JP7170307B2 - Coil manufacturing device, coil manufacturing system, coil manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a coil manufacturing apparatus, a coil manufacturing system, and a coil manufacturing method for joining flat plates by pressurizing and deforming them.

A stator, which is a component of a motor, has coils arranged around a core (stator core). Improving is important.

As a coil capable of improving the space factor in the core, for example, the end surfaces of a flat conductor punched out in a U-shape (U-shape) are joined together by cold pressure welding to form a region for one round of the coil. A coil and its manufacturing apparatus are known (see, for example, Patent Document 1).

According to the technique described in Patent Literature 1, it is possible to improve the space factor and heat dissipation in the core, and to provide a high-quality coil that does not deteriorate in characteristics due to cutting and joining.

Japanese Patent No. 5592554

However, in the coil manufacturing apparatus described above, it cannot be said that the technique for mass-producing good-quality coils has been sufficiently studied, and there is room for improvement from the viewpoint of improving productivity.

The present invention provides a coil manufacturing apparatus, a coil manufacturing system, and a coil manufacturing method that are capable of improving the lamination factor in the core, improving the heat dissipation property, and mass-producing high-quality coils that do not cause characteristic deterioration due to cutting and joining. intended to provide

The present invention solves the above problems by the following means.

The present invention is a coil manufacturing apparatus for forming a helical structure by splicing a plurality of flat conductors, comprising: a bending apparatus for bending each of the plurality of flat conductors; and a joining apparatus for joining the plurality of flat conductors. wherein the bending device is a means for bending each of the flat conductors so that a portion along the direction of spiral progress is inclined with respect to other portions before being supplied to the joining device; a first holding portion and a second holding portion which are capable of sandwiching a flat conductor and the other flat conductor respectively and which are arranged to face each other; and the first holding portion and the second holding portion. and a drive unit for moving the flat conductor and the other flat conductor, pressing the end surfaces of the flat conductor and the other flat conductor along the longitudinal direction of the belt, and joining them together under pressure while shortening the distance in the longitudinal direction of the belt to form the spiral A coil manufacturing apparatus characterized by being means for forming a structure.

Further, the present invention is a coil manufacturing system comprising a plurality of the above coil manufacturing apparatuses.

The present invention also provides a coil manufacturing method for forming a helical structure by splicing a plurality of flat conductors, wherein each of the flat conductors is arranged such that a portion along the direction of helical movement is inclined with respect to the other portions. A bending step of bending, and pressing the end surfaces of the flat conductor that has been bent and the other flat conductor along the longitudinal direction of the belt, and joining them together under pressure while shortening the distance in the longitudinal direction of the belt to form the spiral structure. and a joining step of forming the coil.

INDUSTRIAL APPLICABILITY According to the present invention, a coil manufacturing apparatus, a coil manufacturing system, and a coil manufacturing system capable of mass-producing high-quality coils that are capable of improving the lamination factor and heat dissipation properties in the core and that do not cause characteristic deterioration due to cutting and joining. can provide a method .

BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows the outline|summary of the coil manufacturing apparatus which concerns on embodiment of this invention. FIG. 2A is a top view, (B) a top view, (C) a cross-sectional view, and (D) to (G) top views for explaining a coil piece according to the present embodiment. BRIEF DESCRIPTION OF THE DRAWINGS It is a figure explaining the bending apparatus which concerns on this embodiment, (A) is a top view of a coil piece, (B) is a schematic diagram of a bending apparatus. It is a top view which shows the outline of the bending apparatus which concerns on this embodiment. It is a front view which shows the mode of deformation|transformation by the bending apparatus which concerns on this embodiment. It is a front view which shows the mode of deformation|transformation by the bending apparatus which concerns on this embodiment. It is a front view which shows the joining apparatus which concerns on this embodiment. FIG. 4 is a front view showing a method of joining coil pieces by the joining apparatus according to the present embodiment; FIG. 4 is a front view showing a method of joining coil pieces by the joining apparatus according to the present embodiment; It is a figure which extracts and shows a part of joining apparatus which concerns on this embodiment, (A) Top view, (B) Front view, (C) Top view, (D) Front view. It is a figure explaining the bending part of the coil piece which concerns on this embodiment. BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows the outline of the removal apparatus which concerns on this embodiment, (A) is a top view, (B) - (E) are front views. It is a figure which shows the outline of the coil manufacturing system which concerns on this embodiment. FIG. 4 is a diagram showing an example of molding of a coil according to the present embodiment, (A) a top view and (B) to (E) side views. It is a top view explaining the manufacturing method of the coil concerning this embodiment. It is a schematic diagram showing an example of a method of manufacturing a coil according to the present embodiment. It is a schematic diagram showing an example of a method of manufacturing a coil according to the present embodiment. It is a schematic diagram showing an example of a method of manufacturing a coil according to the present embodiment. It is a figure explaining the attachment method to the status core of the coil which concerns on this embodiment, (A) Side view, (B) Top view, (C) Top view.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

<Coil manufacturing equipment>
FIG. 1 is an external view schematically showing the configuration of a coil manufacturing apparatus 10 according to this embodiment.

The coil manufacturing apparatus 10 of the present embodiment forms a coil having a helical structure by joining a plurality of flat conductors C, and bending means for bending each of the plurality of flat conductors C to form a bent portion B0. (bending device) 30, joining means (joining device) 20 for joining a plurality of flat conductors C, and removing means (removing device) 40 for removing part of the flat conductors C after joining.

The bending device 30 is provided upstream of the bonding device 20, and bends each flat conductor C so that a portion along the direction of spiral movement is inclined with respect to the other portions before being supplied to the bonding device 20. Form part B0.

The joining device 20 is provided downstream of the bending device 30, presses the end faces of the flat conductor C and another flat conductor C along the longitudinal direction of the strip, and performs cold pressure welding while shortening the distance in the longitudinal direction of the strip. Joined bodies (joined coil pieces) CC of flat conductors are formed and spliced to form a spiral structure.

The removing device 40 is provided downstream of the joining device 20 and is a means for removing burrs generated by cold pressure welding of the flat conductor C and another flat conductor C. As shown in FIG.

These will be described in detail below.

<flat conductor>
First, the flat conductor C used in the coil manufacturing apparatus 10 of this embodiment will be described. FIG. 2 is a diagram showing an example of the flat conductor C used in the coil manufacturing apparatus 10 of the present embodiment, and FIG. 1B is a top view of the flat conductor C, and FIG. 1C is an enlarged view of the cross section taken along line XX of FIG. 1D to 1G are top views showing an example of the shape of the flat conductor C. FIG.

As shown in FIG. 4A, the coil 50 of the present embodiment has a helical structure formed by continuously joining a plurality of flat conductors C, and the area of one round of the helical structure ( Hereinafter, the one round area CR) has a (substantially) rectangular shape. Further, the flat conductor C forming the coil 50 is also referred to as a coil piece C in the following description.

The flat conductor (coil piece) C of the present embodiment is configured by a plane as shown in FIG. It is a strip-shaped (tape-shaped) conductor. That is, the coil piece C is a belt-like member having two wide surfaces WS facing each other and two narrow surfaces WT facing each other, and is elongated in a predetermined direction. B) cross section along the line XX) is a rectangular or rounded rectangular conductor as shown in FIG. In the following description, as an example of a flat conductor, a flat conductor having a (substantially) rectangular cross section perpendicular to the longitudinal direction of the belt as shown in the upper diagram of FIG.

Specifically, each of the flat conductors (coil pieces) C has a linear shape ((B) in the figure) or at least one direction changing portion TN having a length equal to or less than the length of one round region CR of the helical structure. (D) to (G) in FIG. Here, the direction changing portion TN is a portion that is bent so as to change the extending direction in the longitudinal direction of the band.

In the case of a flat conductor (coil piece) C having a direction changing portion TN as shown in (D) to (G) of FIG. It is assumed that the vehicle is turning in a direction (always rightward or leftward). Further, in the case of the coil piece C having the direction changing portions TN, it is desirable that at least one (preferably all) of the direction changing portions TN has a non-curved (for example, substantially right-angled) shape.

In the following description, a helical structure (coil The spiral structure to which the strip C is to be subsequently connected) shall also be included in the coil strip C. That is, in the following description, the coil piece C includes a minimum unit coil piece (coil piece before connection) having a direction changing portion TN in a straight line or in the same direction in the longitudinal direction of the band, and the minimum unit coil piece. are connected to form a spiral structure longer than one round region CR of the coil (helical structure to be completed). For convenience of explanation, when it is necessary to distinguish between these coil pieces, the minimum unit coil pieces are called unit coil pieces C0 (C01, C02, C03 . . . C0N), and a plurality of unit coil pieces C0 are connected. A joined coil piece CC (CC1, CC2, . , said.

As an example, the coil piece C (unit coil piece C0) is made of a copper plate (for example, a plate-shaped oxygen-free copper (99.95% or more high-purity copper containing no oxide) with a thickness of 0.1 mm to 5 mm). By punching or the like, it is formed into a shape having a linear shape or a substantially right-angled (non-curved) direction changing portion (corner portion) TN. In other words, when viewed from the top of the wide surface WS, the unit coil piece C0 has a straight line (I shape) with no direction changing portion TN ((B) in the same figure), an L shape having one direction changing portion TN ( (D)), a U-shape (U-shape) having two direction changing portions TN ((E) in the same figure), a substantially C shape having three direction changing portions TN ((F) in the same figure), 4 There is a C-shaped one ((G) in the figure) having two direction changing portions TN. In the following description, the shape is referred to as U-shape, (substantially) C-shape, and substantially O-shape, but all of the direction changing portions TN (corners) are substantially right-angled shapes.

A plurality of coil pieces C (unit coil pieces C0 and/or joined coil pieces CC) have a preparation length L0 that is the total distance in the band longitudinal direction of the helical structure (coil) 50 to be completed. It is set to be longer than the completed length of . The margin is set to the shortened total distance shortened by pressing when all of the plurality of coil pieces C are cold pressure welded. The preparation length L0, the completed length, the margin, and the shortened total distance will be described in detail in the description of the method of manufacturing the coil, which will be described later.

In the following example, the case of manufacturing the coil 50 using the U-shaped (U-shaped) flat conductor (coil piece) C shown in FIG. or any combination of a plurality of shapes shown in FIG.

<Bending device>
A bending device 30 of the present embodiment will be described with reference to FIGS. 3 to 6. FIG. 3A and 3B are schematic diagrams of the bending device 30 of the present embodiment. FIG. 3A is a top view showing the coil piece C before deformation supplied to the bending device 30, and FIG. 3 is a schematic diagram of device 30. FIG. The top view and side view of the coil piece C before deformation are shown together in the upper part of FIG. The figures are shown above and below. 4 is a top view showing an outline of the bending device 30. As shown in FIG. 5 and 6 are front views showing a schematic configuration of a portion (deforming portion 37) of the bending device 30 and the state of bending.

As will be described in detail later in the description of <coil manufacturing method>, actually, the coil pieces C1 and C2 are pressure-welded by the bonding device 20 to shorten the distance therebetween. However, here, for the convenience of mainly explaining the deformation by the bending device 30, the shortening of the distance due to pressure contact (displacement of the length of the long side LS between the state of only contact and the state after pressure contact) will not be mentioned. . Further, in the following description of the coil manufacturing apparatus 10 with reference to FIGS. 3 to 14, the length displacement due to pressure contact will be omitted.

First, referring to FIG. 3A, in this embodiment, as an example, one end surface of each of two U-shaped coil pieces C (C1, C2) having substantially the same shape shown in FIG. TS1 and TS2 are butted against each other to form a junction CP, thereby forming a (substantially) rectangular peripheral region CR having a long side LS and a short side SS. Here, for the sake of convenience, the coil pieces C1 and C2 are referred to, but both of them are obtained by turning the coil piece C of (substantially) the same shape around the end surfaces TS1 and TS2.

In addition, since the coil 50 is formed by continuously forming a predetermined number of one-round regions CR, the other end surfaces TS0 and TS1' are not joined to each other, and one-round region CR in this state is, for example, the junction CP. It is discontinuous at the opposing position. For example, when the coil pieces C1 and C2 shown in FIG. 1A are the first two pieces, the end surface TS0 of the coil piece C1 is connected to another coil piece (not shown) constituting a terminal, for example. The end face TS1' of the coil piece C2 is joined to the end face of the next coil piece (not shown).

That is, in this case, one long side LS (the upper side in FIG. 1A) of the one-circumference area CR is composed of the long side area LS1 (LS11) of the coil piece C1 and the long side area LS1 (LS12) of the coil piece C2. However, the long side LS of the other (lower side of (A) in the figure) of the one-round region CR is the long side region LS2 (LS22) of another (next) same-shaped coil piece (unusual) of the coil piece C2. (illustrated) is composed of long side regions.

As shown in FIG. 1B, the bending device 30 of the present embodiment bends a part of the supplied pre-deformed coil piece C (upper part of FIG. 1B) to a lower part of FIG. It is a device that forms a bent portion B0 by bending the tape. Here, the coil piece C before deformation is a flat plate-like coil piece C that is punched out from a flat plate, and the entire region of the coil piece C is not intentionally deformed, and is substantially in the same plane. It refers to the coil piece C in the existing state.

Specifically, as shown in FIG. 4 , the bending device 30 has, for example, a supply section 31 for the coil pieces C, a transport section 33 , a support section 35 and a deformation section 37 . The supply unit 31 is provided with, for example, a turntable 311 capable of stocking a plurality of (for example, four) undeformed coil pieces C, and the undeformed coil pieces C are supplied from an upstream process.

The undeformed coil pieces C on the turntable 311 are supplied one by one to the support section 35 as the turntable 311 rotates.

The support portion 35 has a support table 351 on which the coil piece C can be placed on its surface (upper surface), and a pressing portion 353 that presses a portion of the coil piece C placed on the support table 351 from above. there is The coil piece C before being deformed is placed on the support table 351 and partly sandwiched between the support table 351 and the pressing portion 353 and temporarily fixed.

Specifically, the support section 35 holds the coil piece C so that, for example, part of the coil piece C protrudes from the support table 351 (in a state where the support table 351 does not exist directly below the part of the coil piece C).

For example, in the case of a U-shaped coil piece C, only one long side region LS2 is sandwiched between the support table 351 and the pressing portion 353, and the short side SS is projected horizontally from the support table 351 (directly below it). is held without the support table 351). The other long-side region LS1 may be placed on the support table 351, but is not pressed by the pressing portion 353 (is not sandwiched between the support table 351) and is allowed to change its posture. ing.

The transport section 33 has, for example, a rail member 331 and a driving section 333 that moves the support section 35 along the rail member 331, for example, in the horizontal direction. Further, the conveying portion 33 temporarily stops the supporting portion 35 at a predetermined pressing position inside the deforming portion 37 .

The deformation portion 37 is configured to be movable (in this example, up and down movement) so as to approach and separate from the support portion 35 .

The deformation portion 37 will be described with reference to FIGS. 5 and 6. FIG. 5(A) to 5(C) are front views (viewed from the lower side of FIG. 4). ), and (D) is a view showing the coil piece C after the deformation shown in (B) and (C) in FIG. is a front view).

6A to 6C are front views (viewed from the lower side of FIG. 4), and FIG. It is a figure which shows the coil piece C after, and an upper figure is a top view and a lower figure is a side view (a front view as the deformation|transformation part 37).

Referring to FIG. 5 , deformation portion 37 has holding portion 371 and biasing portion 373 . In this example, the deforming portion 37 (the holding portion 371 and the biasing portion 373 ) is configured to move up and down so as to approach and separate from the support portion 35 . The biasing portion 373 has an inclined surface 373S that is inclined with respect to the surface of the support table 351 ((A) in FIG. 3).

When the clamping part 371 is lowered, it contacts a part of the upper surface of the coil piece C held by the support part 35 and clamps the coil piece C between itself and the support table 351 . The urging portion 373 is positioned, for example, on the side of the clamping portion 371, and when it is lowered, its inclined surface 373S hits a portion (for example, short side SS) of the coil piece C projecting horizontally from the support table 351. In this example, it is bent downward to form a bent portion B0 ((B) in the figure). In this example, the surface of the coil piece C on the side contacting the deformation portion 37 (the clamping portion 371 and the biasing portion 373) is mountain-folded at the folding portion B0.

The clamping portion 371 and the biasing portion 373 may move up and down at the same timing, or may move up and down at different timings. When the two move up and down at different timings, at least during the descent, the clamping portion 371 first moves down to hold down the coil piece C, and then the urging portion 373 moves down to bend the coil piece C. As shown in FIG.

At this time, the support portion 35 (pressing portion 353) presses only one long side region LS2 of the coil piece C, and the other long side region LS1 of the coil piece C is not pressed by the pressing portion 353 (see FIG. 4). See), when the short side SS is bent downward by the urging portion 373, the posture of the long side region LS1 continuing to this is changed so as to be inclined with respect to the other long side region LS2 (FIG. 5). (B)).

After the deformation, the clamping portion 371 and the biasing portion 373 are lifted as shown in FIG. 4C, and the deformed coil piece C is discharged from the deformation portion 37 by the conveying portion 33 (FIG. 4).

As a result of this deformation, as shown in FIG. 2D, one long side region LS1 of the coil piece C and the short side SS are positioned substantially in the same plane (hereinafter referred to as a reference plane SF0). , when the reference plane SF0 is held horizontally, the other long side region LS2 is bent so as to be inclined with respect to the reference plane SF0 with the bent portion B0 as a boundary. More specifically, the other long-side region LS2 has an end T2 on the other side (away from the short side SS) of the end T1 on the short side SS side, which is positioned below (or above) the reference plane SF0. In other words, the bending device 30 bends the bent portion B0 ((D) The coil piece C is bent from the position indicated by the dashed line in the above drawing.

As described above, in the bending device 30 of the present embodiment, one of the two opposing long sides of the coil piece C (long side regions LS1 and LS2), which are scheduled to constitute one peripheral region CR of the coil 50, is Fold so that it is inclined with respect to the other.

It should be noted that the one long-side region LS1 and the other long-side region LS2 in the above example are only given different names for convenience of explanation. That is, even if the long-side regions LS1 and LS2 are exchanged, the same is true. good.

FIG. 6 is a diagram showing another example of the deformation portion 37. As shown in FIG. The deformable portion 37 shown in FIG. 5 is an example in which the urging portion 373 is positioned on the side of the clamping portion 371 and moves up and down in the same direction as the clamping portion 371 . However, not limited to this, as shown in FIG. It may be provided so that it can move up and down. In this case, during the horizontal movement of the support table 351, the biasing portion 373 is retracted below the support table 351 ((A) in FIG. 3). Then, when the support table 351 moves to the pressing position of the deformation portion 37 and temporarily stops, and the clamping portion 371 descends to clamp the coil piece C (after clamping), the biasing portion 373 moves upward from the support table 351 ( The inclined surface 373S contacts the short side SS of the coil piece C which protrudes in the vertical direction) and protrudes in the horizontal direction from the support table 351, and is bent upward to form a bent portion B0 (FIG. 3B). In this example, the surface of the coil piece C on the side contacting the clamping portion 371 is valley-folded at the folding portion B0.

After the deformation, the clamping portion 371 rises, the biasing portion 373 moves downward from the support table 351, and the deformed coil piece C is moved from the deforming portion 37 by the conveying portion 33, as shown in FIG. It is discharged (Fig. 4).

As a result, for example, as shown in FIG. 4D, one long side region LS1 and short side SS of the coil piece C are positioned within the reference plane SF0, and when the reference plane SF0 is held horizontally, With the bent portion B0 as a boundary, the other long side region LS2 is bent such that the other end T2 is positioned above (or below) the reference plane SF0 rather than the end T1 on the short side SS side. In other words, the bending device 30 bends the bent portion B0 (indicated by the dashed line in FIG. 1D) so that the angle formed by the reference plane SF0 (the long side region LS1) and the long side region LS2 becomes the angle α. Bend the coil piece C from the position of .

When the deformation of one coil piece C (C1) is completed in this manner, the coil piece C (C1) is taken out from the support table 351 by a robot (not shown) or the like, and transferred to a downstream process (joining device 20). be done.

After that, the next coil piece C (C2) is similarly fed onto the support table 351 and deformed.

The bending device 30 performs such bending processing on all the coil pieces C forming the helical structure except for the coil pieces C forming both ends (starting end and terminal end) of the coil 50 . Thereby, good bonding can be performed in the downstream process bonding apparatus 20 .

<Joining device 20>
Next, the joining device 20 will be described. FIG. 7 is a front view showing an outline of the joining device 20. As shown in FIG. The joining device 20 is a device for cold pressure welding two flat conductors (coil pieces) C (C1, C2), and includes a first holding part 11 capable of holding the two flat conductors C (C1, C2) and a second holding part 11. 2 holding part 12, drive part 13 for moving them, and control part 14, and a plurality of band-shaped flat conductors (coil pieces) C that can be continuous to form a spiral shape are spliced together to form a coil 50. form a structure.

The first holding part 11 is movable along a first direction (longitudinal direction of the flat conductor; X direction in the drawing), and is composed of a first upper holding body 111 and a first lower holding body 112. . The first upper holding body 111 and the first lower holding body 112 are arranged to face each other and have facing surfaces OS1 along the first direction. In the present embodiment, for convenience of explanation, the upper holding body in the drawing is referred to as a first upper holding body 111, and the lower holding body in the drawing is referred to as a second lower holding body 122. It is not limited to the top and bottom of That is, FIG. 7 may be a top view of the joining apparatus 20, in which case the first upper holding body 111 may be, for example, the back side holding body, and the first lower holding body 112 may be, for example, the front side holding body. Become. Also, the first upper holding body 111 may be, for example, the left holding body, and the first lower holding body 112 may be, for example, the right holding body.

The first upper holding body 111 and the first lower holding body 112 are movable along the X direction, and the opposing surfaces OS1 along the X direction are aligned in the second direction (thickness direction of the flat conductor; Y direction in the figure) so as to abut or separate from each other. The Y direction is a direction different from the X direction, for example, a direction orthogonal to the X direction.

The second holding portion 12 has the same configuration as the first holding portion 11 and is arranged to face the first holding portion 11 . The second holding portion 12 and the first holding portion 11 have opposing surfaces OS2 along the second direction. That is, although detailed description is omitted, the second holding part 12 is movable along the X direction, and is composed of a second upper holding body 121 and a second lower holding body 122 . The description of “top and bottom” of the second upper holding body 121 and the second lower holding body 122 is the same as that of the first holding portion 11 .

The second upper holding body 121 and the second lower holding body 122 are movable along the X direction and movable along the Y direction so that the opposing surfaces OS1 contact or separate from each other.

Although detailed illustration is omitted in FIGS. 7 to 9, the first upper holding body 111, the first lower holding body 112, the second upper holding body 121, and the second lower holding body 122 have tip ends thereof. are portions that substantially hold the coil piece C (coil piece holding portions 111T, 112T, 121T, and 122T, see FIG. 10). The coil piece holding portions 111T, 112T, 121T, and 122T are configured, for example, by the first upper holding body 111 and the first lower holding member 111T, 112T, 121T, and 122T so as to be able to locally hold (grip) only the vicinity of the pressure contact portion (joint portion) of the coil piece C, for example. It is configured in a claw shape that protrudes horizontally from the holding body 112 , the second upper holding body 121 and the second lower holding body 122 . 7 to 9, the operations of the first upper holding body 111, the first lower holding body 112, the second upper holding body 121 and the second lower holding body 122 are described, but these are the coil piece holding portions 111T. , 112T, 121T, and 122T, and can be read as these.

The first holding portion 11 and the second holding portion 12 are urged by an urging member (for example, a coil spring) 15 in directions in which they are separated from each other along the X direction. Although not shown, the first upper holding body 111 and the first lower holding body 112 are urged by a urging member (for example, a coil spring) in the direction of separation from each other along the Y direction. The upper holding body 121 and the second lower holding body 122 are biased by a biasing member (for example, a coil spring) in the direction of separating from each other along the Y direction.

The drive unit 13 moves the first holding unit 11 and the second holding unit 12 along the X direction and the Y direction via a drive transmission unit (not shown) according to instructions from the control unit 14 .

Outside the first holding portion 11 and the second holding portion 12 in the X direction, one flat conductor (in FIGS. 7 to 9, the first coil piece C1 for convenience) and the other flat conductor (in FIGS. 7 to 9, For convenience, a movement restricting portion 17 is provided to restrict movement of the second coil piece C2) in a predetermined direction. The movement restricting portion 17 abuts on both surfaces of the first coil piece C1 (the second coil piece C2) to restrict movement in the Y direction. In addition, both the coil pieces C1 and C2 are urged in one direction along the X direction (the direction in which the first coil piece C1 and the second coil piece C2 approach), and the other along the X direction (the first coil piece C1 and the second coil piece C2). movement in the direction in which the coil piece C2 separates). More specifically, the movement restricting portion 17 is a roller body biased toward the center of the first holding portion 11 and the second holding portion 12 by a biasing member (coil spring, leaf spring, etc.) 171 . . The movement restricting portion 17 has an uneven shape (for example, a saw blade-like uneven shape) along the circumferential direction on both end sides in the direction of the rotation center axis, and holds the flat conductor C at the portion of the roller body. is doing. For example, the movement restricting portions 17A and 17B of the first holding portion 11 will be described. along the X direction to the left in the drawing (approaching (pressing) direction) (that is, it can also be called a pressing direction biasing member). On the other hand, when the first coil piece C1 moves rightward in the drawing along the X direction, the movement restricting portion 17A rotates counterclockwise and the movement restricting portion 17B tries to rotate clockwise. Concavo-convex shapes provided along the circumferential direction of both ends of the central shaft mesh with each other to prevent rotation, thereby restricting rightward movement of the first coil piece C1. The same applies to the second holding portion 12 as well.

A pressing portion 18 is provided outside the first holding portion 11 and the second holding portion 12 in the Y direction. The pressing portion 18 presses the first upper holding body 111 and the first lower holding body 112 so that they are in contact with each other, and presses the second upper holding body 121 and the second lower holding body 122 so that they are in contact with each other. Press them.

8 and 9 are front views of the first holding part 11 and the second holding part 12 extracted, showing the state of movement of these parts.

FIG. 8 shows mainly the Y direction of the first holding part 11 (the first upper holding body 111 and the first lower holding body 112) and the second holding part 12 (the second upper holding body 121 and the second lower holding body 122). It is a figure explaining the movement along.

In the state shown in FIG. 4A, the facing surfaces OS1 of the first upper holding body 111 and the first lower holding body 112 (the same applies to the second upper holding body 121 and the second lower holding body 122) are closest to each other in the Y direction. This is the spaced position. This position is hereinafter referred to as the Y-direction separated position. This state is the position where the facing surfaces OS2 of the first holding portion 11 and the second holding portion 12 are most separated from each other in the X direction. This position is hereinafter referred to as the X direction separated position.

3B shows a state in which the facing surfaces OS1 of the first upper holding member 111 and the first lower holding member 112 are moved from the state shown in FIG. 2A to the closest position. In this state, the first holding part 11 holds (the wide surface WS of) the first coil piece C1 between the first upper holding body 111 and the first lower holding body 112, and the second holding part 12 holds the second upper holding body 111 and the first lower holding body 112. The second coil piece C2 (the wide surface WS thereof) is sandwiched between 121 and the second lower holding member 122 .

The first holding portion 11 holds the first coil piece C1 so as to protrude in the direction of the second holding portion 12 from the opposing surface OS2 along the Y direction. Similarly, the second holding portion 12 holds the second coil piece C2 projecting in the direction of the first holding portion 11 from the opposing surface OS2 along the Y direction. The protrusion amount A1 of the first coil piece C1 from the first holding portion 11 and the protrusion amount A2 of the second coil piece C2 from the second holding portion 12 will be described later.

In the following description, the position where the facing surfaces OS1 of the first upper holding body 111 and the first lower holding body 112 (the second upper holding body 121 and the second lower holding body 122) are closest to each other is referred to as a holding position. . That is, the first upper holding body 111 and the first lower holding body 112 (the second upper holding body 121 and the second lower holding body 122) are movable between the holding position and the Y-direction separated position.

In addition, as shown in FIG. 4C, a clamping release position (in the Y direction) is included between the clamping position and the Y-direction separated position. The release position in the Y direction (hereinafter referred to as the Y-direction release position) is a smaller distance than the Y-direction separation position, and the first upper holding body 111 and the first lower holding body 112 (the second upper holding body 121 and the second lower holding body 121 are separated from each other). 122) are separated from each other.

The facing surface OS1 of the first upper holding body 111 and the first lower holding body 112 (the second upper holding body 121 and the second lower holding body 122) is closest to the Y-direction release position in FIG. It is also possible to move to a position and transition to the state shown in FIG.

In addition, in FIG. 8 , the positions along the X direction of the first holding portion 11 and the second holding portion 12 are both maintained at the X-direction separated positions.

FIG. 9 is a diagram illustrating movement of the first holding portion 11 and the second holding portion 12 mainly along the X direction.

FIG. 9A shows a position where the first holding portion 11 and the second holding portion 12 are moved from the state shown in FIG. 8B along the X direction so that the facing surface OS2 is closest, This position is hereinafter referred to as the proximity position. That is, the first holding portion 11 and the second holding portion 12 are movable in the X direction between the X-direction separated position shown in FIG. 8 and the close position shown in FIG. 9A. Note that the first holding portion 11 and the second holding portion 12 do not contact each other even at the close position.

At the holding position (FIG. 8B), the first holding part 11 holds the first coil piece C1 by projecting it by a projection amount A, and the second holding part 12 holds the second coil piece C2 by a projection amount of A. Since it is sandwiched by protruding at A2, when the first holding portion 11 and the second holding portion 12 are in the close position (FIG. 9A), the first holding portion 11 and the second holding portion 12 are in contact with each other. However, the first coil piece C1 and the second coil piece C2 are brought into contact (bonded) and pressed against each other. That is, the protrusion amount A1 of the first coil piece C1 from the first holding portion 11 and the protrusion amount A2 of the second coil piece C2 from the second holding portion 12 are the first holding portion 11 and the second holding portion 12, respectively. are in the close position, the amount is slightly longer than the length of contact with each other (the amount that can be pressed against each other after contact).

Further, as shown in FIG. 9(B), a pressure release position (in the X direction) is included between the approach position (FIG. 9(A)) and the clamping position (FIG. 8(B)). The release position in the X direction (hereinafter referred to as the X-direction release position) is a distance smaller than the X-direction separation position (for example, the X-direction separation position shown in FIG. It is a position separated from the part 12 . When the first holding part 11 and the second holding part 12 are at the X-direction release position, the first upper holding body 111 and the first lower holding body 112 are also separated from each other to the Y-direction release position (for example, in FIG. 8C). The second upper holding body 121 and the first lower holding body 112 are also separated from each other and moved to the Y-direction releasing position)).

It is also possible to transition from the X-direction release position shown in FIG. 9(B) to the state (close position) shown in FIG. 9(A).

The holding surfaces of the flat conductors C1 and C2 of the first holding portion 11 and the second holding portion 12 (holding surfaces of the coil piece holding portions 111T, 112T, 121T, and 122T) respectively hold (hold) the flat conductors reliably. It is desirable to add anti-slip to make it easier. In this case, the anti-slip processing is, for example, processing to increase frictional resistance or processing to increase adsorptivity. Specifically, for example, the frictional resistance is increased by subjecting the surface to fine unevenness processing such as sandblasting or attaching fine particles or the like. In addition, so-called sawtooth-shaped unevenness may be formed so that the frictional resistance in one direction is higher than the frictional resistance in the other direction. Further, the adsorption force may be enhanced by creating a vacuum state, or by increasing the adsorption force by vacuum pressure or atomic force due to mirror finishing. If the degree of unevenness processing is large, a non-uniform electric field is generated (corona discharge), which may cause breakage of the coating in the case of manufacturing a coil. Therefore, it is desirable to process fine irregularities that can be formed by sandblasting.

Also, the coil piece holding portions 111T, 112T, 121T, and 122T may be configured in a groove shape capable of accommodating the coil piece C (the holding portion thereof).

The drive unit 13 moves the first holding unit 11 and the second holding unit 12 to the X-direction separated position, the X-direction release position, and the X-direction release position along the X direction via a drive transmission unit (not shown) according to an instruction from the control unit 14 . Move between adjacent positions. The drive transmission section can be configured with an appropriate configuration such as a direct acting guide (linear guide), a cam mechanism, or a rack and pinion. Further, the drive unit 13 moves the first upper holding member 111 and the first lower holding member 112 to Y-direction separated positions along the Y-direction via a drive transmission unit (not shown) according to an instruction from the control unit 14 . While moving between the clamping position and the Y-direction release position, the second upper holding body 121 and the second lower holding body 122 are moved between the Y-direction separated position, the clamping position and the Y-direction release position.

As a result, the driving section 13 moves the first holding section 11 and the second holding section 12 into the clamping state (FIG. 8B), the pressure contact state (FIG. 9A), and the pressure release state (FIG. 8C). ), FIG. 9(B)), a standby state (FIG. 8(A)), or a transition state between these two states.

More specifically, in the pinching state, the first upper holding body 111 and the first lower holding body 112 of the first holding portion 11 move along the Y direction from the Y-direction separated position (FIG. 8A) to the pinching position. (FIG. 8(B)), the first upper holding body 111 and the first lower holding body 112 are caused to sandwich the first coil piece C1, and the second upper holding body 121 and the second holding part 12 are held together. 2 The lower holding body 122 is moved along the Y direction from the Y-direction separated position (FIG. 8A) to the nipping position (FIG. 8B), and the second upper holding body 121 and the second lower holding body 122 are moved. sandwiches the second coil piece C2.

As described above, the first holding portion 11 holds the first coil piece C1 by protruding from the opposing surface OS2 along the Y direction in the direction of the second holding portion 12 by the protrusion amount A1, and the second holding portion 12: The second coil piece C2 is protruded from the opposing surface OS2 along the Y direction in the direction of the first holding portion 11 by a protrusion amount A2 and sandwiched.

In the clamping state, the first upper holding body 111 and the first lower holding body 112 of the first holding section 11 at the Y-direction release position (FIG. 8C) are moved to the clamping position (FIG. 8B). The first upper holding member 111 and the first lower holding member 112 are moved to sandwich the first coil piece C1, and the second upper holding member 12 at the Y-direction release position (FIG. 8C) is moved. When the holder 121 and the second lower holder 122 are moved to the sandwiching position (FIG. 8B), the second coil piece C2 is sandwiched between the second upper holder 121 and the second lower holder 122. be.

In the press-contact state, the first holding portion 11 and the second holding portion 12 that are in the pinched state are moved along the X direction from the X-direction separated position (FIG. 8B) against the biasing force of the biasing member 15 . Move to the proximity position (FIG. 9(A)). At this time, the first coil piece C<b>1 protrudes from the first holding portion 11 and the second coil piece C<b>2 protrudes from the second holding portion 12 . When the first holding portion 11 and the second holding portion 12 are in the close position (FIG. 9A), the protrusion amounts A1 and A2 are greater than the length of contact between the opposite end surfaces in the longitudinal direction of the band. Slightly long portions. That is, before (immediately before) moving to the close position, the facing end surfaces of the first coil piece C1 and the second coil piece C2 first contact (abut) each other. After that, the first holding portion 11 and the second holding portion 12 are moved to the close position (FIG. 9A) by the driving portion 13, so that the contacting end surfaces of the first coil piece C1 and the second coil piece C2 are moved. TS1 and TS2 are butted against each other and pressed to join. More specifically, by pressing the end faces TS1 and TS2 of the first coil piece C1 and the second coil piece C2 against each other, the stable oxide films formed on the end faces TS1 and TS2 are removed, and these are made plastic. Deform to expose the active surface. By bringing the surfaces in the active state close to each other to a thickness of 10 angstroms or less, atomic bonds between the metals are caused to perform cold pressure welding. That is, due to the cold pressure welding, the first coil piece C1 and the second coil piece C2 are compressed (reduced) after the pressure welding compared to before the pressure welding. The amount of shortening is the same between the first coil piece C1 and the second coil piece C2.

That is, when the length of the first coil piece C1 before pressure contact is L01 and the length of the second coil piece C2 before pressure contact is L02, the length of the first coil piece C1 becomes L01' and the length of the second coil piece C1 becomes L01' by pressure contact. The length of the coil piece C2 is shortened to L02', and the shortened amounts SC are the same (SC=L01-L01'=L02-L02').

After moving to the close position, the first holding portion 11 and the second holding portion 12 do not come closer to each other. Pressing stops.

In the pressure contact state, the first upper holding body 111 and the first lower holding body 112 are at the Y-direction released position (FIG. 8(C)), or the Y-direction released position and the X-direction released position (FIG. 9(B)). The second upper holding body 121 and the second lower holding body 122 are moved to the clamping position (FIG. 8B), and the first holding portion 11 and the second holding portion 12 resist the biasing force of the biasing member 15. to the close position, and the end surface TS1 of the first coil piece C1 and the end surface TS2 of the second coil piece C2 are pressed against each other to perform cold pressure welding (FIG. 9A).

In the pressure released state, the first holding portion 11 and the second holding portion 12 in the pressure contact state are controlled to move away from each other along the X direction, and the first holding portion 11 and the second holding portion 12 are separated. Move to the X-direction release position. In addition, the first upper holding body 111 and the first lower holding body 112 are controlled to move in the direction of separation along the Y direction, and the first upper holding body 111 and the first lower holding body 112 are moved in the first Y direction. Move to release position. In addition, the second upper holding body 121 and the second lower holding body 122 are controlled to move in the direction of separation in the Y direction, and the second upper holding body 121 and the second lower holding body 122 are moved in the second Y direction. It moves to the release position (Fig. 9(B)).

In the pressed state, the first holding portion 11 and the second holding portion 12 finally reach the close position, and the further pressing of the first coil piece C1 and the second coil piece C2 is stopped. After the press-contact state, the state transitions to the clamping state via the pressure-released state, and the first holding portion 11 and the second holding portion 12 again clamp the first coil piece C1 and the second coil piece C2.

Here, when the pressure contact state changes to the pressure contact released state (when the pressure contact is released), the biasing member 15 causes the first upper holder 111 and the first lower holder 112 (the second upper holder 121 and the second upper holder 121 to move). The same applies to the lower holding body 122). However, a part of the metal that has flowed due to the plastic deformation of the metal due to the pressing (expanded joint surface) is in close contact with the first holding portion 11 and the second holding portion 12, and the urging force of the urging member 15 alone is sufficient to prevent the first upper surface from In some cases, the holding body 111 and the first lower holding body 112 (the same applies to the second upper holding body 121 and the second lower holding body 122) cannot be separated from each other.

Therefore, in the present embodiment, in the pressure released state (FIG. 9B), in addition to the biasing force of the biasing member 15, the first holding portion (the first upper holding body 111 and the first lower holding body 112) is Along the X direction, it moves in the direction away from the second holding part 12 via the drive transmission part and returns to the first X direction release position. The body 122) is moved along the X direction in the direction away from the first holding portion 11 via the drive transmission portion and returned to the second X direction release position.

Note that even when the first holding portion 11 and the second holding portion 12 are forcibly moved in the direction in which the first holding portion 11 and the second holding portion 12 are separated from each other in addition to the biasing member 15, the movement restricting portion 17 causes the first coil piece C1 and the second coil piece C1 to move apart. The coil pieces C2 are restricted from moving away from each other along the X direction.

In the retracted state, the first holding portion 11 and the second holding portion 12, which are in the pressed state, the pressed released state, or the pinched state, are controlled to move along the X direction to the separated position in the X direction. The holder 111 and the first lower holder 112 are moved along the Y direction to the Y-direction separated position, and the second upper holder 121 and the second lower holder 122 are moved along the Y direction. It moves to the separated position in the Y direction (FIG. 8(A)).

Here, the joining apparatus 20 can perform cold pressure welding by pressing the flat conductors once, but in order to stabilize the joint surface, it is desirable to repeat the pressing a plurality of times for one joint portion. .

For example, in the cold pressure welding of one joint CP, the welding apparatus 20 shortens the pressing time for one time (for example, within 5 seconds) and increases the number of pressing times (for example, about 3 to 10 times). Further, pressing is performed with the pressing interval shortened to such an extent that the joint is not oxidized.

More specifically, the pushing amount (compression amount) of the bonding device 20 at one time is, for example, approximately 0.5 mm for both the first coil piece C1 and the second coil piece C2. Then, one joint CP is repeatedly pressed for, for example, 5 seconds or less each time, about 3 to 10 times, and compressed by about 1 mm or more (preferably 1.5 mm or more, specifically about 2 mm). Let Thereby, a stable joint surface can be obtained.

In this manner, the welding apparatus 20 of the present embodiment repeats the clamping state, the pressure contact state, and the pressure contact release state to cold pressure weld the first coil piece C1 and the second coil piece C2.

When the first holding portion 11 and the second holding portion 12 move to the close position in the press-contact state (FIG. 9A) after the clamping state (FIG. 8B), the first coil piece C1 and the second coil After the end faces of the pieces C2 contact (abut) each other, the end faces are pressed and cold pressure welded. Since the first holding portion 11 and the second holding portion 12 in the close position (pressure contact state) do not approach each other any more, they temporarily transition to the pressure contact released state (FIG. 9B), and the first holding portion 11 and the second holding portion 12 are moved to the Y-direction release position to release the clamping of the flat conductors C1 and C2, and the first holding portion 11 and the second holding portion 12 are moved to the X-direction release position. Then, the first holding portion 11 holds the first coil piece C1 so as to shift to the clamping state and protrude by a predetermined protrusion amount A1, and the second holding portion 12 protrudes so as to protrude by a protrusion amount A2. By holding one coil piece C2 and transitioning to the pressure contact state again, it is possible to repeat a plurality of pressures on one joint portion.

That is, the X-direction release position is a position where the first holding portion 11 can project the first coil piece C1 by the projection amount A1 for teaching, and the second holding portion 12 projects the second coil piece C2. This is the position where it can be protruded by an amount A2 and clamped.

Note that the X-direction release position does not have to be a position at which each of the flat conductors protrudes by the protruding amounts A1 and A2 when the clamping state is subsequently transitioned (as it is at that position). In this case, the first holding part 11 and the second holding part 12 are moved to positions where the flat conductors protrude by the projection amounts A1 and A2 in the pinched state, and then the flat conductors are pinched.

9A, the joining device 20 is configured such that, in addition to the movement restricting portion 17, the first coil piece C1 and the second coil piece C2 move apart along the X direction. It is preferable to provide another movement restricting portion (fixing member 16) that restricts the first coil piece C1 and the second coil piece C2 from moving along the Y direction while restricting the first coil piece C1 and the second coil piece C2.

As an example, the fixing member 16 is slightly wider than the plate thickness of the portions of the first coil piece C1 and the second coil piece C2 that are not plastically deformed, as indicated by the circles in FIG. It has two pairs of columnar protrusions 161 and 162 with an interval narrower than the length in the thickness direction, and a pair of regulating surfaces 163A provided on the outside of both ends in the plate thickness direction of the joint (for example, prism-shaped projections 163A). ) protrusion (or plate) 163 .

As a result, in the compression released state (FIG. 9B) or the retracted state (FIG. 8A), the first holding portion 11 and the second holding portion 12 are moved to the Y-direction release position and the X-direction release position by the driving portion 13 . The first coil piece C1 and the second coil piece C2 are in close contact with the first holding portion 11 and the second holding portion 12 when being moved to the position or the Y-direction separated position and the X-direction separated position. However, the movement of the first coil piece C1 and the second coil piece C2 is restricted. Specifically, for example, the cylindrical projection 161 restricts the movement of the first coil piece C1 in the X direction away from the second coil piece C2 (to the right in FIG. 9A). , the protrusion 162 restricts the movement of the second coil piece C2 in the X direction away from the first coil piece C1 (leftward in FIG. 9B). Further, the protrusion 161 having the restricting surface 163A restricts the first coil piece C1 and the second coil piece C2 from moving upward or downward in the drawing along the Y direction.

In this manner, the first coil piece C1 and the second coil piece C2 can maintain the positions immediately after the pressure contact, and the stability of the joint surface of the joint portion CP can be improved. It is possible to prevent the joint portion CP from being separated with the second holding portion 12 .

In addition, the fixing member 16 is not limited to a protrusion or a plate, and may be a rubber pressing member or the like. Also, the fixing member 16 may not be provided. Moreover, these fixing members 16 may not be provided depending on the pressure welding conditions.

In the above-described embodiment, the first holding portion 11 and the second holding portion 12 are stopped at the X-direction release position and the Y-direction release position in the pressure contact release state. It may pass through the Y-direction release position, but may not stop at that position. In other words, the first upper holding body 111 and the first lower holding body 112 (the same applies to the second upper holding body 121 and the second lower holding body 122) are arranged so that there is no gap between the holding position, the Y-direction released position, and the Y-direction separated position. The first holding portion 11 and the second holding portion 12 may move without stopping, or the first holding portion 11 and the second holding portion 12 may move between the approach position, the X-direction released position, and the X-direction separated position without stopping. .

Conventionally, cold pressure welding has been used to join round wires, but according to the above-described joining apparatus 20 of the present embodiment, good and stable cold pressure welding of flat conductors can be performed. .

Here, the coil piece holding portions 111T, 112T, 121T, and 122T of the first holding portion 11 and the second holding portion 12 will be further described with reference to FIG. FIG. 10 is a diagram showing the coil piece holding portions 111T and 112T of the first holding portion 11 and the coil piece holding portions 121T and 122T of the second holding portion 12 extracted. 8A is a top view of the sandwiched state (FIG. 8B), and FIG. Coil piece C is a side view). FIG. 9C is a top view of the pressure contact state (FIG. 9A), and FIG. It is a front view (a coil piece C is a side view).

In this embodiment, the coil pieces C (C1, C2) are press-contacted at their straight portions, and the spiral structure is formed by adding the coil pieces C one by one and press-contacting them.

The portions to be pressed are, for example, the portions (long side regions LS1 and LS2) forming the long sides of one peripheral region CR, and regions other than the direction changing portion TN of one peripheral region CR. As a result, the press-contact portion (joint portion CP) is located in a part (for example, near the center) of the long side of the one-circumference region CR.

In addition, the splicing of the coil piece C1 and the coil piece C2 consists of one side having the bent portion B0 of the coil piece C1 (for example, the long side region LS2) and one side having the bent portion B0 of the coil piece C2 (for example, the long side region LS2). LS2). Alternatively, the coil piece C1 and the coil piece C2 are spliced together by joining one side of the coil piece C1 that does not have the bent portion B0 (for example, the long side region LS1) and one side that does not have the bent portion B0 of the coil piece C2 (for example, the long side region LS1). side area LS1).

Here, the coil piece C1 and the coil piece C2 are spliced together, as shown in FIG. and one side (long side region LS2).

That is, as shown in this example, in the case of a coil piece C (U-shaped, C-shaped coil piece C, etc.) having long side regions LS1 and LS2 facing each other, for example, the lower portion shown in FIG. The first holding portions 11 (coil piece holding portions 111T and 112T) are inserted in the Z direction into, for example, the long side region LS2 of the coil piece C1 from the side to hold it, and the first holding portion 11 (coil piece holding portions 111T, 112T) is inserted into, for example, the long side region LS2 of the coil piece C2 from the side. 2 holding portions 12 (coil piece holding portions 121T and 122T) are inserted and held in the Z direction, and both end surfaces TS1 and TS2 are pressed against each other. Then, for example, the other long side region LS1 of the coil piece C2 is brought into pressure contact with one long side region LS1 of the next coil piece C (C3) (not shown) at another timing.

Therefore, when the long side region LS2 of the coil piece C1 and the long side region LS2 of the coil piece C2 are held by the first holding portion 11 and the second holding portion 12, the other long side of the coil piece C1 and the long side region LS2 of the coil piece C2 are not pressed at that timing. It is necessary to avoid interference between the region LS1, the first holding portion 11 and the second holding portion 12 (coil piece holding portions 111T, 112T, 121T and 122T).

Here, as shown in the upper part of FIG. 3B, the coil piece C before deformation (the flat plate-like coil piece C in which the long side regions LS1 and LS2 and the short side SS are located substantially on the same plane, and the bent portion B0 are formed. When the coil piece C) that is not attached is press-contacted, inserting the coil piece holding portions 111T, 112T, 121T, and 122T in the direction of the short side SS of the coil piece C at an arbitrary distance allows the coil piece holding shown in FIG. As indicated by the dashed line portions at the ends of the portions 111T, 112T, 121T, and 122T, there is a risk of interference with the other long side region LS1 that is not press-contacted at that timing.

That is, in this case, the tip portions (upper end portions in FIG. 10A) of the first holding portion 11 and the second holding portion 12 (coil piece holding portions 111T, 112T, 121T, and 122T) are As indicated by the oblique hatching in (A), the insertion position must be set (controlled) so that it is reliably arranged in the inner peripheral portion of the one-round region CR.

In addition, since the helical structure of the present embodiment is configured by sequentially connecting the coil pieces C, as the number of joints increases, the coil pieces C (joint The coil piece CC) can be expanded and contracted arbitrarily. In other words, the joined coil piece CC expands and contracts indefinitely due to its own weight, and the state of expansion and contraction changes depending on the number of joined unit coil pieces C0. The shape of the joined coil piece CC (interval between each one round region CR when inserting the first holding portion 11 and the second holding portion 12 (coil piece holding portions 111T, 112T, 121T, 122T)) is unspecified (unspecified). stability), and the setting (or control) for avoiding interference with the other long side region LS1 becomes more complicated.

Therefore, in the present embodiment, the coil piece C is deformed into a predetermined shape by the bending device 30 in advance, and the shape of the coil piece C when held by the first holding portion 11 and the second holding portion 12 is changed to the predetermined shape. was to be maintained at

Specifically, before pressure welding by the bonding device 20, the bending device 30 bends the long side region LS1 of the coil piece C so that it is inclined at a predetermined angle α with respect to the other long side region LS2. to form

Further, as shown in FIG. 10B, the angle .alpha. This is the angle at which the long-side region LS2 is inclined with respect to the long-side region LS1 so as to prevent this from occurring. Further, the long side region LS2 is inclined with respect to the long side region LS1 so that the long side region LS1 on the reference plane SF0 of the coil piece C2 and the coil piece holding portion 121T (the same applies to 122T) do not interfere with each other. be.

More specifically, one coil piece C1 is substantially held between the coil piece holding portions 111T and 112T in the holding region P1. In this case, the separation distance LL1 in the clamping direction (Y direction) between the long-side region LS1 and the long-side region LS2 of the coil piece C1 when viewed from the side is larger than the thickness d1 of the coil piece holding portion 112T (111T) in the clamping direction. A coil piece C1 (long side region LS2) is bent at an angle α.

Similarly, the other coil piece C2 is substantially held between the coil piece holding portions 121T and 122T in the holding region P2. In this case, the separation distance LL2 in the clamping direction (Y direction) between the long-side region LS1 and the long-side region LS2 of the coil piece C2 is larger than the thickness d2 of the coil piece holding portion 121T (122T) in the clamping direction. A coil piece C2 (long side region LS2) is bent at an angle α.

With such a configuration, it is possible to avoid unstable expansion and contraction of the joined coil pieces CC, and even if the length in the spiral traveling direction increases, the interval between each one-round region CR is (approximately) a predetermined interval. can be maintained.

Therefore, as shown in FIG. 1B, the space (space in the Y direction and thickness direction) when inserting the first holding portion 11 and the second holding portion 12 (coil piece holding portions 111T, 112T, 121T, 122T) is can be assured. In addition, as indicated by the dashed line in FIG. 4C, the positions of the tip portions of the first holding portion 11 and the second holding portion 12 (one end portion of the coil piece C in the widthwise direction of the band) can be set arbitrarily. (there is no need to reliably arrange in the inner peripheral area of the one round area CR). This eliminates the need for complicated settings and controls for avoiding interference between the first holding portion 11 and the second holding portion 12 and the other long-side region LS2, thereby significantly improving the pressure welding speed.

Also, it is desirable to secure a space in the X direction in FIG. This will be explained with reference.

FIG. 11 is a top view corresponding to FIGS. 10(A) and 10(C) for further explaining the formation position of the bent portion B0 using the U-shaped coil piece C (C1, C2) as an example.

In the case of the U-shaped coil piece C, as will be described in detail later, two coil pieces C1 and C2 are arranged to face each other, and the long side regions (here, the long side regions LS2) formed with the bent portions B0 are connected to each other. Alternatively, the long side regions (here, long side regions LS1) in which the bent portion B0 is not formed are connected to each other to form a spiral structure.

When the long side regions LS2 in which the bent portion B0 is formed are connected to each other, the coil piece holding portions 111T, 112T, 121T, and 122T are the regions between the bent portion B0 and the end surfaces TS1 and TS2 to be press-contacted. are sandwiched (see FIG. 10(A)). In other words, the coil piece holding portions 111T, 112T, 121T, and 122T are formed at positions where the area between the bent portion B0 and the end surfaces TS1 and TS2 to be pressed can be held securely.

Specifically, as shown in FIG. 11, a bent portion B0 is formed in the vicinity of the long side region LS2 except for the direction changing portion TN.

More specifically, the bent portion B0 is, for example, "the maximum length in the band longitudinal direction of the long side LS forming one peripheral region CR (the length of the region to be the long side LS forming one peripheral region CR , the maximum length in the lengthwise direction of the band) LMAX”, it is desirable to provide it so as to be positioned within a range of less than 30% from the end.

For example, as shown in FIG. 11(A), a virtual one-circle region of a virtual helical structure in a state where the end surfaces TS1 and TS2 of the coil pieces C1 and C2 are brought into contact with each other (state before pressure contact) is area CR'. In this case, the long side LS' forming the virtual one peripheral region CR' is the total length of the long side region LS2 of the coil piece C1 and the long side region LS2 of the coil piece C2, and the long side region LS2 is the total length of the long side region LS2 of the coil piece C1. The long side LS that forms the one-circumference area CR is obtained by press-contacting from the abutting state and shortening the two.

That is, the length in the band longitudinal direction of the long side LS' forming the virtual one peripheral region CR' (the total length of the long side region LS2 of the coil piece C1 and the long side region LS2 of the coil piece C2) is the above is the "maximum length LMAX in the longitudinal direction of the long side LS forming one peripheral region CR" ((B) in the figure).

The bent portion B0 is, for example, 30% from the end on the short side SS side of the maximum length LMAX (total length of the long side region LS2 of the coil piece C1 and the long side region LS2 of the coil piece C2). It is preferable that the length LB1<LMAX×30% be formed so as to be located in the long side area LS2 (the area excluding the hatched direction changing portion TN).

By doing so, the clamping regions P1 and P2 (see FIG. 10) of the coil piece holding portions 111T, 112T, 121T, and 122T are formed in the long side LS' of the virtual one peripheral region CR' including the center thereof. A length of 40% or more of the maximum length LMAX (2×length LB2≧LMSAX×40%) can be secured on the left and right in the X direction.

Alternatively, in each of the coil pieces C1 and C2, the length LB1 from the end on the short side SS side to the bent portion B0 is the length LB2 or less from the bent portion B0 to the end surface TS (TS1, TS2). , a bent portion B0 may be formed.

By doing so, the clamping regions P1 and P2 (see FIG. 10) of the coil piece holding portions 111T, 112T, 121T, and 122T are formed in the long side LS' of the virtual one peripheral region CR' including the center thereof. A length of 50% or more of the maximum length LMAX (2×length LB2≧LMSAX×50%) can be secured on the left and right in the X direction.

If the length that can be secured as the clamping regions P1 and P2 of the coil piece holding portions 111T, 112T, 121T, and 122T is short, clamping may become difficult. Since a region with a length of 40% or more including the center can be secured in the long side LS' of the virtual one-circle region CR', it is easy to hold the coil piece holding portions 111T, 112T, 121T, and 122T. becomes. This also eliminates the need for complicated settings and controls for avoiding interference between the first holding portion 11 and the second holding portion 12 and the other long side region LS2, and the pressure contact speed can be significantly improved. .

It goes without saying that the width of the coil piece holding portions 111T, 112T, 121T, and 122T in the X direction and the pressure contact amount (pressing amount) of the coil piece C are taken into consideration for the formation position of the bent portion B.

By the way, as shown in FIG. 10(D), after the two coil pieces C1 and C2 are cold pressure welded, a burr 55 due to extrusion is generated at the joint CP. If this burr 55 remains, there is a possibility that it will still interfere with the first holding portion 11 and the second holding portion 12 during the next press contact. Therefore, in the present embodiment, after the completion of cold pressure welding, the coil pieces (joined coil pieces CC) are taken out from the first holding portion 11 and the second holding portion 12, the burrs 55 are removed by the removing device 40, and the coil pieces are removed. Cold pressure welding is performed between C (joined coil piece CC) and another (new) coil piece C.

In each figure of the present embodiment, the joint CP is illustrated for convenience of explanation, but in reality this joint is substantially invisible (extremely difficult).

<Removal device>
The removing device 40 will be described with reference to FIG. 12A and 12B are schematic diagrams of the removing device 40, FIG. 12A is a top view similar to FIGS. 10A and 10C, and FIGS. 10(B) and 10(D) are a front view (a side view of the joined coil piece CC) of the removing device 40. FIG.

As shown in FIG. 10(D), burrs 55 are generated at the joint portion of the joined coil piece CC immediately after being ejected from the joining apparatus 20 . The burrs 55 are generated vertically up and down so as to be substantially orthogonal to the wide surfaces WS of the joined coil pieces CC at the joining portion.

The removing device 40 is a device for removing a part of the joined coil pieces CC after cold pressure welding, and more specifically, removes the burrs 55 generated by pressing the two coil pieces C together.

Specifically, as shown in FIG. 12 , the removing device 40 includes a coil piece holding portion 41 and a removing portion 43 . The coil piece holding portion 41 is composed of a first coil piece holding portion 411 and a second coil piece holding portion 412 that are arranged to face each other. The first coil piece holding part 411 and the second coil piece holding part 412 hold both sides (for example, the short side SS part) separated by a predetermined distance in the longitudinal direction of the band across the burr 55 after welding of the joined coil piece CC. (Both sides of the wide surface WS are held between them).

The removing unit 43 is, for example, cutting means (scissors) configured to be able to advance and retreat in the Z direction with respect to the coil piece C held by the coil piece holding unit 41 . In addition, the removal unit 43 can also move up and down in the Y direction.

The coil pieces joined by the joining device 20 (joined coil pieces CC) are taken out from the joining device 20 by a robot or the like and transferred to the removal device 40 (see FIG. 1). In the removing device 40, when the joined coil piece CC is held by the coil piece holding portion 41, the removing portion 43, which has retreated to the rear in the Z direction (lower side in FIG. CC direction) (the same figure (B)), for example, first cut off the burr 55 protruding upward (the same figure (C)). After that, the removing part 43 temporarily retreats backward in the Z direction, moves downward in the Y direction, and then moves forward again in the Z direction ((D) in the figure) to cut off the burr 55 protruding downward ((D) in the same figure). Figure (E)).

Although illustration is omitted, the cutting means of the removing unit 43 is not limited to scissors, and may be a cutter having saw teeth capable of horizontal movement (horizontal rotation), for example.

Since the burr 55 is removed by the removing device 40 each time the joining by the joining device 20 is completed, interference between the first holding portion 11 and the second holding portion 12 and the joined coil pieces CC can be avoided. That is, the joined coil piece CC always avoids interference between the first holding portion 11 and the second holding portion 12 and the joined coil piece CC in a state where the burr 55 of the joint portion CP is removed, and the new coil piece C and can be spliced.

Next, a coil manufacturing system 100 of the present embodiment and a coil manufacturing method for sequentially connecting a plurality of coil pieces C using the same will be described with reference to FIG. 13 .

FIG. 13(A) is a schematic diagram of the coil manufacturing system 100, and FIG. 13(B) is a diagram showing a specific example of the coil manufacturing system 100 and the joined coil pieces CC sequentially formed.

As shown in FIG. 1A, in this embodiment, one or two bending devices 30, one joining device 20 and one removing device 40 are united as a set of coil manufacturing devices 10, The coil manufacturing units (coil manufacturing apparatuses) 10_1, 10_2, 10_3, . The coil manufacturing system 100 is configured by connecting the coils in the form of a line.

For example, when manufacturing the coil 50 having 5 turns (10 coil pieces C are used) using all U-shaped coil pieces C, the coil manufacturing system 100 includes, for example, 9 units connected in series. coil manufacturing units 10_1 to 10_9. Then, the deformation of the coil pieces (formation of the bent portion B0), joining, and deburring are performed each time the unit coil pieces C0 are joined to form the joined coil pieces CC.

In this case, for example, four and five coil manufacturing units 10 may be operated in parallel, and two bonded coil pieces CC manufactured by these units may be finally bonded to form a 5-turn coil 50 .

A specific description will be given with reference to FIG. FIG. 1B is a diagram showing the state of coil pieces C (unit coil pieces C0 and joined coil pieces CC) in the process of being manufactured for each coil manufacturing unit (coil manufacturing apparatus) 10. The coil pieces C are coil manufacturing units. 10 (a side view of the coil piece C). Also, the coil pieces C (joined coil pieces CC) in the joining device 20 of each coil manufacturing unit 10 are shown by extracting only the portion of the coil pieces C joined in the device.

Here, as an example, a plurality of (here, five (unit coil pieces C01, C02, C03, C04, and C05) unit coil pieces C01, C02, C03, C04, and C05) U-shaped (U-shaped) unit coil pieces C0 having two direction changing portions TN are prepared. , are connected (continuously) to manufacture a coil (helical structure) 50 (joined coil piece CC).

The first coil manufacturing unit 10_1 is composed of, for example, two bending devices 30_1A and 30_1B, one joining device 20_1, and one removing device 40_1. 10_N (10_4 in this example) each comprise one bending device 30_2 . . . 30_N (30_4) and one joining device 20_2 . 40_4).

In the coil manufacturing system 100, first, in order to form a one-round region CR1 of the first round of the helical structure (which is the same as the one-round region of the joined coil piece CC1 (one-round joint region)), two U-shaped unit coil pieces C01 and C02 are prepared and supplied to the first coil manufacturing unit 10_1. In the first coil manufacturing unit 10_1, the unit coil piece C01 is bent in the bending device 30_1A ((B) (1) in the figure), and the unit coil piece C02 is bent in the bending device 30_1B (( B)(2)). Then, the deformed unit coil pieces C01 and C02 are taken out by a robot (not shown) or the like and supplied to the joining device 20_1. In the joining device 20_1, as shown in FIG. 10, the unit coil pieces C01 and C02 are held by the first holding portion 11 and the second holding portion 12, respectively, and one end surface TS1 of the unit coil piece C01 and the unit coil piece C02 are separated from each other. One end faces TS2 are connected (cold pressure welding) to form a joined coil piece CC1 ((B) (3) in the figure). At this time, for example, the joining device 20_1 presses the end surfaces TS1 and TS2 at the respective straight line portions of the unit coil piece C01 and the unit coil piece C02, and the joining area of the joining coil piece CC1 for one round (one joining area) is pressed. The length is made to match the length of the one round region CR of the coil 50 .

More specifically, in this example, as shown in FIG. 10, the long side region LS2 of the unit coil piece C01 (coil piece C1) is held by, for example, the first holding section 11, and the unit coil piece C02 (coil piece C2) is held. The second holding portion 12 holds the long side region LS2 of , and presses the TS1 and TS2 of both. In this example, the long side region LS2 of the unit coil piece C01 is a long side region inclined with respect to the reference plane SF0 on which the short side SS and the long side region LS1 exist, and the long side region LS2 of the unit coil piece C02 is the long side region LS2. , and the long side area slanted with respect to the reference plane SF0 on which the short side SS and the long side area LS1 are present. That is, the robot turns over one unit coil piece C0 from the state where it is placed on the bending device 30 . Specifically, for example, the unit coil piece C01 is placed on the bending device 30_1A so that the pressing surface (the surface in contact with the pressing portion) of the bending device 30_1A faces downward (see FIG. 13(B) ( 1)) is turned upside down, and held by the first holding portion 11 (FIGS. 13B(2) and 13B(3)). On the other hand, the robot holds the unit coil piece C02 on the second holding part 12 without turning it over from the state of being placed on the bending device 30_1B (while keeping the front and back at the time of deformation) (Fig. 13(B) (1 ), (B) (3) in FIG.

That is, the long side region LS2 of the newly joined unit coil piece C01 and the long side region LS2 of the unit coil piece C02 are held horizontally by the first holding portion 11 and the second holding portion 12, respectively. This step is hereinafter referred to as "performing a new bonding area leveling step". Then, both are pressed to form a joined coil piece CC1 (FIG. 13(B)(3)).

Then, the joined coil piece CC1 is taken out again by a robot (not shown) or the like, and the burr 55 is removed by the first removal device 40_1 arranged downstream of the joining device 20_1 ((B) (4) in the figure). In the removing device 40_1, when the joined coil piece CC1 is held by the coil piece holding portion 41, the removing portion 43 advances to remove, for example, the burr 55 protruding upward. The removing part 43 retreats and descends once, and advances again to remove the burr 55 protruding downward (see FIG. 12).

In this way, the removing device 40 is configured to be able to move forward and backward with respect to the burr 55 generated by joining the unit coil pieces C0, and advances to the burr 55 for each joint by the joining device 20 to remove it. do.

As a result, a one round region CR (CR1) of the first round of the helical structure is formed. After that, the joined coil piece CC1 is taken out by a robot (not shown) or the like, and supplied to the joining device 20_2 of the second coil manufacturing unit 10_2 arranged downstream of the first removal device 40_1 (FIG. 13(B) (6 )).

At this time, that is, when supplying to the joining device 20_2 of the second coil manufacturing unit 10_2, one end surface TS1 of the joined coil piece CC1 (the unjoined end surface TS1 of the unit coil piece C02) and a new unit coil piece One end face TS2 of C03 is horizontally held by first holding portion 11 and second holding portion 12, respectively, and cold pressure welded.

Then, in the bending device 30_2 of the second coil manufacturing unit 10_2, the unit coil piece C03 to be joined next is bent ((B) (5) in the same figure), and the deformed unit is bent by a robot or the like (not shown). Take out the coil piece C03. In the second coil manufacturing unit 10_2 and subsequent units, the deformed unit coil pieces C0 are connected one by one to the previously formed joined coil pieces CC. become a platform.

In the second joining apparatus 20_2, one end surface TS1 of the joined coil piece CC1 (unjoined end surface TS1 of the unit coil piece C02) and one end surface TS2 of the unit coil piece C03 are formed into straight portions in the same manner as described above. are cold pressure welded to form a joined coil piece CC2 ((B) (6) in the figure). Specifically, the long side region LS1 of the joined coil piece CC1 (the unit coil piece C02) is held by, for example, the first holding unit 11 (while maintaining the front and back sides when pressed in the joining apparatus 20_1), and the unit coil piece C03 is held. The second holding unit 12 holds the long side region LS1 of .

That is, the new joint regions (the long side region LS1 of the joined coil piece CC1 (unit coil piece C02) and the long side region LS1 of the new unit coil piece C03) are horizontally held by the first holding portion 11 and the second holding portion 12. A leveling step (a new bonding area leveling step) is performed. In this leveling step, the long-side region LS2 of the unit coil piece C01 and the long-side region LS2 of the unit coil piece C02 that have already been joined are tilted from the horizontal state immediately after joining ((B) (4) in FIG. 4). , a grading step (a step of grading the bonded region) is also performed at the same time. Then, the end faces TS1 and TS2 of both are pressed ((B) (6) in the same figure).

The long-side region LS1 of the joined coil piece CC1 (unit coil piece C02) is a long-side region located substantially on the same plane (reference plane SF0) as the short side SS. It is a long-side region positioned substantially on the same plane (reference plane SF0) as the side SS.

For example, the robot is placed on the bending device 30_2 so that the pressing surface of the bending device 30_2 (the surface in contact with the pressing portion) faces downward (the posture shown in FIG. 13B (1)). ), the unit coil piece C03 is held by the second holding portion 12 ((B) (5) and (B) (6) in FIG. 1) to form a joined coil piece CC2. do.

Then, the joining coil piece CC2 is taken out by a robot (not shown) or the like, and the burr 55 is removed by the second removal device 40_2 arranged downstream of the joining device 10_2 ((B) (7) in the figure). As a result, a joined coil piece CC2 shown in (7) of FIG. After that, the joined coil piece CC2 is taken out by a robot or the like and supplied to the joining device 20_3 of the third coil manufacturing unit 10_3 ((B) (9) in the figure).

On the other hand, in the bending device 30_3 of the third coil manufacturing unit 10_3, the unit coil piece C04 to be joined next is bent ((B) (8) in the figure), and the deformed unit is bent by a robot or the like (not shown). Take out the coil piece C04.

In the third joining device 20_3, one end surface TS1 of the joined coil piece CC2 (an end surface to which the unit coil piece C03 is not joined) and one end surface TS2 of the unit coil piece C04 are joined in a straight line portion in the same manner as described above. Cold pressure welding is performed to form a joined coil piece CC3 ((B) (9) in the figure). Specifically, the long side region LS2 of the joined coil piece CC2 (the unit coil piece C03) is held by, for example, the first holding unit 11 (while maintaining the front and back sides when pressed by the joining device 20_2), and the unit coil piece C04 is held. The second holding unit 12 holds the long side region LS2 of . That is, the new joint regions (the long side region LS2 of the joined coil piece CC2 (unit coil piece C03) and the long side region LS2 of the new unit coil piece C04) are formed by the first holding portion 11 and the second holding portion 12. A horizontal holding process (horizontalization process of a new bonding area, tilting process of bonded areas (long side area LS1 of unit coil piece C02 and long side area LS1 of unit coil piece C03)) is performed, Both end surfaces TS1 and TS2 are pressed. The long side region LS2 of the joined coil piece CC2 (unit coil piece C03) is a long side region slanted with respect to the reference plane SF0, and the long side region LS2 of the unit coil piece C04 is also slanted with respect to the reference plane SF0. It is a long side area.

Further, for example, the robot moves the unit coil piece C04 while it is placed on the bending device 30_3 (without turning it inside out) so that the pressing surface (the surface in contact with the pressing portion) of the bending device 30_3 faces upward. It is held by the second holding part 12 to form the joined coil piece CC3.

Then, the joining coil piece CC3 is taken out by a robot (not shown) or the like, and the burr 55 is removed by the third removal device 40_3 arranged downstream of the joining device 10_3 ((B) (10) in the figure). As a result, a one round region CR (CR2) of the second round of the helical structure is formed. After that, the joined coil piece CC3 is taken out by a robot or the like and supplied to the joining device 20_4 of the fourth coil manufacturing unit 10_4 ((B) (12) in the figure).

On the other hand, in the bending device 30_4 of the fourth coil manufacturing unit 10_4, the unit coil piece C05 to be joined next is bent ((B) (11) in the figure), and the unit after deformation is made by a robot or the like (not shown). Take out the coil piece C05.

In the fourth joining device 20_4, one end surface TS1 of the joined coil piece CC3 (an end surface to which the unit coil piece C04 is not joined) and one end surface TS2 of the unit coil piece C05 are joined in a straight line portion in the same manner as described above. Cold pressure welding is performed to form a joined coil piece CC4 ((B) (12) in the figure). Specifically, the long side region LS1 of the joined coil piece CC3 (the unit coil piece C04) is held by, for example, the first holding unit 11 (while maintaining the front and back sides when pressed by the joining device 20_3), and the unit coil piece C05 is held. The long-side region LS1 is held by the second holding portion 12, and new joining regions (long-side region LS1 of joined coil piece CC3 (unit coil piece C04) and long-side region LS1 of new unit coil piece C05) are formed. is horizontally held by the first holding portion 11 and the second holding portion 12 (horizontalization step of the new bonding area, the bonded area (the long side area LS2 of the unit coil piece C03 and the unit coil piece C04 2) is performed to incline the long side region LS2), and the two end faces TS1 and TS2 are pressed against each other. The long-side region LS1 of the unit coil piece C05 is a long-side region positioned on the reference plane SF0, and the long-side region LS1 of the joined coil piece CC3 (unit coil piece C04) is also a long-side region positioned on the reference plane SF0. .

Further, for example, the robot performs a reversing step of reversing the unit coil piece C05 from the state placed on the bending device 30_4 so that the pressing surface (the surface in contact with the pressing portion) of the bending device 30_4 faces downward. is held by the second holding portion 12 (FIG. 1B(11), FIG. 1B(12)) to form the joined coil piece CC4.

Then, the joining coil piece CC4 is taken out by a robot (not shown) or the like, and the burr 55 is removed by the fourth removing device 40_4 arranged downstream of the joining device 10_4 ((B) (13) in the figure). As a result, a joined coil piece CC4 shown in (13) of FIG. 1B is obtained. After that, the joined coil piece CC4 is taken out by a robot or the like. Thereafter, by repeating this for a predetermined number of turns N as necessary, a helical structure having a region CR for one round of N turns is formed.

Thus, in this embodiment, the bent coil pieces C1 and C2 are joined at the end surfaces TS1 and TS2. Specifically, the coil piece C1 and the coil piece C2 are spliced together by one side having the bent portion B0 of the coil piece C1 (for example, the long side region LS2) and one side having the bent portion B0 of the coil piece C2 (for example, long side region LS2) (for example, (B) (1) to (B) (3) in FIG. 1), or one side (for example, long side region LS1) that does not have the bent portion B0 of the coil piece C1 and one side (for example, the long side region LS1) of the coil piece C2 that does not have the bent portion B0 (for example, (5) in FIG. 4B, (6) in FIG. 3B), or Join with

Then, as described above, the bending process of the coil piece C by the bending device 30 ((B) (1) in the same figure) is performed, and one of the coil pieces C is subjected to the reversing process ((B) (2) in the same figure), A process of leveling a new bonding area (a process of tilting a bonded area) is performed (FIG. 1B(1) to FIG. 1B(3)), and a bonding process is performed by the bonding apparatus 20 (FIG. B) (3)), and a removal step is performed by the removal device 40 ((B) (4) in the figure).

After that, the coil piece C is bent by the bending device 30, and one of the coil pieces C is turned over ((B) (5) in the same figure). ((B)(6) in FIG. 1), and a removal step is carried out by the removing device 40 ((B)(7) in FIG. 1).

Subsequently, the bending process of the coil piece C by the bending device 30 is performed ((8) in FIG. 1B), the new bonding area is leveled, and the bonding process is performed by the bonding device 20 ((B) in the same figure). (9)), and a removal step is performed by the removal device 40 ((B) (10) in the figure).

After that, the coil piece C is bent by the bending device 30, and one of the coil pieces C is turned over ((B) (11) in the same figure). ((B) (12) in the same figure), and a removal process is carried out by the removing device 40 ((B) (13) in the same figure).

This is repeated until one long side LS of the opposing long sides LS of one peripheral region CR becomes the other long side LS as shown in FIGS. A helical structure is obtained with a shape that is inclined with respect to.

In other words, in the coil manufacturing apparatus 10 of the present embodiment, the coil pieces are connected (spliced) in a state in which the coil pieces spread in the advancing direction of the spiral. It is then molded (eg, pressed) into a coil 50 with elastic and/or plastic deformation that compresses it in the direction of travel of the helix to form a coil 50 in which each circumference of the helix is close to each other.

In this example, the coil piece C to be newly connected is supplied to the bonding device 20 after the bending portion B0 is formed by the bending device 30 (immediately before connection each time connection is made). However, the present invention is not limited to this, and the bending process of the coil pieces C by the bending device 30 may be performed in advance for all necessary coil pieces C. FIG. That is, for example, when forming the coil 50 using a total of 20 coil pieces C, after forming the bent portions B0 on all of the 20 coil pieces C by the bending device 30, they are joined one by one. It may be configured to supply to the device 20 .

Even in this case, the removal device 40 removes the burr 55 of the joint CP each time one joint CP is formed. With such a configuration, the joined coil piece CC avoids interference between the first holding portion 11 and the second holding portion 12 and the joined coil piece CC while the burr 55 of the joint portion CP is always removed, and a new joint coil piece CC is formed. It can be joined with the coil piece C.

FIG. 14 is a diagram showing an example of a completed helical structure 50' discharged from a predetermined number (Nth) of coil manufacturing units 10_N (the number of turns of the coil is different from that in the above embodiment). 1A is a front view (top view) seen from the direction of the spiral axis, and FIG. Figures (C) to (E) are arrow views (side views) in the direction of V2 after molding.

The completed helical structure 50' is molded into the desired shape. That is, the coil piece C of this embodiment is bent by the bending device 30 before cold pressure welding, and immediately after being discharged from the coil manufacturing device 10, as shown in FIG. A gap G is formed in .

Therefore, molding is performed to narrow the gap G. Specifically, first, annealing is performed to soften the helical structure 50'. That is, a helical structure 50' made of a metal material (for example, a copper plate) is heated in a furnace to an appropriate temperature (for example, the recrystallization temperature or higher), held for a predetermined time, and slowly cooled in the furnace. As a result, the metal material forming the helical structure 50' becomes a texture free of internal stress and is softened. In other words, the annealing makes the helical structure 50' easily plastically deformable. Alternatively, it can be said that the annealing controls the plastic modulus of the helical structure 50' (lowers the elastic limit of the helical structure 50'). After annealing, the (metal material of) the helical structure 50' is softened, but when no external force is applied to the helical structure 50', the shape (gap G shown in FIG. 14B) is maintained. be.

Then, the helical structure 50' having the shape shown in FIG. 4B is immersed in a liquid insulating resin and integrally covered with the insulating resin. Alternatively, the helical structure 50' may be integrally coated with the insulating resin by spraying the liquid insulating resin. As a result, the insulating resin also enters the gaps G between the one-round regions CR, and a spiral structure 50' in which the periphery of the flat conductor is covered with the insulating resin from one end to the other end along the spiral traveling direction is obtained. be done.

After that, as shown in FIG. 4C, the helical structure 50′ is compressed in the direction of the helical axis so that the gap G of the helical structure 50′ becomes smaller, and the helical structure is elastically and/or plastically deformed in the direction in which the helical structure advances. are brought close to each other and solidified. The annealed helical structure 50' is easily elastically and/or plastically deformed, the gap G between the one-round regions CR disappears, and the one-round regions CR are fixed (solidified) in close contact with each other. . Alternatively, it is fixed (solidified) in a state in which the gap G between each one-round region CR is extremely small. Each of the close or close one-round regions CR is insulated ((C) or (D) in the figure).

Furthermore, for example, in the case of the coil 50 attached to the stator core, if necessary, it may be concave or convex in the axial center direction of the helical structure (radial direction of the stator core) according to the shape of the stator core. As shown in (E), it is formed into a curved shape in which the inner peripheral end portion and the outer peripheral end portion are not flush with each other. As a result, the coil 50 integrally coated with the insulating resin is obtained.

Conventionally, a long conductor wire corresponding to the completed length of a coil is coated with an insulating resin and then wound to form a helical structure. However, in this case, the insulating resin is stretched near the outer periphery of the curved portion of the winding, and the thickness of the coating becomes thin, which is a factor in deterioration of the withstand voltage. Also, for example, in the case of coating with an insulating resin before molding as described above, the same problem arises because the coating thickness of the insulating resin varies due to pressing. In this embodiment, the helical structure 50' is softened by annealing in a state in which there is a gap G between each one-round region CR, and is integrally coated with an insulating resin, and then the gap G is eliminated (made extremely small). ) and solidify. In other words, the flat conductor can be covered with the insulating resin substantially uniformly along the direction of spiral movement from one end to the other end of the spiral structure 50', thereby improving the uniformity of the film thickness of the insulating resin. be able to. Further, it is also possible to bond the one round regions CR of the helical structure 50' to each other with an insulating resin.

The joining apparatus 20 of the present embodiment uses a coil piece C that is longer by the compression amount (shrinkage amount) by cold compression (longer by the margin) based on the length of the coil 50 after completion of the compression by cold compression. The coil 50 is manufactured by adding the coil piece C while repeating (contraction).

Therefore, cold pressure welding is performed while measuring the distance in the longitudinal direction BL of the coil piece C (see FIG. 2B). The measurement of the distance in the longitudinal direction BL of the band is performed by, for example, providing a slip detection mechanism (not shown) in the first holding portion 11 and the second holding portion 12 (or in the vicinity thereof), so that the coil held by the first holding portion 11 The distance in the longitudinal direction BL of the band is measured by detecting slippage when the piece C (first coil piece C1) and the coil piece C (second coil piece C2) held by the second holding portion 12 are pressed. be able to. The distance in the band longitudinal direction BL may be measured simultaneously with cold pressure welding (in real time), or before and after cold pressure welding (or before or after cold pressure welding). As a result, it is possible to achieve high precision in the dimensions of the completed coil.

As shown in FIGS. 2(A) and 2(E) to 2(G), the substantially right-angled direction changing portions TN of the coil pieces C are the corners of the coil 50. As shown in FIG. That is, according to the joining apparatus 20 of the present embodiment, by joining the coil pieces C configured to have the substantially right-angled direction changing portions TN by punching or the like, the corners on the inner peripheral side and the outer peripheral side are formed. A substantially right angle coil 50 can be manufactured. Conventionally, coils made of flat conductors are manufactured by winding long flat conductors, but in winding, at least the corners on the inner circumference side of the coils are unavoidable to have a curved shape, and the space factor is However, there was a limit to improvement in heat dissipation and heat dissipation.

However, according to the coil manufacturing apparatus 10 of the present embodiment, since the shape formed by the punching process can be connected as it is, a right-angled (substantially right-angled) corner can be realized even on the inner peripheral side of the coil, and the space factor can be reduced. It is possible to manufacture a coil 50 that can improve heat dissipation and can improve heat dissipation by eliminating excess space.

In particular, the junction CP between the coil pieces C is provided in a straight portion avoiding the direction changing portion TN (corner). That is, pressure contact is performed using the straight portions of the coil pieces. As a result, it is possible to improve the shape accuracy of the direction changing portion TN, and for example, it is possible to maintain the corners formed at right angles (substantially right angles) in the punching process.

Furthermore, according to the present embodiment, it is possible to improve the lamination factor, thereby mass-producing high-quality coils with improved heat dissipation, thereby improving productivity.

<Coil manufacturing method>
Next, the coil manufacturing method of this embodiment will be described. The coil manufacturing method of the present embodiment can be implemented, for example, in the coil manufacturing apparatus 10 described above.

That is, the coil manufacturing method of the present embodiment is a coil manufacturing method in which a plurality of flat conductors (coil pieces C) are spliced together to form a spiral structure. A bending step of bending so as to be inclined with respect to other portions, and pressing the end surfaces of the bent flat conductor C and the other flat conductor C along the longitudinal direction of the band to press-contact while shortening the distance in the longitudinal direction of the band. It has a bonding step of splicing to form a spiral structure and a removing step of removing a part of the flat conductor after bonding.

Here, the bending process can be performed by the bending device 30 described above, and for each of the coil pieces C, two opposing sides scheduled to form one peripheral region CR (for example, the long side forming the long side LS One of the regions LS1 and LS2 (for example, the long side region LS2) is bent so as to be inclined with respect to the other (for example, the long side region LS1).

Then, a process of leveling a new bonding region is performed, and in the bonding process, the end surfaces of the coil pieces C are pressure-welded by the bonding device 20 .

Further, the removing process can be performed by the removing device 40 described above, and removes the burrs 55 generated by the pressing of the plurality of flat conductors C. As shown in FIG.

Since the detailed methods of the bending process and the removing process are as described above, the description here is omitted, and the pressure welding method in the bonding apparatus 20 will be mainly described below. It should be noted that, again, in the coil manufacturing method of the present embodiment, each coil piece C is subjected to a bending process (a configuration in which the bending process is performed one by one immediately before joining, or the total number of the necessary coil pieces C may be used). may be bent), a coil piece C (C01) having a bent portion B0 is pressed (joined) with another coil piece C (C02) having a bent portion B0, and the pressure contact Each time, the burr 55 generated at the joint CP is removed (see FIG. 13).

However, in the following description, since the pressing method is mainly described in detail, descriptions of the bending process and the removing process (deburring process) performed before and after pressing are omitted or simplified.

First, with reference to FIG. 15, the outline of pressure welding of the coil pieces C will be described. This figure is a top view of the coil piece C. As shown in FIG. A plurality of coil pieces C used in the present embodiment can form a virtual helical structure (hereinafter referred to as "virtual helical structure") by abutting the end faces TS1 and TS2. Specifically, (a new joint region is subjected to a horizontalization step), and the longitudinal end surfaces TS1 and TS2 of the unit coil piece C01 and the unit coil piece C02 are brought into contact with each other as shown in FIG. It is set so as to be able to form a one round region (virtual one round region) CR' of the virtual helical structure 50V shown in FIG. In the virtual helical structure 50V, the length of the virtual 1-circle area CR' in the spiral traveling direction is the length of the 1-circle area CR ((C) in the figure) of the helical structure (coil) 50 in the completed state. It is set to be longer than the length by the pressing amount of the pressure contact.

The joining device 20 presses the unit coil piece C01 and the unit coil piece C02 in the band longitudinal direction to form the joined coil piece CC shown in FIG. The length of is made to match the length of the one round region CR of the helical structure (coil) 50 . The end faces TS0 and TS1' opposite to the end faces TS1 and TS2 in FIG. ).

That is, in the coil manufacturing method of the present embodiment, a plurality of strip-shaped flat conductors (coil pieces C) formed with bent portions B, which can form the helical structure 50 when continuous, are prepared, and the strip lengths of the plurality of coil pieces C are prepared. The preparation length L0, which is the total distance in the direction, is set to be longer by a margin M than the completed length L in the longitudinal direction of the spiral structure (coil) 50 to be completed, and the plurality of coil pieces The end faces of C are pressed together in the longitudinal direction of the band, and cold pressure welding is performed while shortening the distance in the longitudinal direction of the band. A plurality of coil pieces C are spliced together to form a helical structure (coil) 50 by setting a shortened total distance S for shortening all pieces C by cold pressure welding to an allowance M.

Specifically, referring to FIG. 16, four U-shaped (U-shaped) unit coil pieces C0 having two direction changing portions TN (C01 to C04) are prepared, and these are connected (continuously connected). 1) A case of manufacturing a coil (helical structure) 50 having a spiral shape of two turns will be described as an example. (A) is a top view of the unit coil pieces C01 to C04, and (B) to (D) are development views of the joined coil pieces CC. 50 shows the axial center of the helical structure (the center of the joint CP). In addition, the two-dot chain lines at both ends of the coil piece in FIG. 4B to FIG. The position of the finished edge does not move in the direction).

Assuming that the lengths of the unit coil pieces C01 to C04 in the band longitudinal direction are L01 to L04, respectively, the preparation length L0, which is the total distance in the band longitudinal direction, is L01+L02+L03+L04. The preparation length L0 is set to be longer than the completed length L of the coil 50 in the spiral longitudinal direction by a margin M (L0=L+M). When the unit coil piece C01 and the unit coil piece C02 are pressed along the longitudinal direction of the band and cold pressure welded, the length L01 of the unit coil piece C01 in the longitudinal direction of the band is compressed (reduced (reduced ( The amount of compression is the length of the distance S1 from the center of the joint CP (the amount of compression S1), and the length L02 of the unit coil piece C02 in the longitudinal direction of the band is compressed to L2' (the amount of shortening (compression) is the length of the joint CP A jointed coil piece CC1 (length LC1) is formed by a distance S2 (amount of compression S2) from the center ((B) in the figure), and an end surface of the jointed coil piece CC1 (a unit coil piece C01 or When the unit coil piece C03 is cold pressure welded to the unit coil piece C03 (the end surface of the unbonded side of C02) and the unit coil piece C03, the unit coil piece C03 is compressed to L03' by these pressures (the amount of shortening (compression) is the distance S3 from the center of the joint CP). length (compression amount S3)), the joint coil piece CC1 is compressed to LC1′ ((the shortening (compression) amount is the length of the distance S4 from the center of the joint CP (compression amount S4)), and the joint coil piece CC2 ((C) in the same figure) Further, when the end surface of the joined coil piece CC2 (the end surface on the side where the unit coil pieces C01, C02, and C03 are not joined) and the unit coil piece C04 are cold pressure welded, By these presses, the unit coil piece C04 is compressed to L04' (the shortening (compression) amount is the length of the distance S5 from the center of the joint CP (compression amount S5)), and the joint coil piece CC2 is compressed to LC2' ( (The amount of shortening (compression) is the length of the distance S6 from the center of the joint CP (compression amount S6)), the length of the completed length in the longitudinal direction of the spiral (the length from the start point ST to the end point ET) L of the coil 50 (helical structure ) is completed ((D) in the same figure) The total amount of shortening of the coil pieces (total shortened distance S= S1+S2+S3+S4+S5+S6) corresponds to the margin M.

The method of manufacturing the coil of this embodiment will be described again in chronological order. First, based on the length L of the coil 50 in the completed state, the lengths L01 to L04 of the unit coil pieces are set so that the total shortened distance S=the margin M, and the compression amounts S1 to S1 through cold pressure welding are set. S6 is set.

Then, using the coil pieces set in this manner (each having a bent portion B0 (not shown) formed), the end surfaces of the unit coil piece C01 and the unit coil piece C02 are pressed by set amounts of compression S1 and S2. Then, they are added by cold pressure welding to form a joined coil piece CC1. The amounts of compression S1 and S2 at this time are grasped by measuring the distance between the unit coil pieces C01 and C02 in the band longitudinal direction by detecting the slippage of the unit coil pieces C01 and C02 when they are pressed. The method of grasping the amount of compression is the same as in the following cold pressure welding.

After one joint region (for example, the vicinity of the end surface where the unit coil piece C01 and the unit coil piece C02 are joined) is cold pressure welded, burrs are generated at the joint due to the pressing. I do.

Next, the coil piece (joined coil piece CC1) is left in the vicinity of the end face to be cold-welded (the end face where the unit coil piece C01 or the unit coil piece C02 is not joined), and the direction of spiral movement of the spiral structure to be completed is Cold pressure welding is performed with another coil piece (unit coil piece C03) while elastically and/or plastically deforming it. At this time, the amount of elastic deformation and/or plastic deformation of the joined coil piece CC1 in the spiral advancing direction is determined by the first holding portion 11 and the second holding portion 12 in which the coil piece is held during cold pressure welding, and the amount of deformation of the joined coil piece CC1. The amount is set to avoid interference with CC1. Also, the amount of deformation is the same in the following cold pressure welding.

Thereafter, coil pieces are added in the same manner. That is, the end face of the joined coil piece CC1 (the end face on the side to which the unit coil piece C01 or C02 is not joined) and the unit coil piece C03 are pressed by the set compression amounts S3 and S4 to join by cold pressure welding. A coil piece CC2 is formed. After that, the joint region is deburred, and the joint coil piece CC2 is elastically and/or plastically deformed in the spiral advancing direction of the spiral structure to be completed, leaving the vicinity of the end face to be cold-welded. The end face of CC2 and the unit coil piece C04 are pressed by the set compression amounts S5 and S6 and are spliced by cold pressure welding to obtain a completed helical structure.

<Modified example of coil piece>
FIG. 17 is a diagram showing an example of connection when coil pieces have different shapes.

FIG. 1A is a top view showing an example of connection using L-shaped coil pieces. Here, four L-shaped unit coil pieces C0 are used to form a joint coil piece for one turn. is shown. Although illustration is omitted for convenience of explanation, in this case as well, the preparation length L0, which is the total length of each coil piece in the band longitudinal direction, is the completed length of the helical structure (coil) to be completed in the helical longitudinal direction. It is set to be longer by a margin M than the length L. The margin M is set to a shortened total distance S shortened by pressing when all of the plurality of coil pieces are cold pressure welded.

It should be noted that the coil connection pieces for one turn need not all be configured in the same shape (L-shape). In other words, the L-shaped I-shaped (straight line) or U-shaped (U-shaped) coil pieces may be combined to form a coil connection piece for one turn.

FIG. 1B is a top view showing a connection example in which the C-shaped unit coil piece C0 and the I-shaped unit coil piece C01 are combined. Although illustration is omitted for convenience of explanation, in this case as well, the preparation length L0, which is the total length of each coil piece in the band longitudinal direction, is the completed length of the helical structure (coil) to be completed in the helical longitudinal direction. It is set to be longer by a margin M than the length L. The margin M is set to a shortened total distance S shortened by pressing when all of the plurality of coil pieces are cold pressure welded.

Alternatively, a substantially C-shaped unit coil piece having three direction changing portions TN and an L-shaped unit coil piece having one direction changing portion TN may be combined to form a coil connection piece for one turn. Furthermore, the unit coil pieces forming the first and second turns of the helical structure may be different combinations.

(C) shows a unit coil piece C0 having two U-shaped (U-shaped) direction changing portions TN, and a coil piece (O-shaped (square square) for one round of the helical structure to be completed. Fig. 10 is a development view of forming a joined coil piece by combining the coil piece (shape) with the coil piece) C1. The two-dot chain lines at both ends of the coil pieces in the figure indicate the finished ends of the completed coil. ) will be described as

The joint portion of the O-shaped coil piece C1 is cut. When one end of the U-shaped unit coil piece C0 and one end of the O-shaped coil piece C1 are cold pressure welded, the U-shaped unit coil piece C0 is compressed by an amount S0, and the O-shaped coil piece C1 is compressed. Each can be compressed by an amount S1 and repeated to form a helical structure. In FIG. 16, (when U-shaped unit coil pieces C0 having the same length are used), as shown, the joint CP is approximately along the axial center of the spiral structure at each circumference of the spiral structure. Although formed at the same position (overlapping position), in the case of FIG. It is formed.

<Modified example of coil>
18A and 18B are diagrams showing a modification of the coil 50. FIG. 18A is a side view corresponding to FIG. 14C, and FIG.

In the coil piece C of this embodiment, the widths WA, WB, WC, WD, WE, . may be In this case, the thicknesses D1 to D5 of the coil piece C (the axis The thickness in the direction) is made different according to the widths WA to WE. This coil 50 has an outer shape of a truncated quadrangular pyramid, as shown in the figure.

<How to attach to the stator core>
An example of attaching the coil 50 of the present embodiment to the stator core will be described with reference to FIG. 19 . FIG. 19A is a side view of the coil 50 and the cassettes 51A and 51B when the axial direction of the spiral of the coil 50 is the lateral direction in the figure. FIG. 19B is a top view of FIG. 19A. FIG. 19C is a top view showing another example of attachment to stator core 60. As shown in FIG.

The spiral shaft coil 50 of this embodiment is molded along the outer shape of the stator core as shown in FIG.

For this reason, for example, as shown in FIG. 19A, the coil 50 is sandwiched between a pair of cassettes 51A and 51B, and the cassettes 51A and 51B are attached to the stator core 60. As shown in FIG. Specifically, the cassette 51A has a support portion 53A that is inserted into the inner peripheral side of the helical structure of the coil 50 to support the coil 50, and a collar portion 52A that is provided on one side in the axial center direction. The cassette 51B similarly has a support portion 53B and a collar portion 52B.

In this case, the supporting portion 53A is inserted into the inner periphery of the coil 50 from the side of the cassette 51A on which the flange portion 52A is not formed, and the other cassette 51B is overlapped to remove the unevenness provided on the supporting portions 53A and 53B. Both are engaged at the illustrated engaging portion. Then, the cassette-equipped coil 50 is attached to the stator core 60 as shown in FIG. Although not shown, the stator core 60 has a fixing portion for the cassette-equipped coil 50, and the cassette-equipped coil 50 is fixed by being fitted (engaged) with the fixing portion.

Alternatively, as shown in FIG. 4C, the coil 50 may be attached to a single cassette 51C having a flange portion 52C only on one side in the axial center direction of the helical structure and attached to the stator core 60. In that case, in order to prevent the coil 50 from coming out of the stator core 60 (or causing unnecessary movement (vibration)) due to the centrifugal force during operation, the stator core 60 is provided with a notch 61 so that the coil 50 with the cassette is attached to the stator core. After attaching to 60 , it is preferable to fit the retainer ring 62 covering the upper side of the cassette-equipped coil 50 with the notch 61 of the stator core 60 .

A stator (not shown) is constructed by attaching the coils 50 to the stator core 60 in this way, and a known rotor is assembled to the stator so that it can rotate to manufacture a motor (not shown).

In the above-described embodiment, the case where the coil piece C is U-shaped has been described as an example. Various modifications are possible, for example, the shape of the coil piece C may be changed to another shape (Fig. 2(B), Fig. 2(D), Fig. 2(F), Fig. 2(G), Fig. 3(H)). In the case of , the configuration of the bending device 30 and its deformed position, the configuration of the bonding device 20 and its bonding position, and the removing device 40 are changed so as to obtain the shape of the coil 50 (helical structure) shown in FIG. The configuration of , and the removal position and the like due to this are changed as appropriate.

Further, the coil manufacturing apparatus 10 of the present embodiment has been described as an example including the bending device 30, the joining device 20, and the removing device 40, but the coil manufacturing device 10 according to the present invention includes the bending device 30, A configuration including the joining device 20 may be employed, or the coil manufacturing device 10 may be configured to include the joining device 20 and the removal device 40 .

In the coil manufacturing apparatus 10 (see FIG. 1), the bending device 30, the joining device 20, and the removing device 40 may be accommodated in one accommodating portion (housing). The device 20 may be accommodated in one accommodating portion (housing), or the joining device 20 and the removing device 40 may be accommodated in one accommodating portion (housing).

Also, in the coil manufacturing system 100 (see FIG. 13), a plurality of coil manufacturing units 10_N may be accommodated in one accommodating portion (housing).

Further, the configuration is not limited to the configuration in which the coil pieces C are deformed one by one before joining. The piece C may be configured to be joined by the joining device 20 .

As described above, the present invention is not limited to the embodiments described above, and can be configured in various embodiments. For example, the direction changing portions TN of the coil pieces may be curved.

In addition, one coil piece is not limited to one formed by punching a single copper plate, and a plurality of thin flat conductors (for example, flat conductors having a square cross-sectional shape in the longitudinal direction of the band) are formed in the transverse direction of the coil. They may be arranged in parallel. Alternatively, the coil may be partially formed of coil pieces obtained by punching a sheet of copper plate and partially formed of coil pieces formed by parallel arrangement of thin flat conductors.

INDUSTRIAL APPLICABILITY The present invention can be used, for example, when manufacturing coils (rectangular coils, edgewise coils) using flat conductors.

10 Coil manufacturing equipment (coil manufacturing unit)
11 First holding part 12 Second holding part 13 Driving part 14 Control part 15 Biasing member 16 Fixing member 17 Movement restricting part 18 Pressing part 20 Joining device 30 Bending device 31 Feeding part 33 Conveying part 35 Supporting part 37 Deformation part 40 Removal Device 41 Coil piece holding part 43 Removing part 50 Coil (helical structure)
50V virtual spiral structures 51A, 51B, 51C cassettes 52A, 52B, 52C collars 53A, 53B support 55 burr 60 stator core 100 coil manufacturing system 111 first upper holding body 112 first lower holding body 121 second upper holding body 122 Second lower holding bodies 111T, 112T, 121T, 122T Coil piece holding portion 161 Protrusion 162 Protrusion 163A Regulating surface 311 Turntable 331 Rail member 333 Driving portion 351 Supporting table holding portion 353
371 Clamping portion 373 Biasing portion 373S Inclined surface 411 Coil piece holding portion 412 Coil piece holding portion C Coil piece (flat conductor)
CC Joined coil piece CP Joined portion CR One round area TN Direction changing portion TS End face

Claims (25)

A coil manufacturing device for forming a helical structure by splicing a plurality of flat conductors,
a bending device for bending each of the plurality of flat conductors;
and a joining device for joining the plurality of flat conductors,
The bending device is
Means for forming a bent portion by bending each of the flat conductors so that a portion along the direction of spiral progress is inclined with respect to other portions before being supplied to the joining device,
The bonding device is
a first holding portion and a second holding portion which are capable of sandwiching the flat conductor and the other flat conductor and which are arranged to face each other;
a drive unit that moves the first holding unit and the second holding unit,
A means for forming the helical structure by pressing the end surfaces of the flat conductor and the other flat conductor along the longitudinal direction of the belt, and joining them together under pressure while reducing the distance in the longitudinal direction of the belt.
A coil manufacturing device characterized by: each of the plurality of flat conductors has a length equal to or less than the length of one circumferential region of the helical structure;
The coil manufacturing apparatus according to claim 1, characterized in that: The bending device is a means for bending so that one of two opposing sides of the flat conductor that is to constitute the one peripheral area is inclined with respect to the other.
3. The coil manufacturing apparatus according to claim 2, characterized in that: The two opposing sides are sides on the long side of the one peripheral region,
The coil manufacturing apparatus according to claim 3, characterized in that: splicing the flat conductor and the other flat conductor,
One side of the flat conductor having the bent portion and one side of the other flat conductor forming the bent portion, or one side of the flat conductor not having the bent portion and the other side of the flat conductor Either join one side that does not have a bent part,
is either
5. The coil manufacturing apparatus according to any one of claims 1 to 4, characterized in that: At least one of the flat conductor and the other flat conductor has a direction changing portion bent so as to change the extending direction in the longitudinal direction of the band,
The bending device forms the bent portion in the vicinity of the direction changing portion,
6. The coil manufacturing apparatus according to any one of claims 1 to 5, characterized in that: The folded portion is located on the long side of the one peripheral area,
3. The coil manufacturing apparatus according to claim 2, characterized in that: The bent portion is located in a range of less than 30% from the end portion of the maximum length in the longitudinal direction of the long side that constitutes the one peripheral area,
8. The coil manufacturing apparatus according to claim 2 or 7, characterized in that: The plurality of flat conductors are capable of forming a virtual helical structure (hereinafter referred to as a "virtual helical structure") by abutting the end faces thereof, and the virtual helical structure is formed in a direction in which the spiral advances. The length of the virtual one-round region is set to be longer than the length of the one-round region by the pressing amount of the pressure contact,
The bonding apparatus presses the flat conductor and the other flat conductor to form a bonded flat conductor, and measures the length of the area corresponding to one circumference of the bonded flat conductor (hereinafter referred to as "one circumference area to be bonded"). is equal to the length of the one-round region,
3. The coil manufacturing apparatus according to claim 2, characterized in that: wherein the joining device presses the end surfaces of each of the plurality of flat conductors at the respective straight portions;
10. The coil manufacturing apparatus according to any one of claims 1 to 9, characterized in that: Equipped with a plurality of coil manufacturing apparatuses according to any one of claims 1 to 10,
A coil manufacturing system characterized by: A coil manufacturing method for forming a helical structure by splicing a plurality of flat conductors,
a bending step of bending each of the flat conductors such that a portion along the direction of spiral progress is inclined with respect to the other portion to form a bent portion;
a joining step of pressing the end surfaces of the folded flat conductor and the other flat conductor along the longitudinal direction of the belt, and joining them together under pressure while reducing the distance in the longitudinal direction of the belt to form the spiral structure; A method for manufacturing a coil, comprising: each of the plurality of flat conductors has a length equal to or less than the length of one circumferential region of the helical structure;
13. The coil manufacturing method according to claim 12, characterized in that: In the bending step, each of the flat conductors is bent so that one of two opposing sides scheduled to constitute the one peripheral area is inclined with respect to the other.
14. The coil manufacturing method according to claim 13, characterized in that: The two opposing sides are sides on the long side of the one peripheral region,
15. The coil manufacturing method according to claim 14, characterized in that: splicing the flat conductor and the other flat conductor,
connecting one side of the flat conductor having the bent portion and one side of the other flat conductor having the bent portion, or
Either connecting one side of the flat conductor that does not have the bent portion and one side of the other flat conductor that does not have the bent portion,
16. The coil manufacturing method according to any one of claims 12 to 15, characterized in that: At least one of the flat conductor and the other flat conductor has a direction changing portion bent so as to change the extending direction in the longitudinal direction of the band,
Forming the folded portion in the vicinity of the direction changing portion,
17. The coil manufacturing method according to any one of claims 12 to 16, characterized in that: The bent portion is formed so as to be located on the long side of the one peripheral area,
14. The coil manufacturing method according to claim 13, characterized in that: The bent portion is located in a range of less than 30% from the end portion of the maximum length in the longitudinal direction of the long side that constitutes the one peripheral area,
19. The coil manufacturing method according to claim 13 or 18, characterized in that: The plurality of flat conductors are capable of forming a virtual helical structure (hereinafter referred to as a "virtual helical structure") by abutting the end faces thereof, and the virtual helical structure is formed in a direction in which the spiral advances. The length of the virtual one-circling region is set to be longer than the length of the one-circling region of the helical structure by the pressing amount of the pressure contact,
In the joining step, the flat conductor and the other flat conductor are pressed to form a joined flat conductor, and the length of the one round region of the joined flat conductor is the length of the one round region of the spiral structure. match the
14. The coil manufacturing method according to claim 13, characterized in that: In the joining step, the end faces are pressed against each other at straight portions of the plurality of flat conductors.
21. The coil manufacturing method according to any one of claims 12 to 20, characterized in that: A molding step of molding the helical structure into a curved shape in which the inner peripheral end portion and the outer peripheral end portion are not flush with each other,
22. The coil manufacturing method according to any one of claims 12 to 21, characterized in that: Having a coating step of integrally covering the helical structure with a coating,
23. The coil manufacturing method according to claim 22, characterized in that: A removal device is provided for removing unnecessary portions of the flat conductor generated by bonding,
characterized byClaim 1coilmanufacturing device. Having a removing step of removing a part of the flat conductor after bonding,
A claim characterized by12coil described inProduction method.

Images