JPH1175351A - Method and apparatus for forming coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and an apparatus for forming coils for electric rotary machines wherein an oval coil is formed into a hexagonal coil by an almost automated process without damage to insulating films, the time for setup is reduced, the accuracy of formed coil dimensions, and workability are enhanced. SOLUTION: An oval coil 30 has an insulating tape wound around the coil surface. Of the upper and lower straight portions 30a, 30b and the left and right looped portions 30c of the coil 30, the straight portions 30a, 30b are formed in the directions opposite to them, respectively, by a straight portion shaping unit under pressure. Further, the looped portions 30c are pulled in the direction of the length by a loop forming unit 34, and formed toward the inner circumference side under pressure. Thereby, the oval coil 30 is formed into a semicylindrical coil. Thereafter, straight portion clamps 81a, 81b are moved up and down and left and right and rotated to move the loop forming unit 34 in the directions of Z3 and Z4 to form the coil into an almost hexagonal coil. Subsequently, the radius forming jig 78 of a radius shaping unit 77 is advanced to form the radius of the coil end portion 30d to form a hexagonal coil.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a coil forming method and a coil forming machine for forming a coil used in a rotating electric machine.

[0002]

2. Description of the Related Art A coil used in a high-voltage electric motor as a rotating electric machine is generally formed by winding a rectangular copper wire with an insulating coating into a flat, substantially isosceles trapezoidal shape as shown in FIG. (Hereinafter referred to as a sea-shaped coil) and using a coil forming machine as shown in FIG.
The coil is manufactured by molding according to the order shown in (b) and (c).

[0003] More specifically, Fig. 32 (a) shows a state in which the coil 1 is clamped as viewed from the side, and the same lower linear portion as the upper linear portion ab of the coiled coil shown in Fig. 30. (Center) Two sides of cd are clamped 2 and 3 respectively.
And clamp the two end portions e and f with clamps 4, respectively.
Hold at 5. FIG. 32D shows a cross section taken along the line II of FIG. FIG. 32 (b) shows a state in which the upper straight portion ab is being stretched in the direction of the arrow A1 and is being formed, and the end portions e and f gradually approach the center of the coil, and FIG. The overall length is shorter than in a). FIG. 32E is a cross-sectional view taken along the line II-II of FIG.
Shown in FIG. 32 (c) shows the upper straight line part ab by the arrow A1.
(F) shows the state of the coil viewed from the side.

[0004] The state after the coil is formed is an end part e,
f is a straight line as shown by a solid line.
(B) Stator core slots indicated by phantom lines (a, b)
32, the radius of R1 and R2 shown in FIG.
(As shown by the dotted line in (f)).
In this method, an operator performs a coil end correcting operation from below using a wooden hammer and a battens, and forms the coil end up to R indicated by a dotted line in FIG.

[0005] In the conventional coil forming machine, as shown in FIG. 31, an upper straight portion ab of a coil 1 of a shell shape is gripped by a clamp 2, and a lower straight portion cd is gripped by a clamp 3. The end portions e and f are fitted and held by the clamps 4 and 5, and the upper linear portion ab of the coil 1 is first pulled and formed by the clamp 2 in the direction of arrow A1. That is, the link 9 and the link 10 are pulled downward in the direction of the arrow A1 around the fulcrum pin 8 supported by the bearing 7. At this time, the clamps 4 and 5 of the end portions e and f are drawn in the directions of arrows A2 and A3, respectively, as the coil 1 is deformed. The clamp 3 remains stationary and does not move.

[0006]

In such a coil forming machine, when the length of the coil, the cross-sectional dimension of the coil, and the coil opening angle θ are changed, a setup change is required. And
Not only was the rounding work of the coil 1 complicated, but also a lot of setup time was required for molding the coil 1. In addition, if the coil 1 molding dimensions are not accurate, the insulation may be damaged when the coil is inserted into the slot of the iron core.

That is, in the conventional winding process, a rectangular copper wire is wound by a winding machine to form a rounded coil, each rectangular copper wire of the rounded coil is fixed, and the rounded coil is formed into a turtle-shaped coil. It is formed in the working process in the order of winding the insulating tape around the coil surface, and has the above-mentioned problems.

In order to improve these, the winding process has been changed
The winding was manufactured using a conventional coil forming machine as shown in FIG. 31 while considering and substantially considering the process automation by changing to →. Then, when winding the insulation tape around the seam-shaped coil, the machine can not follow the corners of the left and right curved parts and the insulation tape can be wound, and the coil shape when winding the insulation tape is formed in an oval shape And made several prototypes. That is, as shown in FIG. 34 (a), a rectangular copper wire is wound by a winding machine to form an oval coil 20, and after winding the insulating tape, the left and right loop portions 20a of the oval coil 20 are clamped. The straight portion of the oval coil 20 is gripped by the clamps 2a and 3a. And the clamps 4a, 5
a, while pulling the loop portion 20a in the left-right direction with the respective pins 4aa and 5aa, clamps 2a and 3a
When the linear portion of “0” is moved toward the inner peripheral side, the clamps 2a, 3
The loop portion 20a is transformed into a loop portion 21a having a shape close to a circular shape from the base point a, and the oval coil 20 is
Becomes one. It has been found that it is difficult to deform the loop portion 21a from this shape to form a seam-shaped coil. Further, since the loop portion 20a is pulled in the left-right direction by the pins 4aa and 5aa, the insulating coating of the loop portion 20a in contact with the pins 4aa and 5aa is damaged.

SUMMARY OF THE INVENTION The present invention has been made in view of the above, and has a substantially automatic process, in which an oval-shaped coil is formed into a hollow coil without damaging an insulating film, thereby shortening the setup time and improving the accuracy of the coil forming dimension. It is an object of the present invention to provide a coil forming method and a coil forming machine which can realize the above-mentioned and have good workability.

[0010]

According to a first aspect of the present invention, there is provided a coil forming method and a coil forming machine in which an insulated tape is wound around a coil surface formed by winding a rectangular copper wire with an insulating coating. The upper and lower linear portions of the upper and lower linear portions and the left and right loop portions forming the oval coil are formed by pressing the upper and lower linear portions in a direction opposite to the upper and lower linear portions, and the coil is extended. -This is a coil forming method in which the inside of the loop is pressed toward the inner circumference side while the lower straight portion is pulled in the length direction to form an oval-shaped coil into a sea-shell type coil.

[0011] According to this method, by forming an oval coil in which an insulating tape is mechanically wound into a hollow coil, the winding force of the insulating tape becomes constant and the tape is not damaged, and the insulation strength is maintained. As a result, the degree of overlap of the tape on the surface of the wound coil becomes constant, so that the insulation strength of the coil is improved. In addition, molding from an oval coil to a hollow coil eliminates the conventional work of fixing a rectangular copper wire, thereby improving productivity.

A second aspect of the present invention relates to a coil forming method for synchronizing the pressure forming and the tensioning operation, wherein a local forcing force is not applied to a molding portion or a tensioned portion by the synchronous operation, and the insulating tape is damaged or damaged. No deformation.

[0013] A third aspect of the present invention is a linear part forming frame which is mounted on a base and has linear part forming units for forming upper and lower linear parts of an oval coil, respectively. A loop forming frame which is provided and has a loop forming unit for forming left and right loop portions of the oval coil respectively, and which can be moved left and right on the base via a hole screw, and on the upper and lower sides of the tip of the loop forming unit. A forming jig disposed, a loop clamp portion disposed between the forming jigs at a tip of the loop forming unit, and detecting a change in length of the upper and lower linear portions incorporated in the loop forming unit. And a servomotor for controlling the movement of the linear part forming unit, the loop forming unit, the forming jig, and the loop clamp unit. When the coil is formed by using the coil forming machine according to the forming method of the first aspect, the same operation and effect as those of the first aspect can be obtained.

According to a fourth aspect of the present invention, the loop clamp portion is opposed to the resin coil holding portion provided at the tip, the coil hooking pin implanted at the tip of the side surface of the coil holding portion, and the coil holding portion. A coil forming machine comprising a clamp lid having a coil holder made of resin at a tip end, wherein a coil hooked by the coil hooking pin is held with a gap formed between the coil holding portion and the coil holder. Then, the loop portion is held by forming a gap between the coil holding portion and the coil presser, and the insulating tape is rubbed because the loop portion is not restrained by the coil holding portion or the coil presser in various molding work states. Since the insulating tape does not move and is not restrained, the insulating tape does not shift between the coil holding portion, the coil presser and the rectangular copper wire, and the insulating tape on the coil surface is hardly damaged.

According to a fifth aspect of the present invention, the forming jig has a substantially rectangular shape and the lower end is attached to the base of the loop forming unit by a fulcrum pin, and the projection of the body is fixed to the tip rod of the actuator by a connecting pin. A coil forming machine is formed by a swing arm and a piece-shaped pressurizing section fixed to a top end of the swing arm with a fulcrum pin and having a plurality of rotating rollers made of resin at a lower portion. Since the loop portion is pressed by the rotating roller, the crushing operation can be easily performed.

According to a sixth aspect of the present invention, the rotary roller of the pressing section is formed with a large diameter and a small diameter, and the small diameter is disposed on both sides of the large diameter, or the large diameter is disposed on the corner side of the opposite loop portion. It is characterized by.
According to a seventh aspect of the present invention, a portion of the lower side of the lower linear portion is formed lower than the other lower side surface of the lower linear portion near the corner of the loop portion of the shell-shaped coil by the rotating roller having the large diameter according to the sixth aspect. This is a coil forming method for forming a concave portion. Claim 6
According to claim 7, depending on the size of the oval-shaped coil and the thickness, shape, strength, etc. of the rectangular copper wire to be formed, the spring-back action and residual stress during the forming step from the oval-shaped coil to the seam-shaped coil are reduced. Due to the influence, the lower side portion of the lower straight portion may be warped near the corner of the loop portion, and a predetermined straight portion may not be formed at the lower side portion. Therefore, it is prevented by forming the concave portion α at the lower side portion. .

According to an eighth aspect of the present invention, the straight portion forming unit for forming the straight portion forming frame is a straight portion clamp, and the tip is a round forming jig disposed below the straight portion forming frame and the loop forming frame. This is a coil forming machine that additionally installs a round forming unit that moves up and down, and is a forming machine that integrally forms an oval coil → a sea-shaped coil → a turtle-shaped coil.

According to a ninth aspect of the present invention, there is provided a molding method for integrally molding an oval coil → a seam-shaped coil → a turtle-shaped coil by the coil molding machine according to the eighth aspect. According to a tenth aspect of the present invention, the clamp lid forming the loop portion clamp is provided with a shoulder substantially matching the shape of the loop portion of the sea-shell coil. The large radius of the coil does not return (no spring back) and the shape of the loop does not increase. Then, the coil does not interfere with each other when the turtle-shaped coil is inserted into the slot of the iron core, and the insulating tape is not damaged at the time of the inserting operation, so that the insulation deterioration of the coil can be prevented.

According to another aspect of the present invention, a support piece which contacts the lower side of the corner radius portion is implanted on the side surface of the head of the vertical clamp forming the straight portion clamp. Even if a compressive stress is applied to the lower side, it protrudes to the lower side and is supported by a support piece. As a result, the coil does not protrude below the straight section, the coils do not interfere with each other when the turtle-shaped coil is inserted into the slot of the iron core, and the insulating tape is not damaged at the time of the insertion work, and the insulation of the coil is prevented. Deterioration can be prevented.

According to a twelfth aspect of the present invention, the round forming jig moves up and down obliquely in the direction of the loop portion, so that the loop portion can be formed linearly when forming into a turtle-shaped coil. According to a thirteenth aspect of the present invention, the round forming jig is provided with a side plate outside the portion where the coil is in contact with the concave shape, so that it is possible to prevent the flat copper wire wound at the time of molding into the turtle-shaped coil from falling apart. .

According to a fourteenth aspect of the present invention, the head of the side plate of the round forming jig is formed in a mushroom shape, and even if the round forming jig is pressed at an angle slightly different from the inclination angle of the coil end portion, The coil end can easily accommodate the turtle-shaped coil into the iron core slot without further tilting.

According to a fifteenth aspect of the present invention, a rotatable bearing having an elastic body inserted therein is installed in a holding portion of the radius forming jig, and the radius molding jig is attached to a coil end portion having a three-dimensional curve. Because the pressing jig swings according to the coil end part even if the positioning is not accurate,
The efficiency of the positioning work of the round forming jig is improved.

In another aspect, a side piece for fixing the upper and lower linear portions forming the oval coil disposed on the linear portion clamp, and a clamp lid and a clamp for the loop portion clamp for fixing the left and right loop portions are provided. In the base, the side piece has the upper part of the side piece travel outward, the clamp lid has the upper part of the clamp lid lowered inward, and the clamp base has the lower part of the clamp base lowered inward, respectively. It is one with a slope. As a result, the coil end portion connected to the loop portion from the straight portion of the tortoise-shaped coil does not fall inward with respect to the normal direction of the iron core, and if the gap between the coils that intersect in the slot is small. Contact will not cause insulation deterioration.

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below with reference to FIGS. 1 to 8 showing a molding machine and a molding method for forming an oval coil into a hollow coil. In FIG. 1, two types of three frames are provided on a base 31,
The center is a straight portion forming unit 32a for forming the upper straight portion 30a and the lower straight portion 30b of the oval coil 30, respectively.
A straight part forming frame 33 having 32b is fixed to the base 31. On both left and right sides of the straight portion forming frame 33, a loop forming frame 35 having a loop forming unit 34 for forming left and right loop portions 30c of the oval coil 30 is movably mounted in the left and right direction via a ball screw 36. Have been. Above and below the tip of the loop forming unit 34, a total of four forming jigs 37 described later are installed (only one is shown in FIG. 1). The linear portion forming units 32a and 32b and the loop forming unit 34 are controlled to move vertically (arrows Y1 and Y2) or left and right (arrows Z3 and Z4) by a servomotor M. A load cell (not shown) is provided in the loop forming unit 34.

Next, the loop forming unit 34 is provided with a servomotor M and an encoder at the rear end thereof, and a forming jig for applying pressure to the left and right loop portions 30c of the oval coil 30 at the upper and lower ends to form each. 37 are installed. As shown in FIG. 2, the forming jig 37 is formed by a turning arm 38 having a substantially rectangular shape and a pressing portion 41 fixed to the upper end of the turning arm 38 by a fulcrum pin. And
A lower end of the revolving arm 38 is attached to a base 42 of the loop forming unit 34 by a fulcrum pin 39, and an upper end has a plurality of (two in FIG. 2) rotary rollers 40 made of resin in the lower axial direction. A pressurizing portion 41 having a shape is fixed by a fulcrum pin, and a bent protruding portion 38a of the body of the revolving arm 38 is fixed to a tip rod 44a of an actuator 44 by a connecting pin 43 (the rear end of the actuator 44 can be vertically turned). The base 42 of the loop forming unit 34
Is fixed to). When the actuator 44 is operated by a control device (not shown) and the tip rod 44a moves in the axial direction, the revolving arm 38 bends with the lower end as a fulcrum, the protruding portion 38a moves diagonally upward, and the pressing portion 41 Move in the direction.

A resin coil holding portion 46 having a metal coil hooking pin 45 is attached to the tip of the base 42 (FIG. 3 shows the molding jig 37 viewed from the upper and lower surfaces in FIG. 2). It is a state diagram). The retraction cylinder 4 moves the base 42 in the axial direction (moves in the Z direction in FIG. 1) as shown in FIG.
7, a clamp cylinder 48 and a gap cylinder 49 which move vertically in FIG. 4 (moving in the X direction in FIG. 1) are arranged in the base 42 in the axial direction. There is a clamp lid 50 facing the tip of the clamp cylinder 48 and the gap cylinder 49, and a resin coil holder 50a is attached to the tip of the clamp lid 50 so as to face the coil holding portion 46. A knurled nut 51 facing the tip of the gap cylinder 49 is mounted through. The coil holding portion 46
Between the coil holder 50a and the loop 30c of the coil 30
Are held with a gap δ.

A method of forming an oval coil into a sea-shaped coil using such a coil forming machine will be described. First, a rectangular copper wire with an insulating film is wound a predetermined number of times by a device (not shown) to produce an oval coil 30 as shown in FIG. 5, and an insulating tape is wound around the entire surface by a taping machine (not shown). The size of the oval coil 30 is, for example, a distance between the upper and lower linear portions 30a and 30b is about 160 mm, and an inner diameter of the loop portion 30c is about 80 mm. This oval-shaped coil 30 is formed into a shell-shaped coil 60 as shown in FIG.

In FIG. 1, which shows a schematic view of the entire coil forming machine, upper and lower linear portions 30a, 30b of an oval coil 30 are shown.
Are held by the linear portion forming units 32a and 32b, respectively, and in this state, the retracting cylinder 47 is advanced in the Z direction to move the clamp lid 50 onto the loop portion 30c, and
The gap cylinder 49 is also advanced while the cylinder 48 is advanced. 6, the tip of the gap cylinder 49 and the tip of the knurl nut 51 come into contact with each other, and one side of the loop 30c comes into contact with the coil holding portion 46, and the other side has a gap δ formed by the coil presser 50a. Will be retained. At this time, the oval coil 30 is pulled by the coil hooking pin 45 in the Z3 direction shown in FIG. 7 (the left half of FIG. 1 is shown).

In this state, when pressure is applied to the inner side of the coil by the upper straight portion 30a by the two straight portion forming units 32a and the lower straight portion 30b by the two straight portion forming units 32b (FIG. 8). , B direction), the upper and lower linear portions 30a,
30b is the Z3 direction shown in FIG. 7 (Z3, Z4 direction in FIG. 1)
This is detected by a load cell (not shown) built in the loop forming unit 34, the ball screw 36 is moved, and the loop forming unit 34 is moved in the axially expanding direction. In synchronization with this pressurization work, 4
The operation of the actuators 44 causes the forming jigs 37, 3
7a, the pivot arm 38 of FIG.
Are rotated in the direction of arrow A shown by
0 starts pressurizing the loop portion 30c. When the loop portion 30c is pressurized, the axial lengths of the upper and lower linear portions 30a and 30b increase, so that the length is always detected by a load cell built in the loop forming unit 34, and the ball screw 36 is moved to make the loop forming unit 34 move. Is moved in the direction to expand in the axial direction.

The upper and lower linear portions 30a, 30b are pressed by the respective linear portion forming units 32a, 32b,
Pressing of the forming jigs 37 and 37a onto the loop portion 30c and adjustment of the axial expansion movement of the loop forming unit 34 are repeatedly performed by an automatic control device, and as shown in FIG. Is about 4 incline to the coil hooking pin 45
At 5 degrees, the pressurizing portion 41 of the forming jig 37a is crushed and formed while pressing the loop portion 30c until the pressing portion 41 is substantially horizontal with respect to the coil hooking pin 45, and a predetermined seam-shaped coil 60 is formed. Work ends.

The upper and lower straight portions 30a and 30b are pressed in the Y1 and Y2 directions, the elongated coil is pulled in the Z3 and Z4 directions, and the forming jigs 37 and 37a are pressed against the loop portion 30c by pressing. Since all the moldings are performed synchronously by the servomotor, unnecessary concentrated force is not applied to each molding portion, and the loop corners 60 formed on the seam-shaped coil 60 are not pressed.
A coil having a predetermined shape in which the R dimension of d (shown in FIG. 6) is also a predetermined size can be formed. Then, since the work is performed in synchronization, no strong force is applied to both loop corners 60d hooked on the coil hooking pin 45, and damage to the insulator at the loop corner 60d can be prevented.

From these results, by forming the oval coil 30 into which the insulating tape is mechanically wound into the hollow coil 60, the winding force of the insulating tape becomes constant and the tape is not damaged and the insulation strength is increased. The insulation strength of the coil is improved because the tape can be maintained and the degree of overlap of the tape on the surface of the wound coil is constant. In addition, forming the small-sized coil 30 into the hollow coil 60 improves productivity because the conventional flat copper wire fixing operation is eliminated. Furthermore, the loop part 3
0c is the gap δ between the coil holding portion 46 and the coil presser 50a.
Is formed and held, and in various molding operation states, the loop portion 3 is formed.
0c is not restrained by the coil holding portion 46 or the coil presser 50a, so that the insulating tape is not rubbed and is not restrained. Since there is no deviation between the coils, there is almost no damage to the insulating tape on the coil surface.

Next, a molding machine and a molding method for molding from an oval coil to a seam-shaped coil to a tortoise-shaped coil will be described with reference to FIGS. FIG. 9 shows a molding machine 100 for forming a tortoise-shaped coil by additionally installing a straight section clamp having a round forming unit and a support piece in FIG. 1 (only two loop forming jigs 37 are shown on the left side). 10 and 11 show a detailed view of the straight portion clamp, and FIG. 12 shows a detailed view of the round forming unit.

In FIGS. 10 and 11, a straight portion clamp 8 serving as the straight portion forming units 32a and 32b shown in FIG.
Reference numeral 1 denotes an L-shaped shutter 74 which moves up and down by a cylinder 71, and a cylinder
2. A concave vertical clamp 75 which moves up and down by
The lower linear portions 30a and 30b are pressed from the side and the cylinder 73 is pressed.
And a horizontal clamp 76 operated by the Also, on the side surface of the head of the vertical clamp 75, a corner radius portion 30e formed between the straight portion 30a and the coil end portion 30d.
A support piece 83 is planted so as to be in contact with the lower side.

Next, the round forming unit 77 is for forming the coil end portion 30d, and is disposed on the left and right of the lower part of the straight portion forming frame 33 on the base 31 and is vertically moved obliquely by the cylinder 79 (in the direction D in FIG. 12). On the head, a concave R-shaped jig 78 that can freely move in the directions of arrows A, B, and C (shown in FIG. 12) is implanted. The side plate 84 (the side wall of the recess →
The side surface shape of the head of FIG. 16) is a mushroom-shaped round shape, and the head contacts the coil (see FIG. 15).

Also, as shown in FIGS. 17 and 18, shoulders 80 which are similar to the shape of the loop portion 30c of the shell-shaped coil 60 are provided at both ends of the coil presser 50a of the clamp portion 70 shown in FIG.

A method for forming a sea-shell-shaped coil into a tortoise-shaped coil using the coil-forming machine thus formed will be described. First, after the oval coil 30 is set in the coil forming machine 100, the retracting cylinder 47 is operated to advance the whole of the clamp cylinder 48, the gap cylinder 49, the clamp lid 50, and the coil presser 50a. The coil 30 is formed into a fish coil 60. Thereafter, before forming into a tortoise-shaped coil, the gap cylinder 49 is advanced, and the clamp cylinder 48 is operated to provide a grip with the seam-shaped coil 60 with a gap δ. Next, as shown in FIG.
2b by arrows X1, Y1, T1 and X2, Y2, T
Move in two directions. Then, the loop portion 30c gradually comes closer to the center and becomes shorter than the entire length of the shell-shaped coil 30. Therefore, the force is detected by a load cell (not shown), and the servo motor M is operated to operate the loop portion forming unit 34. Move in the Z3, Z4 directions. At this time, an appropriate voltage command is sent from a control device (not shown) to the servo motor M so that the detected pressure value at the load cell becomes the same as the set pressure, and the rotational torque of the servo motor M is controlled to form a substantially tortoise-shaped coil. Mold into

Subsequently, the radius forming jig 78 of the radius forming unit 77 is advanced, and the coil end portion 30d (FIG. 1)
5) as shown in FIG. 33 so as to fit into slots (euro) of the stator core. At this time,
The loop portion 30c gradually comes closer to the center, and the overall length becomes shorter. Then, similarly, an appropriate voltage command is sent to the servo motor M from a control device (not shown) so that the detected pressure value at the load cell becomes the same as the set pressure, the rotational torque of the servo motor M is controlled, and the molding operation is completed. .

Next, the effects in the formation of the sea-shell-shaped coil → tortoise-shaped coil are as follows. The upper and lower straight portions 30a,
At the time of press-forming the 30b and the coil end 30d, the loop portion 30c is pressed outward with an appropriate force by the shoulder 80 of the coil presser 50a substantially conforming to the shape of the shell-shaped coil 60. The shoulder 80
Does not come back, and the large radius of the oval coil 30 does not return (there is no spring back), and the shape of the loop portion 30c does not increase. Then, even when the turtle-shaped coil is placed in the slot of the iron core, the coils do not interfere with each other, and it is possible to prevent insulation deterioration of the coil without damaging the insulating tape at the time of placing. In addition, the coil hooking pin 4
5 and the loop portion 30c of the coil do not come into contact with each other with strong pressure, and damage to the insulating tape can be prevented, so that deterioration of coil quality can be prevented.

The upper straight portion 3 of the oval coil 30
A support piece 83 is provided on the side surface of the vertical clamp 75 of the straight portion clamp 81 for fixing Oa so as to contact the lower side of the corner radius portion 30e formed between the straight portion 30a and the coil end portion 30d. When the oval coil 30 gripped by the straight portion clamp 81 is formed into a tortoise-shaped coil, even if a compressive stress is applied to the lower side of the corner radius portion 30e, it is prevented by the support piece 83 from protruding downward. The phenomenon that the coil protrudes below the straight portion 30a does not occur. For this reason, even when the turtle-shaped coil is placed in the slot of the iron core, the upper linear portion 30a and the lower linear portion 30b do not interfere (contact state), and the insulating tape is not damaged.

When the turtle-shaped coil is formed using the straight part clamp 81 without the support piece 83, the corner radius 30e from the upper straight part 30a to the coil end part 30d of the turtle-shaped coil is twisted ( 27, the upper side 30e2 is subjected to tensile stress (in the direction of arrow T in FIG. 27), and the lower side 30e1 is subjected to compressive stress (in the direction of arrow C in FIG. 27). 30
In e1, a phenomenon occurs in which the coil projects further below the lower straight portion 30b. In this case, the upper linear portion 30a and the lower linear portion 30b of the tortoise-shaped coil cannot be accommodated when they are inserted into the slot of the iron core, or when the interference occurs, the insulating tape is damaged and the insulation tape is damaged. Becomes

Further, in the round forming of the coil end portion 30d, the side plate 84 is provided outside the place where the coil comes into contact, so that the round forming jig 78 is advanced by the cylinder 79 after forming the coil into a substantially turtle-shaped coil. When the round forming jig 78 is pressed against the end portion 30d to perform the round forming,
Even if the round forming jig 78 is not correctly oriented in the normal direction of the end portion 30d, the side plate 84 corrects the angle of the end portion 30d, and the end portion 30d does not further tilt. Also, the wound wires 85 can be easily accommodated in the slots of the iron core without falling apart, and there is no interference between the coils and no damage to the insulating tape.

When the round forming is carried out by the round forming jig 78 without the side plate 84, the inclination of the end portion 30d is gradually changed from the upper and lower straight portions 30a and 30b to the left and right loop portions 30c. When the round forming jig 78 is pressed at an angle slightly different from the inclination angle of the portion 30d, the end portion 30d is further inclined (shown in FIG. 28) and cannot be accommodated in the slot of the iron core. Alternatively, the coils may interfere with each other to damage the insulating tape, resulting in insulation deterioration. Further, when the round forming jig 78 is pressed, the wound wire 85 is broken (shown in FIG. 29), which makes the coil defective.

Further, the round forming jig 7 is attached to the loop portion 30c.
Since the coil 8 is pressed obliquely upward and formed, it is possible to form the coil into a predetermined shape without expanding the coil end portion of the turtle-shaped coil outward. And the setup can be improved by the consistent molding of the oval-shaped coil → the sea-shaped coil → the turtle-shaped coil.

(Second Embodiment) Rotary Roller 4 of Pressing Unit 41
0 is a pressurizing portion 41a which is replaced with a resin boat shape 40a as shown in FIGS. Since the rotating roller 40 is circular, it comes into contact with the coil surface by point contact, so that small irregularities are formed on the coil surface without practical problems. However, the coil surface is formed smoothly by replacing the contact surface with the boat shape 40a.な 良 い こ 良 い 良 い 良 い 良 い.

(Third Embodiment) As shown in FIG. 21, a pressurizing portion 41b presses a loop portion 30c of a lower straight portion 30b.
Of the leading roller 40b on the side of the lower linear portion 30b, a ring is fitted to the other rotating roller 40b.
Larger than the outside diameter of When the oval-shaped coil 30 becomes closer to the seam-shaped coil 62 by molding, a lower side portion 62c of the lower straight portion 62b near the loop corner 62d side.
Is formed lower than the other lower side surface of the lower linear portion 62b by the leading roller 40b to form the concave portion α (the leading roller 40b).
The lower straight portion 62b, which is not in contact with b, is formed lower than the lower side surface line to form the concave portion α). This depends on the size of the oval coil and the thickness, shape, strength, etc. of the rectangular copper wire to be formed.
Lower part 6 of lower straight portion 62b near the corner 62d of the loop portion due to the effect of spring back and residual stress.
2c may be warped and a predetermined linear portion may not be formed in the lower side portion 62c.
2c is prevented by forming a concave portion α (a leading roller 40b having a large outer diameter may be formed from the beginning instead of the ring fitting. Alternatively, a leading roller having a large outer diameter may be removed during the molding process. May be replaced).

(Fourth Embodiment) As shown in FIG. 22, a pressurizing portion 41c for pressurizing a loop portion 30c of a lower straight portion 30b.
Are formed in an array of three, and the central rotating roller 4
The outer diameter of Oc is made larger than the rotating rollers 40 on both sides. This has the same effect as the third embodiment.

(Fifth Embodiment) FIG. 23 shows a fifth embodiment. Upper and lower straight portions 30a, 30b of the oval coil 30
And a coil holder 50aa and a coil holding portion 46a of a loop portion clamp 70 for fixing the left and right loop portions 30c.
2, the coil holder 50 a has a coil holder 50 a so that the upper part of the side piece 82 projects outward (in the direction of arrow X in FIG. 23), and the coil holder 50 aa has the upper part of the holder 50 a lowered inward (in the direction of arrow X in FIG. 23). The lower portion of the holding portion 46a is inside of 46a (FIG. 23).
Respectively, so as to descend in the direction of arrow X).

When the coil is gripped by the straight portion clamp 81 and the loop portion clamp 70 and formed into a substantially turtle-shaped coil from the hollow coil 60, the coil end portion 30d has the side piece 82 and the coil presser 50a as shown in FIG. The torsion coil provided in the coil holding portion 46 is twisted in the direction of the arrow β to complete the R-shaped tortoiseshell coil. When this tortoise-shaped coil is housed in the slot of the iron core, as shown in FIG. 25, the cross section of the end portion 30d is oriented in the normal direction of the iron core, the gap between the intersecting coils is not reduced, and insulation deterioration due to contact can be prevented.

(Sixth Embodiment) FIG. 26 shows a sixth embodiment of the present invention, which shows a round forming jig 78 for the coil end portion 30d. An elastic body 88 is provided on the holding portion 86 of the round forming jig 78.
(For example, made of rubber), and a rotatable bearing 87 is provided. In this way, even when the radius forming jig 78 is pressed against the end portion 30d forming a three-dimensional curve, it rotates to some extent freely along the end portion 30d to accurately position the radius molding jig 78. The round forming operation of the end portion 30d can be performed without doing so. As a result, the efficiency of the positioning operation of the round forming jig 78 is improved.

[0051]

As described above, according to the present invention, the winding force of the insulating tape is obtained by first forming the small-sized coil obtained by mechanically winding the insulating tape into a shell-shaped coil and then forming the same into a turtle-shaped coil. And the insulation strength can be maintained without damaging the tape, and the degree of overlap of the tape on the wound coil surface is also constant, so that the insulation strength is improved without coil deformation. In addition, molding from an oval coil to a seam-shaped coil to a turtle-shaped coil eliminates the conventional work of fixing a rectangular copper wire, thereby improving productivity.

[Brief description of the drawings]

FIG. 1 is a schematic view showing a coil forming machine of the present invention for forming an oval shape into a seagull shape,

FIG. 2 is a side view showing a loop forming unit and a forming jig of the coil forming machine of the present invention;

FIG. 3 is a side view showing a loop forming unit and a forming jig when FIG. 2 is viewed from above,

FIG. 4 is a loop clamp diagram,

FIG. 5 is an oval coil diagram.

FIG. 6 is a figure of a sea-shaped coil,

FIG. 7 is a diagram showing a state in which an oval coil is held by a loop forming unit and a forming jig;

FIG. 8 is a diagram showing a molding state of a shell-shaped coil formed by a loop molding unit and a molding jig;

FIG. 9 is a schematic diagram showing a coil forming machine of the present invention for forming into an oval shape → a seashell shape → a turtle shape;

FIG. 10 is a side view of a straight portion clamp (straight portion forming unit);

FIG. 11 is a front view of a straight portion clamp (straight portion forming unit);

FIG. 12 is a front view showing a positional relationship between a coil and a round forming unit;

FIG. 13 is a flowchart showing a process of forming into a tortoise-shaped coil;

FIG. 14 is a detailed view of a coil formed by a support piece of a straight portion clamp,

FIG. 15 is a front view of a round forming jig,

FIG. 16 is a side view of a round forming jig,

FIG. 17 is a diagram corresponding to FIG. 4 in which a shoulder is provided in a loop clamp,

18 is a front view of FIG. 17,

FIG. 19 is a diagram corresponding to FIG. 8, showing a modification of the molding jig;

20 is a view corresponding to FIG. 3 of FIG. 19,

FIG. 21 is a diagram corresponding to FIG. 19, showing a modification of the molding jig;

FIG. 22 is a diagram corresponding to FIG. 19, showing a modification of the molding jig;

FIG. 23 is a coil diagram of a grip according to a modified example of the straight portion clamp and the loop clamp;

FIG. 24 is a detailed view of the loop portion of the formed tortoise-shaped coil in FIG. 23;

25 is a coil end diagram when the coil is housed in the slot in the modification of FIG. 23,

FIG. 26 is a diagram corresponding to FIG. 15 showing a modification of the radius forming jig;

FIG. 27 is a coil end diagram not using the modification of FIG. 23;

FIG. 28 is a coil state diagram not molded by a mushroom-shaped round molding jig,

FIG. 29 is a coil state diagram not molded by a mushroom-shaped round molding jig,

FIG. 30 is a plan view showing a planar shape of a sea-shell type coil;

FIG. 31 is an essential part perspective view showing an example of a conventional coil forming machine;

FIG. 32 shows a forming order by a conventional coil forming machine;
(A), (b) and (c) are front views, (d) and (e) are cross-sectional views taken along arrows II and II-II, (f) is a side view,

FIG. 33 is a coil dimensional diagram showing a completed state of forming a tortoiseshell coil;

FIG. 34 is a modified coil diagram in which an oval coil is formed by a conventional coil forming machine.

[Explanation of symbols]

30 ... oval coil, 30a ... upper straight part, 30b, 62b ... lower straight part, 30c ...
Loop part, 31 ... base, 32a, 3
2b: Linear part forming unit, 33: Linear part forming frame, 34: Loop forming unit, 35: Loop forming frame, 36: Ball screw, 37,
37a: forming jig, 38: swing arm, 3
8a: bent projection, 39: fulcrum pin,
40 ... rotating roller, 41, 41a ...
Pressing part, 42 ... base, 43 ...
Connecting pin, 44 ... actuator, 44
a: tip rod, 45: coil hooking pin,
46: coil holding portion, 47: evacuation cylinder,
50 ... clamp lid, 50a ... coil presser,
51 ... knurl nut, 60, 61, 6
2 ... sea-shell type coil, 60d, 60d ... loop corner,
62c: lower part, 70: loop clamp part, 71, 72, 73, 79: cylinder, 74
… Shutter, 75… Vertical clamp, 7
6 horizontal clamp 77 round forming unit
78: R forming jig, 80: Shoulder,
81: straight part clamp, 82: side piece,
83 ... support piece, 84 ... side plate,
85 ... strand, 86 ... holding part,
87 ... bearing, 88 ... elastic body,
M: servo motor, α: recess,
δ: gap.

Claims (16)

[Claims] 1. An oval coil formed by winding an insulating tape on a coil surface formed by winding a rectangular copper wire with an insulating coating, and an upper / lower straight portion and left and right loops forming the oval coil. Of the parts, the upper and lower straight parts are press-formed by the straight part forming unit in the direction opposite to the upper and lower straight parts, and the inside of the loop is pulled while pulling the extending upper and lower straight parts in the length direction. A coil forming method characterized by forming an oval coil into a hollow coil by press-forming the inner peripheral side with a loop forming unit. 2. The coil forming method according to claim 1, wherein the pressing and the tensioning are performed synchronously. 3. A linear part forming frame which is mounted on a base and has a linear part forming unit which forms upper and lower linear parts of an oval coil and moves up and down, and on both left and right sides of the linear part forming frame. A loop forming frame which is disposed and has a loop forming unit for forming the left and right loop portions of the oval coil respectively, and which can be moved left and right on the base via a ball screw; and A forming jig disposed, a loop clamp portion disposed between the forming jigs at a tip of the loop forming unit, and detecting a change in length of the upper and lower linear portions incorporated in the loop forming unit. Load cell, and the linear portion forming unit,
A coil forming machine comprising: a loop forming unit, a forming jig, and a servomotor for controlling movement of a loop clamp unit. 4. The loop clamp portion includes a resin coil holding portion provided at a tip, a coil hooking pin implanted at a tip of a side surface of the coil holding portion, and a resin coil opposed to the coil holding portion. 4. The coil forming machine according to claim 3, comprising a clamp lid having a coil retainer at a tip, wherein the coil hooked by the coil hooking pin is held with a gap formed between the coil holding portion and the coil holder. 5. The shaping jig has a substantially rectangular shape, a lower end of which is attached to a base of the loop forming unit by a fulcrum pin, and a protruding portion of a body portion is fixed to a tip rod of an actuator by a connecting pin. 4. The coil forming machine according to claim 3, wherein said coil forming machine is formed by a piece-shaped pressurizing portion fixed to the upper end of said revolving arm with a fulcrum pin and having a plurality of rotating rollers made of resin at a lower portion. 6. The rotary roller of the pressurizing section is formed with a large diameter and a small diameter, and a small diameter is provided on both sides of the large diameter, or the large diameter is provided on a corner side opposite to the loop portion. The coil forming machine as described. 7. A rotating roller having a large diameter of the pressing unit,
2. The coil forming method according to claim 1, wherein a lower part of the lower linear portion near the corner of the loop portion of the seam-shaped coil is formed lower than another lower surface of the lower linear portion to form the concave portion. 8. A straight part forming frame mounted on a base and having straight part clamps which respectively form upper and lower straight parts of an oval coil and move up and down, and are disposed on both left and right sides of the straight part forming frame. A loop forming frame for forming left and right loop portions of the oval coil, the loop forming frame being movable on the base via ball screws left and right, and a loop forming frame disposed above and below the tip of the loop forming unit. A molding jig provided, a loop clamp portion disposed between the molding jigs at the tip of the loop molding unit, and a length variation of the upper and lower linear portions incorporated in the loop molding unit. A load cell, a round forming unit mounted on a base, disposed at a lower portion between the linear part forming frame and the loop forming frame, and a tip round forming jig moves up and down; A coil forming machine comprising a unit, a loop forming unit, a forming jig, a loop clamp unit, and a servomotor for controlling movement of each of the round forming units. 9. A coil forming method in which an oval coil formed by winding an insulating tape around a coil surface formed by winding a rectangular copper wire with an insulating coating is formed into a shell-shaped coil and then into a tortoise-shaped coil. Of the upper and lower straight portions and the left and right loop portions forming the oval coil, the upper and lower straight portions are press-formed by the straight portion clamps in the direction opposite to the upper and lower straight portions and stretched. While pulling the upper and lower straight parts in the length direction, the inside of the loop is pressed inward by the loop forming unit by the loop forming unit to form an oval shaped coil into a coiled coil, and then the upper and lower straight parts are pivoted. A coil forming method characterized in that, when pressure forming is performed in a direction opposite to the horizontal direction at right angles, the left and right loop portions are axially pressed outward by a round forming jig to form a tortoise-shaped coil. 10. The coil forming machine according to claim 8, wherein a shoulder substantially conforming to the shape of the loop portion of the coil is provided on a clamp lid forming the loop portion clamp. 11. The coil forming machine according to claim 8, wherein a support piece which is in contact with a lower side of the corner radius portion is planted on a side surface of a head of the vertical clamp forming the straight portion clamp. 12. The coil forming machine according to claim 8, wherein said round forming jig moves up and down obliquely in a loop portion direction. 13. The round forming jig is provided with a side plate outside a location where the coil is in contact with the concave shape.
2. The coil forming machine according to 2. 14. The coil forming machine according to claim 8, wherein the head of the side plate of the round forming jig has a mushroom shape. 15. The coil forming machine according to claim 8, wherein a rotatable bearing in which an elastic body is inserted is installed in a holding portion of the round forming jig. 16. A side piece for fixing upper and lower linear portions forming an oval coil disposed on the linear portion clamp,
Clamps on the clamp lid and clamp base of the loop clamp to fix the left and right loops, so that the upper part of the side piece travels outward to the side piece, and the upper part of the clamp lid falls down to the inside of the clamp lid. 9. The coil forming machine according to claim 8, wherein the base is inclined so that the lower portion of the clamp base is lowered inward.