JPS59193722A - Production of coil-shaped metal parts - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing a coiled metal component used, for example, in an electric motor.

Conventionally, the stator and/or housing of an electric motor are assembled from separate plate pieces. That is, a stack of separate plates is fastened together to form a single component, which supports an electric coil and is wrapped in a cast metal fitting.

The present invention aims to simplify the manufacture of such conventional parts and reduce their cost.

When a ring is formed by bending a metal strip around one of its edges, the edge forming the outer edge of the ring stretches and becomes thinner.

Therefore, even if both sides of the material forming the ring are completely parallel, the cross section of the ring will have a slight taper. On the other hand, a problem with forming rings from strips in this manner is that the inner edges of the rings produced by bending the metal strips tend to wrinkle during processing.

By producing coiled metal parts by the method according to the invention, the above-mentioned problems are solved and the main objectives of simplification of production and reduction of costs are achieved.

According to the present invention, a notch is formed along at least one side of a flat metal strip, and one end of the metal strip is attached to a strip end mounting device such that a length of the strip is approximately tangential to the mandrel. Let it stretch,
S) To attach the end of the IJ tube, rotate the device and wind the strip in the longitudinal direction around the mandrel to form a helical coil.While winding the strip into a coil, bring it into contact with the pressurizing surface and attach it to the coil. An axial force is applied to compress the coil, tightening the part of the strip that is in contact with the pressure surface between the part of the strip already wound into a coil and the pressure surface, and tightening the stop against the pressure surface. (2) A flow of metal is created in the IJ tube, such that the flow of metal compensates for the distortion of the strip caused by the bending at the edge, and when the coil is completed, the force is relaxed. Coiled metal parts are produced by removing the finished formed coil from the mandrel and securing the turns of the coil in close contact before or after removal of the coil from the mandrel.

The turns of the coiled part thus obtained are secured by means such as welding along the outer edge of the coil, either before or after removal from the mandrel.

Hereinafter, the present invention will be described in detail with reference to the drawings.

FIG. 7 shows a machine for closely winding metal strip into a helical coil, the machine having a bed l with a headstock at one end. The headstock has the necessary drive motor and additional gearing to drive the mandrel 3. The mandrel 3 passes through a hole 13 inside the die q and pressure plate S supported on the tailstock.

In addition, in the figure, the mandrel 3 is partially cut away to show the die-cut. A strip guide 9 is provided on the bed l on the side of the die q. If necessary, one pair of guide rollers can be provided at the entrance of the strip guide. The die cover, the pressure plate S and the strip guide 7 are slidable on the bed 1 in the direction of the arrow 9 by means of elastic loading means. The elastic loading means can be constituted, for example, by a pressurizing device comprising at least one hydraulic accumulator, as shown in FIG.

At the end of the mandrel 3 on the headstock side there is a shoulder 10, on which a device for attachment to the shoulder is provided. The mandrel 3 may be inserted through the shoulder or may be integral with the shoulder.

The installation of the device ii is, for example, the metal to be treated) IJ
It can be constituted by a pin that is passed through a hole in the tip edge of the knob S. Alternatively, a slot may be formed in the shoulder 10 into which the end of the strip fits.

The die ψ forms an open channel 12 with the mandrel 3. The channel 12 has a straight inlet portion U, without grooves 7, in line with the strip guide 7, which is smooth into the sizing portion /Q2 of the strip forming reservoir at the location of a longitudinal line passing through the central axis of the mandrel 3. It follows. The sizing part /U is further followed by a third part /23 extending so as to surround the mandrel, and this third part 3 increases in depth successively until it ends at a point 1 on the surface of the die. ing.

In the inlet section /2/, the channel is slightly deeper than the thickness of the strip S to be treated, so that the strip C can be inserted into this inlet section without contacting the previously wound coil. can pass freely. The depth of the channel decreases until the point where the sizing portion /l begins, at which point the depth of the channel is substantially equal to the thickness of the strip. The cross-section of the channel /2 is shaped in its sizing part /22 to induce a flow of metal from the inside to the outside of the ring to be formed and to give the strip the desired profile. This compensates for the tapering that occurs during winding.

At the beginning of the coiling operation, the tailstock is advanced to a position close to the shoulder lO. The leading edge of the metal strip S is then inserted into the inlet part /2/ of the die via the roller slot and the strip guide, and the attachment is attached to the shoulder 10 by the device //. The die-hiro is then pressed by the hydraulic accumulator until it comes into contact with the shoulder 10, and the rotational drive of the machine is started, and the inlet section/l
The leading edge of the strip S, which is not initially under pressure at /, extends from the inlet part /, l/ to the sizing part /22
be drawn into.

At this time, due to the gradual decrease in the depth of the channel, the strip S comes into contact with the step 10 and is therefore subjected to the action of the compressive force applied from the hydraulic accumulator to the die Hong via the pressure plate S. It turns out. The shape of the sizing portion /22 is A-shaped to give the strip a taper that compensates for the taper created as the strip S is wound around the mandrel 3. The action taken on the strip by this sizing portion /22 prevents the formation of wrinkles at its inner edge. Thus, by the time each transverse segment of the strip leaves the sizing part No. 2, its surfaces remain parallel within a predetermined range. A continuation of 30 revolutions of the mandrel forms the first turn of the coil of strip, which leaves the channel at position /2'i over the new metal strip that is subsequently fed into the sizing section /here.

As the number of turns in the coil increases, Daihiro, pressure plate S
The strip guide 7 then moves away from the shoulder 10 against the load due to hydraulic pressure. The coil C thus formed
are formed in close contact under a constant compressive force and serve to provide a reaction force to the force applied to the pressure plate 5 and the die. In this way, a reaction force is created by the previously wound turn-like coil which effectively causes the forming of the strip in the sizing part /21.

The coil transmits a driving force to the turn being wound by frictional contact with that turn, creating a force that draws the strip S into the machine.

To avoid any distortion of the installation, it is preferable to wind the coil with several turns before placing it under compressive force. The driving force for the turn being wound is thereby transmitted continuously throughout the forming process of the turn in the sizing section 122.

Once the desired length of coil has been wound, the mandrel is removed, the strip S is cut, and the coil is pulled out.

In the case of the machine shown in FIG. 3, the die q is similar to that of FIG. 7, but the radially outer edges of the channels /2 have been removed. The radially inner edge of the channel/J is formed by a mandrel as in the previous embodiment. The cylinder of the hydraulic accumulator is provided inside the headstock, and its piston rod is pivotally mounted to the tailstock/7. The piston and cylinder arrangement in this example is reversed compared to that shown in FIG.

Although the die is preferably an axially movable member of the machine, the die may be fixed and the wound coil may be displaced away from the die. It should be noted that it is also possible for the guide rollers g to provide a certain amount of preforming to the strip. Also, instead of hydraulic pressure, air pressure, spring pressure, etc. may be used to load the coil.

In addition, in order to accurately compensate for the twist caused by bending, the die is formed so that the amount of compensation is too large or too small.
This also makes it possible to obtain a coil with a desired cross-sectional shape that does not have parallel surfaces.

Figures 6 to 9 show a portion of a typical metal IJ tube S before rolling. As shown,
The strip S has regular U-shaped notches 60.6/ along its side edges and has a uniform thickness. 7th
The figure and No. 1 O show the coil C of the strip after the coiling treatment described above.

As seen in FIG. 7, the width of the notch 60 decreases on the radially inner side of the coil C, while the width of the notch A/ increases on the radially outer side of the coil C.

The thickness of the coil C of the coiled strip is io
It may be changed as shown in the figure. In accordance with the example, the dimensions shown in Figures 1 and 7 are then compared in Table 1.

Table 1 60 Figure 7 Dimensions Before treatment Strip after treatment Strip A I. 8]5], 793B
O,6470,649G O,038U
, 036 J O, 0380° 038 Zone N in FIG. 7 is a processing zone where molding is performed. The dished or conical shape of the coil C shown in FIG. io can be compensated for during processing or removed during final assembly, if desired.

FIG. 3 shows the shape of the strip S. The resulting coiled product is shown in FIG. After the coiling process, the coiled material C has adjacent turns in close contact and has a weld F as illustrated in FIG. Chapter S
The end ring g shown in the figure.

The coil assembly is completed. The final assembly in Figure S is for an electric motor, with coil C forming the stator and/or motor housing.

The electrical wiring coil is supported by the notches A (7, t, i).

The outermost notch 61 is formed by a fin protruding outward. - To give an example, 1.244 fins and outer notches 6/ were provided. The overall diameter of coil C was t, gg inches to the tip of the fins g:l.

The inner diameter of coil C was 3.20 inches (approx./A, 6 cm). Also, the length of the coil 0 is 75 inches (approx./
/, 6tm). Strips of various widths and thicknesses can be processed and coils of various diameters can be wound. The entire assembly is much simpler and less expensive to manufacture using the present invention, compared to prior art constructions that utilize stator plate laminates and cast-cut housings.

[Brief explanation of drawings]

Figure 1 is a perspective view of a machine for manufacturing coiled metal parts, with a part of the mandrel removed to expose the die;
The figure shows the state after several turns have been formed, and is a cross-sectional view in the axial direction of the mandrel with the mandrel omitted; FIG. 3 is a perspective view showing the deformed structure of the tail stock; and FIG. 9 9 is an end view of a strip product with a squirt finish made in accordance with the present invention; FIG. S is a cross-sectional view of an assembly including the product of FIG. 9; Figure 6 is a partially enlarged opening of the metal strip before coil forming, Figure 7 is a view showing a portion corresponding to the strip portion of the fourth factor after coil forming, and Figure 8 is an enlarged view of another strip before coil forming. FIG. 9 is a cross-sectional view taken along the line XX in FIG. 6, and FIG. IO is a cross-sectional view taken along the line X-X in FIG. be.

Claims (3)

[Claims] (1) A notch 60, 61 is formed along at least one side of the flat metal strip S, and one end of the metal strip is attached to the strip end attachment device L/ so that a certain length of the strip is attached to the mandrel 3. The ends of the strip are attached by rotating the device and winding the strip in its longitudinal direction around one mandrel to form a helical coil C. While winding the strip into a coil, the pressure surface /2, compress the coil by applying an axial force to the coil, and connect the part of the strip that is in contact with the pressure surface /2 with the part of the strip that has already been wound into a coil and the pressure surface. and draw the strip through the pressurized surface, creating a flow of metal in the strip that compensates for the distortion of the strip caused by the bending at the edges. and, when the coil is completed, relaxing said force, removing the finished formed coil from the mandrel, and fixing the turns of the coil in close contact, either before or after removal of the coil from the mandrel. A method for manufacturing shaped metal parts. (2) Claim 1 includes intentionally giving the finished formed coil a thickness that varies in its width direction.
A method for manufacturing a coiled metal part as described in . (3) The method for manufacturing a coiled metal component according to claim 1 or 2, which includes fixing the turns of the coil in close contact with each other by welding along the outer edge of the coil.