness of the outer diameter side while decreasing the thickness of the inner diameter side at the site bending. Coil manufacturing method according to claim 1, characterized in that pressing while regulating at least one of movement of the side surfaces of the outer diameter side and the side surface of the inner diameter side of the flat wire. The coil manufacturing method according to claim 1 or 2, wherein an inclined portion that bends in the thickness direction of the flat wire is formed at the same portion of each wound layer. A coil manufacturing device that bends a flat wire with an insulating layer coated on the surface of the core material along a plane orthogonal to the thickness and winds it in a spiral shape.
A pressing deformation portion that presses and deforms both planes of the flat wire to reduce the thickness on the inner diameter side and increase the thickness on the outer diameter side at the bending portion during bending.
A winding part that bends the flat wire and winds it spirally,
Have,
The pressing deformation portion is provided with flat surfaces that are diagonally opposed to both planes of the flat wire, and the pair of flat surfaces first abut on the inner diameter side from a state in which they are diagonally opposed to each other, and then fall to the outer diameter side. A coil manufacturing apparatus characterized in that it is configured to be pressed in such a manner. The fourth aspect of claim 4, wherein the flat wire has a regulating means for restricting the movement of at least one of the inner diameter side side surface and the outer diameter side side surface, and presses the flat wire in a regulated state. Coil manufacturing equipment. The coil manufacturing apparatus according to claim 4 or 5, further comprising an inclined portion forming portion that is located at the same portion of each winding layer and forms an inclined portion that bends in the thickness direction of the flat wire.

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