JPH06284651A - Manufacture of coil for motor - Google Patents

Abstract

PURPOSE:To manufacture a honeycomb coil of motor through combination of simple bending works. CONSTITUTION:A conductor 1e is secured by means of end setting clampers 19b, 20b, position setting clampers 9f, 9g, 10f, 10g, and a fixing clamper 8b. Each setting base and a slide base are then shifted in the axial direction 5 of the conductor 1e and the direction perpendicular thereto under control of a computer thus shaping the conductor 1e into a desired shape.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a coil of an electric motor, which realizes manufacturing of a coil mounted on a stationary portion and a rotor of the electric motor by a combination of simple bending processes.

[0002]

2. Description of the Related Art FIG. 10 shows a hexagonal coil shown on page 272 of "Rotating Machinery Assembly Course [textbook]", for example, published by the Foundation for Vocational Training Materials Study Group. In the figure, 1 is a coil wire. 1a is referred to as a lead portion, 1b is referred to as a coil end portion, 1c is referred to as a straight portion, and 1d is referred to as a nose portion, as shown in the figure. Conventionally, as a typical manufacturing method for molding a coil into a hexagonal shape having a shape as shown in Fig. 10, a method of putting the coil in a dedicated molding die is used. Add a description.

FIG. 11 shows a dedicated molding die used in the above manufacturing method. In the figure, 2 is a molding die, and the nose portion 1 of FIG.
Block 2a and pin 2b for fixing d, block 2c for attaching coil end portion 1b, bender 2d for bending in a hexagonal shape, and hole 2 for inserting the pin portion of bender 2d
e, a block 2f to which the coil straight portion 1c is added. The molding procedure is as follows. First, as shown in FIG. 12, the conductor 1e is cut into a predetermined length and both ends thereof are rolled to process the lead portion 1a.

Next, the portion corresponding to the nose portion 1d is shown in FIG.
As shown in (3), the pin 3b and the pin 3a are sandwiched by the cap 3b to be inserted and bent along the pin 3a to be processed into a pine needle shape. A plurality of conductors 1e processed in the same manner are combined and mounted on the block 2a of the molding die 2 as shown in FIG. 14, and further pins 2b are inserted and fixed. Then, the respective bundles of the conductors 1e are bent in the opposite directions as shown by the arrows in the drawing to be attached to the block 2c, and at the same time, the molding die 2
Also be attached to the surface of.

Next, as shown in FIG. 15, the vendor 2d
Is inserted into the hole 2e so as to sandwich the bundle of the one conductor 1e, and is bent so as to follow the block 2f. The other conductor 1e
Bend in a similar manner. Next, the bender 2d is inserted so as to sandwich the bundle of the one conductor 1e into the hole 2e located closer to the lead portion 1a than the above insertion position, and is bent to the position of the block 2c. Process so that The other bundle of conductors 1e is processed in the same manner to form the shape shown in FIG. Finally, as shown in FIG. 17, each lead portion 1a is bent by the bender 4 so as to be arranged at a predetermined position to form a hexagonal coil as shown in FIG.

[0006]

As described above, the conventional method for manufacturing a coil of an electric motor requires a dedicated mold for each coil having different dimensions, a problem of processing accuracy, and an apparatus for various coil dimensions. Since there is a problem of general versatility and operability, etc., automatic molding equipment is not generally adopted, and there is a problem that the work efficiency is low mainly due to the manual molding as described above by partial mechanization. .

The present invention has been made to solve the above problems, and realizes automatic mechanical forming by disassembling a bent portion of a coil wire into a simple two-dimensional bending. To aim.

[0008]

In the method of manufacturing a coil for an electric motor according to the present invention, each processed portion is decomposed into a simple two-dimensional bending using a coil wire as a processing unit, and these two-dimensional bending processes are combined. It was done like this.

[0009]

In the present invention, the bending process in the middle is a two-dimensional bending process in the same plane, and the three-dimensional coil shape is the final step, so that the forming by an automatic machine can be realized.

[0010]

Next, an embodiment of the present invention will be described. In FIG. 1, first, the reference point 6 of the conductor 1e is set, and the lead portion 1a is processed by cutting the conductor 1e into a predetermined dimension in the direction of each end. This is achieved in the conventional way.
Next, as shown in FIG. 2, a first point 7a and a second point located at a distance from the reference point 6 in the direction of each end according to the size of the coil determined by the capacity of the electric motor, the application, etc. 7b
To set. Next, similarly, a third point 7c and a fourth point 7 closer to the reference point 6 than the first point 7a and the second point 7b are.
Set d. Next, similarly, points of the fifth point 7e and the sixth point 7f are set at positions closer to the reference point 6 than the third point 7c and the fourth point 7d. Further, similarly, the reference point 6
The seventh point 7g and the eighth point 7h are set at the positions closest to the.

3 to 5, 8a is a fixed base, 8b is a fixed clamper, and 8c is a fixed clamper 8.
A cylinder that presses b against the fixed base 8a sets the reference point 6, the seventh point 7g, and the eighth point 7h of the conductor 1e.
Reference numerals 9a and 10a denote axis slide bases whose movements are controlled in the direction of the axis 5 of the conductor 1e, and reference numerals 9b and 10b denote right-angle slide bases mounted on the axis slide bases 9a and 10a, respectively, which are perpendicular to the axis 5 of the conductor 1e. Movement is controlled in the direction by cylinders 9c and 10c.

9d, 9e and 10d, 10e are position setting bases mounted on the right-angle slide bases 9b and 10b, respectively, and are movable in the direction of the axis 5 of the conductor 1e. Reference numerals 9f, 9g, 10f and 10g denote position setting clampers that are pressed against the position setting bases 9d, 9e, 10d and 10e by the cylinders 9h, 9i, 10h and 10i, respectively, and the third point 7c and the fifth point 7 respectively.
e, the fourth point 7d and the sixth point 7f are set. 11a
And 12a are end setting bases that are controlled to move in the direction of the axis 5 of the conductor 1e and at a right angle, 11b and 12b are end setting clamps mounted on the end setting bases 11a and 12a, respectively, and cylinders 11c and 12c. Is pressed to set the first point 7a and the second point 7b of the conductor 1e.

In the structure of FIG. 3, first, the reference point 6 of the conductor 1e is fixed by the fixed clamper 8b. At this time, the 7th
7g and the eighth point 7h are also set. Next, move the end setting bases 11a and 12a to predetermined positions,
The first point 7a and the second point 7b are set. Next, the axis slide bases 9a and 10a are moved to predetermined positions to move the position setting clampers 9f, 9g, 10f and 10g.
, The third point 7c, the fifth point 7e, and the fourth point 7 respectively.
Set d and the sixth point 7f. Conductor 1 in this state
The setting of the points 7a to 7h of e is as shown in FIG.

After the conductor 1e is set in this way, each of the bases 9a, 10a, 9b, 10b, 11a and 12a.
According to the shape of FIG. 4, the computer 1 or the like controls the movement of the conductor 1e in the direction of the axis 5 and the direction perpendicular thereto. In this case, the bending angles of the first point 7a to the eighth point 7h are 9
Although it is bent so as to be within 0 degree, the shape of the coil element wire 1 differs depending on the capacity and the application. However, if it is bent over 90 degrees, the hexagonal shape cannot be formed. The final state at this time is shown in FIG. The thus obtained processed product shown in FIG. 4 is processed into the shape of the coil end portion shown in FIG. 7 in FIG. 6, and then the nose bending process is performed in FIG.
The final coil wire 1 shown in is obtained.

Next, the coil end portion 1b is processed by using the coil end portion processing apparatus shown in FIG. The coil end portion processing apparatus of FIG. 6 has four sets of semi-circular convex molds 13a and 13b for machining the coil end portion 1b to a predetermined radius, and concave molds 14a and 14b facing the semi-circular molds 13a and 13b, and a coil reference point 6 fixed. Clamping part 15, cylinder 13 for applying pressure by vertically moving convex mold 13b and concave mold 14a arranged as shown by arrow C, and pedestals 17a and 17b for fixing these mechanical parts. There is.

Two sets of opposing convex molds 13a and 13b and concave molds 14a and 14b, which are opposed to each other, are arranged on both sides of the clamp part 15, and these four sets of convex and concave molds have four coil end parts. As shown by the arrow D so as to be located at 1b, the structure is movable along the axis 5. The reference point 6 of the conductor 1e of FIG. 4 is fixed to the clamp portion 15 of the coil end portion processing apparatus configured as described above, and the four coil end portions 1b are sandwiched by four sets of opposed convex and concave types, respectively. Then, the conductor 1e having the shape shown in FIG. 7 is obtained.

Next, the coil nose portion 1d is machined by using the nose bending device shown in FIG. 8 to finish the machining. The nose bending device shown in FIG. 8 has a pin portion 17a wound around the nose portion 1d with a predetermined radius around the coil reference point 6 and the conductor 1.
a cap portion 17d for pressing e from the side and a cylinder 17f for moving and applying pressure to the cap 17d, and a bender portion 17b and 17c for rotating the conductor 1e around the pin 17a around the pin 17a. A power unit 17e for driving the bender units 17b and 17c, and a pedestal unit 17g for fixing these mechanical units.
It consists of

The reference point 6 of the conductor 1e having the shape shown in FIG. 7 is fixed to the position of the pin 17a of the nose bending apparatus thus constructed, and the final coil wire shown in FIG. 9 is formed by bending the reference point 6 around the pin 17a. Get one. The respective devices used in the above-described molding process are connected to each other by a transfer device, and realize a series of continuous operations from the starting process to the final process.

[0019]

As described above, according to the present invention, each processed portion of the coil wire is decomposed into a simple two-dimensional bend and these are combined to obtain a predetermined shape. Can be changed easily. Therefore, a versatile device can be obtained. Further, since the reference point of the coil wire is fixed and bending is performed, the processing accuracy can be improved and automation can be easily achieved.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing setting of a reference point of a conductor.

FIG. 2 is an explanatory diagram showing bending positions of conductors.

FIG. 3 is a perspective view of a plane bending apparatus embodying the present invention.

FIG. 4 is an explanatory view showing a conductor processed by the plane bending apparatus of FIG.

5 is an explanatory view showing a final state in which the flat bending apparatus of FIG. 3 is operated.

FIG. 6 is a perspective view of a coil end portion processing apparatus for processing the coil end portion of the conductor of FIG.

FIG. 7 is an explanatory view showing the conductor processed in FIG.

FIG. 8 is a perspective view of a nose portion bending device that processes a nose portion of a conductor.

FIG. 9 is a perspective view showing the shape of a final coil wire.

FIG. 10 is a perspective view of a general hexagonal coil.

FIG. 11 is a perspective view showing a conventional coil-dedicated molding die.

FIG. 12 is an explanatory view showing a conventional coil manufacturing process.

FIG. 13 is an explanatory diagram showing a conventional coil manufacturing process.

FIG. 14 is an explanatory diagram showing a conventional coil manufacturing process.

FIG. 15 is an explanatory view showing a conventional coil manufacturing process.

FIG. 16 is an explanatory diagram showing a conventional coil manufacturing process.

FIG. 17 is an explanatory diagram showing a conventional coil manufacturing process.

[Explanation of symbols]

 1e conductor 5 axis line (reference straight line) 6 reference point 7a first point 7b second point 7c third point 7d fourth point 7e fifth point 7f sixth point 7g seventh point 7h eighth point Point 8a Fixed base 9a, 10a Axis slide base 9b, 10b Right angle slide base 11a, 12a End setting base

Claims (1)

[Claims] 1. A reference point is set between both ends of a conductor having a predetermined length, and a first point and a second point are provided at positions of a predetermined length in the direction of each end from the reference point, respectively. A third point and a fourth point are located closer to the reference point than the first point and the second point, respectively, and a third point and a fourth point are located closer to the reference point than the third point and the fourth point, respectively. The fifth point and the sixth point are set at positions closer to the reference point than the fifth point and the sixth point, respectively, and the seventh point and the eighth point are set, respectively, and the first point before processing is set. From the above, the bending plane including the reference line connecting the eighth point and the reference point is set, and any one of the bending planes faces the reference point in the final step of processing,
In a method of manufacturing a coil of an electric motor, wherein the conductor is bent into a hexagonal shape so that both ends of the conductor are arranged substantially parallel to each other on the same side, in the bending plane, the reference point of the conductor and the seventh First fixing point and the eighth point above
Step, between the one end and the first point is the first base, between the other end and the second point is the second base, and the third point and the A second step of fixing the fifth base to the third base, and the fourth and sixth points to the fourth base, respectively. The base of No. 4 is moved in the direction of the reference straight line and parallel to the reference straight line with the reference point as the center,
The third step of bending so that the bending angle of each of the eighth points is within 90 degrees from the point of, between the first point and the third point, and between the fifth point and the seventh point. Point, between the second point and the fourth point, and between the sixth point and the eighth point, and project in opposite directions with the bending plane interposed therebetween. A method of manufacturing a coil of an electric motor, which comprises the fourth step of bending at a predetermined radius.