JPH0274140A - Formation of honeycomb coil and device therefor - Google Patents

Abstract

PURPOSE:To improve the workability and to protect the insulation layer of strand from damage when a coil is formed by moving linear clamps in the opposite directions while pulling an original coil toward the opposite end sides. CONSTITUTION:An original coil 2 is pulled toward the opposite end sides by means of loop clamps 45 thus forming an approximately honeycomb coil 1. Since the corner section R7 is bent while being subjected to sufficiently high tension, the curvature can be reduced and the coil end section 9 is prevented from S-shaped deformation. Since wood hammering is not required at the corner section R7, coil forming efficiency can be improved. A forming device moves linear clamps 22, 23 in the opposite directions through a clamp moving means while pulling the original coil 2 toward the opposite end sides by means of the loop clamp 45 so as to finish the original coil 2 into an approximately honeycomb-shaped coil, thereafter the coil end section 9 is finished.

Description

DETAILED DESCRIPTION OF THE INVENTION [Objective of the Invention] (Industrial Application Field) The present invention relates to a method and apparatus for forming a hexagonal coil that can improve the forming accuracy of coil end portions.

(Prior Art) In general, a hexagonal coil 1 having a shape as shown in FIG. 15 is produced by forming an original coil 2 (see FIG. 17) in which a wire 2a (see FIG. 18) is wound into a sea cucumber shape, for example. In addition, as shown in FIG. 16, an insulating tape 3 such as mica tape is spirally wound around the hexagonal coil 1 obtained and formed (hereinafter, this insulating tape 3 is wound. The hexagonal coil 1 is referred to as the "own coil 4"). And this own coil 4
is inserted into the slot 6 of the stator core 5 as shown in FIGS. 19 and 20. At this time, if the bending radius 8 of the corner R portion 7 of the white coil 4 is too large or the shape of the coil end portions 9 is uneven, the adjacent coil end portions 9 may overlap each other as shown in FIG. There is a risk that the coil end portions 9 may interfere with each other and become impossible to insert.Therefore, it is necessary to form the coil end portions 9 with high precision by minimizing the bending radius 8 of the corner R portions 7 as much as possible.

However, in the method of forming the original coil 1 using a conventional coil forming apparatus as shown in Japanese Patent Application Laid-Open No. 59-169352, the loop portions 10 at both ends of the original coil 2 are clamped with loop clamps 11 as shown in FIG. In addition, with the inner straight part 12 clamped by the straight part clamp 13, the straight part clamp 13 and the loop clamp 11 are moved to form the original coil 2 into the hexagonal shape coil 1. In such a forming method, as shown by the two-dot chain line in FIG. 22, the bending radius 8 of the corner R portion 7 often swells greatly, resulting in the coil end portion 9 being formed into a large S-shape. . Therefore, at the end, the operator places a jig such as a piece of wood or a piece of plastic on the corner R part 7 and the coil end part 9 on the molding device, and hits the jig with a wooden hammer or the like from above. It was necessary to modify the coil end portion 9 as shown by the solid line in FIG.

(Problems to be Solved by the Invention) Since the forming of the corner R portion 7 and the coil end portion 9 using a wooden hammer or the like as described above is done manually, the work is time-consuming and the efficiency of the forming work is extremely low. bad for Moreover,
In order to reduce the bending radius 8 of the corner R part 7 by hitting it, it is necessary to locally apply a large force to the periphery of the corner R part 7.
There was a risk of damaging the insulating layer 2b on the surface of a. especially,
If the strand 2a has a flat shape with an aspect ratio (the value obtained by dividing the cross-sectional width by the thickness) of 4 or more, when the strand 2a is struck to reduce the bending radius 8, the strand 2a will bend into the corner radius. It is easy to buckle at the part 7, and in order to correct the buckling, it is often necessary to further hammer and reshape.Furthermore, if the wire 2a is thick, it is necessary to increase the hammering force. The large force and the large number of hits caused further damage to the insulating layer 2b. Since such damage to the insulating layer 2b is fatal to the insulating performance of the coil, it is desirable to omit or minimize the work of hitting it with a wooden hammer, etc. However, at present, this work must be done in advance. ,
As shown in FIG. 21, the bending radius 8 of the corner R portion 7 is too large, and when the white coil 4 is inserted into the slot 6 of the stator core 5, adjacent coil end portions 9 interfere with each other. There is a risk that such white coil 4
If an attempt is made to insert the insulating tape 3 while forcibly correcting it with a wooden hammer or the like, the insulating tape 3 is often damaged, and in any case, a decrease in insulation properties is unavoidable.

The present invention aims to solve such technical problems, and therefore, its purpose is to improve the forming accuracy of the corner R part and the coil end part by machine, and to correct the corner R part by hitting it with a wooden hammer etc. You don't have to do much work,
Therefore, the efficiency of the forming operation can be improved, and the insulating layer of the wire is not damaged during forming, and the insulating tape on the surface of the white coil is not damaged when inserting the coil, maintaining good insulation performance. The purpose of the present invention is to provide a method for forming a hexagonal coil and an apparatus therefor.

[Structure of the Invention (Means for Solving the Problems)] The method for forming a hexagonal coil of the present invention includes clamping the loop portions at both ends of the original coil with loop clamps on both sides, and clamping the inner straight portions of the original coil on both sides. In the method of forming the original coil into a tortoiseshell-shaped coil while being clamped by the straight line clamps, the straight line clamps on both sides are moved in opposite directions while the original coil is pulled toward both ends by the loop clamps on both sides. This method is characterized in that the original coil is formed into a shape close to a hexagonal coil, and then the coil end portions are finished formed.

In order to carry out the above forming method, the forming apparatus of the present invention includes loop clamps on both sides that clamp the loop portions at both ends of the original coil, and straight line clamps on both sides that clamp the i portions on both sides of the original coil. a tensioning means for pulling the loop clamps on both sides toward both ends of the original coil; and a tensioning means for pulling the loop clamps on both sides toward both ends of the original coil; and a tensioning means for moving the straight portion clamps on both sides in opposite directions while continuing the pulling operation of the tensioning means, thereby converting the original coil into a hexagonal coil. The coil end portion is molded into a shape close to that of the coil end portion, and then the linear portion clamp and the loop clamp are moved in a predetermined direction to final form the coil end portion.

(Function) According to the forming method of the present invention, the original coil is formed into a shape close to a hexagonal coil while being pulled toward both ends by the loop clamp. In this way, since the corner R portion is bent under sufficient tension, the bending radius of the corner R# can be reduced, and S-shaped deformation can be prevented from occurring in the coil end portion. Moreover, if the material is bent with sufficient tension applied in this manner, the bending radius of the corner R portion will not increase as much due to springback after molding. Therefore, there is almost no need to hit the corner R part with a wooden hammer, etc., so the forming efficiency can be improved, and there is no need to damage the insulation layer of the strands. Since there is no need to forcefully insert the coil by hitting it, there is no need to damage the insulating tape on the surface of the coil itself.

Further, according to the forming apparatus of the present invention, the loop clamp pulls the original coil toward both ends, and the clamp moving means moves the straight portion clamps on both sides in opposite directions to form the original coil into a shape close to a hexagonal coil. After that, finish forming the coil end part. In this case as well, since the corner R portion is bent under sufficient tension, there is almost no need for correction work using a wooden hammer or the like for the corner R portion.

(Embodiment 11q) An embodiment of the present invention will be described below with reference to FIGS. 1 to 14.

First, the overall configuration of the molding apparatus will be explained. FIG. 1 shows a plan view of the entire molding device. In the figure, 21 is a base of the molding device, and left, right, and center body frames 21a, 21b, and 21c are provided on the top surface of the base. . and,
Two pairs (four in total) of straight line part clamps 22.23 are provided on the central body frame 21c, and these straight line part clamps 22.23 clamp the double-sided wire part 12 of the original coil 2.
(See Fig. 9) Coil side 17 of tortoiseshell coil 1
(See Figure 15) are clamped at four locations. Here, regarding the support structure of the pair of straight part clamps 22 that clamp the lower straight part 12 in FIG.
This will be explained with reference to the plan view in FIG. 2 and the vertical sectional side view in FIG. 3. That is, the double-sided wire portion clamp 22 is fixed to a clamp holder 24 extending left and right, and its fixed position is aligned with the length of the straight portion 12 of the original coil 2 in the left and right direction (the second
Arrow x1 in the figure. x2 direction). The clamp holder 24 is fixed to a revolving frame 25, and this revolving frame 25 is connected to a pair of arc-shaped guide plates 26 (see FIG. 3), for example, with eight guide rollers 27.
It is swingably supported via the This rotating frame 25 is connected to a rod 28a of a hydraulic cylinder 28,
Due to the expansion and contraction movement, the rotating frame 25 and, in turn, the linear portion clamp 22 rotate around the arc center P1 of the guide plate 26 as shown by the arrow G1. G, is rotated in the direction. This rotation center Pl coincides with the ridge corner of the straight part 12 of the original coil 2 (see FIGS. 11 and 14), and the rotation of the rotating frame 25 causes the straight part 12 (straight part clamp 22) to rotate about the point P1. It is rotated in the direction of arrow C,,C,, as shown in FIG. In addition, in FIGS. 2 and 3, the bracket 29 and the guide plate 26 that pivotally support the hydraulic cylinder 28 are fixed to a vertical slide frame 30, and this vertical slide frame 30 is fixed to the front of the main body frame 21c. vertically along the pair of guide rails 31 (arrows AI, A in Fig. 3).
The hydraulic cylinder 32 is supported in a sliding motion in two directions (two directions), and the sliding motion is executed by a hydraulic cylinder 32 fixed to the front of the main body frame 21c. These hydraulic cylinders 28
, 32, a vertical slide frame 30, a guide plate 26, a guide roller 2, etc., constitute a clamp moving means 33.

On the other hand, the support structure of the straight part clamp 23 that clamps the straight part 12 on the second side of the original coil 2 and the clamp moving means 3
4 has a configuration as shown in the plan view of FIG. 4 and the vertical lvi side view of FIG. That is, the double-sided wire portion clamp 23 is fixed to a clamp holder 35 extending left and right, and the fixing position of the eye is aligned in the left and right direction (arrow 1 in FIG. The clamp holder 35 can be adjusted in the X2 force direction).
The rotating frame 36 is swingably supported by a pair of arc-shaped guide plates 37 (see FIG. 5) via, for example, eight guide rollers 38.

The rotating frame 36 is rotated around the center Q1 of the circular arc of the guide plate 37 by the operation of the hydraulic cylinder 39, and is rotated by +1 in the directions of the arrows H1 and H2. This rotation center Qt
corresponds to the ridge corner of the straight part 12 of the original coil 2, and the first
1 and 14), the rotation of the rotating frame 36 causes the straight portion 12 (straight portion clamp 23) to rotate in the directions of arrows H1 and B2 with the point Q1 as the rotation center. Also, the fourth
In the figures and FIG.
1, and this vertical slide frame 41 is slidable in the vertical direction (directions of arrows B1 and B2 in FIG. 5) along a pair of guide rails 43 fixed to the front and rear slide frames 42 on the upper surface of the main body frame 21c. The sliding movement is carried out by a hydraulic cylinder 44.

Furthermore, the front and rear slide frames 42
They are supported so as to be slidable in the front-rear direction (in the direction of arrows C1 and C2 in FIG. 5) along a pair of guide rails 19 fixed to the upper surface of the cylinder, and the sliding movement is executed by a hydraulic cylinder 20.

On the other hand, as shown in FIG.
A pair of loop clamps 45 are provided on both left and right sides of. Both left and right loop clamps 45 are attached to the original coil 2.
The loop portions 1o at both ends of the loop portion 1o are clamped, and the structure is symmetrical to each other. Therefore, here, the sixth
Figure (top view), Figure 7 (front view) and Figure 8 (side view)
Only the configuration of the left loop clamp 45 will be described with reference to FIG. That is, at the tip of the loop clamp 45, there is an insertion groove 46 for inserting the loop portion 1o of the original coil 2.
is formed, and the loop portion 10 inserted into this %lJ groove 46 is prevented from coming out by the pin 47 and clamped. This loop clamp 45 is connected to the clamp holder 4
8 to the front and rear slide frames 71 and 49, and these four front and rear slide frames are connected to the left and right slide frames 5.
It is supported so that it can slide in the front and rear directions (directions of arrows 1 and 1 in FIG. This is carried out by the operation of a hydraulic cylinder 52, which is a clamp moving means fixed to the upper surface of the cylinder 5o. In addition, the left and right slide frames 5o have a main body frame 21a.
It is supported so as to be slidable in the left-right direction (in the direction of arrows B1 and D2 in FIG. 6) along a pair of guide rails 53 fixed to the upper surface of.

On the left side of this left and right slide frame 50, an auxiliary slide frame 54 is supported so as to be slidable in the left and right direction along the guide rail 53, and on this auxiliary slide frame 54, an air cylinder 55 serving as a tensioning means is oriented rightward. The rod 55a of this air cylinder 55 is fixed.
The tips of the slide frames 50 are connected to the left and right slide frames 50.

Before starting molding of the original coil 2, the rod 55a of the air cylinder 55 is retracted to the stroke end, and the pin 47 of the loop clamp 45 is placed in contact with the inner periphery of the loop portion 10 of the original coil 2. Slide the left and right slide frames 50 and the auxiliary slide frame 54 until the auxiliary slide frame 54 is locked at that position. : Keep it more fixed. Note that air is supplied to the boat on the rod 55a side of the air cylinder 55 via a pressure reducing valve (not shown) with a large relief amount.

In the above configuration, the hydraulic cylinders 20, 28° 32,
39, 44, and 52 are all equipped with a position detection device, and the stop position of each hydraulic cylinder is automatically determined by a value set in a control device (not shown).

Next, the steps of forming the original coil 2 into the hexagonal coil 1 using the forming apparatus having the above configuration will be explained in order.

First, in the first step shown in FIG. 9, both straight portions 12 of the original coil 20 wound into a sea cucumber shape are clamped by four straight portion clamps 22 and 23, and the loop portions 10 at both ends are clamped. It is clamped by a loop clamp 45. In this case, FIG. 9(b) is a top view (plan view) of the clamped state of the original coil 2, so that the straight section clamp 23 on the upper side of the figure is behind the straight section clamp 22 on the lower side of the figure. It is set to be located at .

Next, in a second step shown in FIG.
Air is supplied to the boat on the rod 55a side through a pressure reducing valve with a large relief amount, and the original coil 2 is pulled to both ends (arrow DI, E2 direction) through the loop clamp 45.
, While continuing this tensile movement A'1, press the hydraulic cylinder'
32 and 44, the straight part clamps 22 and 23 are moved in the vertical direction (in the direction of arrow A2+81), thereby moving the original coil 2 to the tortoise shell +1'- and the coil 1 as shown in Fig. 14). Form into a shape similar to. In this process, the loop clamp 45 is turned inside (arrow D2.E, direction)
・The rod 552 of the air cylinder 55 is pulled
Air is pushed back toward the pressure reducing valve from the I side port, but since the relief amount of the pressure reducing valve is sufficiently large, the tensile force exerted by the air cylinder 55 is kept at a constant value. In this way, it is possible to form the corner R portion 7 and the coil end portion 9 while applying a large tensile force, thereby reducing the bending radius 8 of the corner R portion 7, and
Preventing S-shaped deformation in the coil needle part 9 11
-7 I can do it.

Next, in the third step shown in FIG. 1, the straight portion clamp 22.2':3 is moved to point P by the operation of the hydraulic cylinders 28, 3Q while continuing the above-mentioned tensioning operation.

Center on QX and arrow G1. F (Rotate in one direction.

Thereafter, in a fourth step shown in FIG. 12, while continuing the above-described tensioning operation, the upper straight portion clamp 23 in the figure is moved downward in the figure (in the direction of the arrow Ci) by the operation of the hydraulic cylinder 20.

Next, in a fifth step shown in FIG. 13, while continuing the above-described tensioning operation, the left and right loop clamps 45 are moved rearward (in the j direction of arrow l2) by the operation of the left and right hydraulic cylinders 52. In this process, the loop clamp 45 is pulled inward (in the direction of arrows D2 and E1), but the tensile force by the air cylinder 55 is kept at a constant value based on the same principle as in the second step. In this way, the corner R portion 7 and the coil end portion 9 can be molded while applying a large tensile force.

After that, the tensioning operation by the air cylinder 55 is stopped, and a molding jig (not shown) such as a piece of wood or a piece of plastic is attached to the end R portion 9a (see FIG. 14) of the coil end portion 9.
While facing the end R part 9, hit it with a wooden hammer etc.
Form a. In this case, in the second step, the corner R portion 7 has already been formed with a small bending radius 8, so there is no need to correct the corner R portion 7 by hitting it with a wooden hammer.
However, since there is no S-shaped deformation in the coil end portion 9, the end R portion 9a can be easily repaired, and the number of hits (strike force) is kept to a minimum, preventing damage to the insulating layer 2b of the wire 2a. No need to worry.

After removing the hexagonal coil 1 formed in this way from the straight section clamps 22, 23 and the loop clamp 45,
Wrap the insulating tape 3 around the hexagonal coil 1, and connect the own coil 4.
Manufacture. This own coil 4 is inserted into the slot 6 of the stator core 5. In this case, since the corner R portion 7 is automatically formed, there is little variation in dimensions, and
During the forming, the corner R portion 7 is bent to a small bending radius with sufficient tension applied, so the corner R portion 7
The amount by which the bending radius 8 increases due to springback is small, and the coil end portion 9 does not form an S-shape. Therefore, the dimensional accuracy of the white coil 4 is high, and the insertion of the own coil 4 can be performed smoothly.There is no need to hit the own coil 4 with a wooden hammer or the like and forcefully insert it into the slot 6. There is no need to damage the insulating tape 3.

Furthermore, in the above embodiment, the tensile force is applied by the air cylinder 55 to both ends of the original coil 2 in all steps from the second step to the fifth step, but the above-mentioned tensile force is applied only in the second step. Even so, the intended purpose of the present invention can be fully achieved, and effects similar to those of the above-mentioned embodiments can be obtained.

In the above embodiment, the shape of the original coil 2 is a sea cucumber (
Although the coil is formed into an isosceles trapezoidal shape, it is also possible to use an original coil wound into an oval, hexagonal, or other planar shape, for example.

Further, in the above embodiment, the air cylinder 55 is used as a tensioning means for tensioning both ends of the original coil 2, but a hydraulic cylinder or the like may be used.

[Effects of the Invention] As is clear from the above description, according to the method and device for forming a hexagonal coil of the present invention, both ends of the original coil are stretched while being molded into a shape similar to a hexagonal coil.
By applying a sufficient tensile force to the corner R portion during molding, the bending radius of the corner R portion can be reduced, and S-shaped deformation of the coil end portion can be prevented, thereby improving molding accuracy. Therefore, there is almost no need to hit the corner R part with a wooden hammer, etc., which improves the forming efficiency, and also prevents damage to the insulation layer of the strands. Since there is no need to forcefully insert the coil by hitting it, there is no need to damage the insulating tape on the surface of the coil itself, and overall insulation performance can be maintained well.

[Brief explanation of the drawing]

1 to 14 show an embodiment of the present invention, in which FIG. 1 is an overall plan view, FIG. 2 is a plan view of a means for moving the front (lower) straight section clamp, and FIG. Figure 3 is the same as in Figure 2.
- Longitudinal side view shown along line m, Figure 4 is rear side (upper side)
A plan view of the moving means of the straight section clamp, Fig. 5 is the same as Fig. 4.
6 is a plan view of the moving means of the loop clamp, 7 is a front view of the same, and 8
The figure is a side view of the same side, and Figures 9 to 13 show the molding process. ). (b) and (C) are sectional views showing the second step, respectively. A plan view and a front view, and FIGS. 11(a) and (b) are a sectional view and a plan view showing the third step, respectively, and FIGS. 12(a) and (b).
) are a cross-sectional view and a plan view showing the fourth step, respectively, and FIG.
) and (b) are a cross-sectional view and a plan view showing the fifth step, respectively, and FIG. 14 is a diagram showing the moving path of the straight portion of the original coil during molding. Fig. 15 is a perspective view of the hexagonal coil, Fig. 16 is a perspective view of the hexagonal coil (white coil) after winding with insulating tape, Fig. 17 is a front view of the original coil, and Fig. 18V is a cross section of the coil. An enlarged view, Fig. 19 is a partial plan view of the stator, Fig. 20 is a developed view showing the normal insertion state of the own coil, and Fig. 21 is equivalent to Fig. 20 when the coil ends are interfering with each other. 10 (c) showing the conventional molding method.
) is an equivalent diagram. In the drawing, 1 is a hexagonal coil, 2 is an original coil, 3 is an insulating tape, 4 is a white coil, 5 is a stator core, and 7 is a corner radius.
9 is a coil end portion, 10 is a loop portion, 12 is a straight portion, 20 is a hydraulic cylinder, 22 and 23 are straight portion clamps, 25 is a rotating frame, 28 and 32 are hydraulic cylinders, 33 and 34 are clamp moving means , 36 is a rotating frame, 3 and 44 are hydraulic cylinders, 45 is a loop clamp, 52 is a hydraulic cylinder (clamp moving means), and 55 is an air cylinder (tensioning means).

Claims (1)

[Claims] 1. The original coil is turned into a tortoiseshell coil with the loop portions at both ends of the original coil being clamped by loop clamps on both sides, and both straight portions of the original coil being clamped by straight portion clamps on both sides. In the forming method, the original coil is pulled into both end sides by the loop clamps on both sides, and the straight part clamps on both sides are moved in opposite directions to form the original coil into a shape close to a hexagonal coil; A method for forming a tortoise-shell coil, characterized in that the end portion of the coil is then finished formed. 2. Loop clamps on both sides that clamp the loop portions at both ends of the original coil, straight section clamps on both sides that clamp both straight sections of the original coil, and tension that pulls the loop clamps on both sides toward both ends of the original coil. and the linear portion clamps on both sides are moved in opposite directions while continuing the tensioning operation of the tensioning means to form the original coil into a shape close to a hexagonal coil, and then the linear portion clamp and the loop clamp are moved. A tortoiseshell-shaped coil forming device comprising a clamp moving means for moving in a predetermined direction to finish forming a coil end portion.