WO2014157218A1 - 同芯巻コイルの成形方法及び成形装置 - Google Patents
同芯巻コイルの成形方法及び成形装置 Download PDFInfo
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- WO2014157218A1 WO2014157218A1 PCT/JP2014/058316 JP2014058316W WO2014157218A1 WO 2014157218 A1 WO2014157218 A1 WO 2014157218A1 JP 2014058316 W JP2014058316 W JP 2014058316W WO 2014157218 A1 WO2014157218 A1 WO 2014157218A1
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- forming
- mold
- coil
- fin
- wire
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
- H02K15/0442—Loop windings
- H02K15/045—Form wound coils
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/06—Embedding prefabricated windings in machines
- H02K15/062—Windings in slots; salient pole windings
- H02K15/065—Windings consisting of complete sections, e.g. coils, waves
- H02K15/066—Windings consisting of complete sections, e.g. coils, waves inserted perpendicularly to the axis of the slots or inter-polar channels
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
- Y10T29/49011—Commutator or slip ring assembly
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
- Y10T29/49012—Rotor
Definitions
- the present invention relates to a method and an apparatus for forming a concentric coil, and in particular, a coil end portion protruding from an end surface in the axial direction of a stator core is made into a plurality of different non-linear shapes from a rectangular wire that is wound by a predetermined number of turns.
- the present invention relates to a forming method and a forming apparatus for forming a concentric winding coil to be formed.
- a stator coil molding method and a molding apparatus are known in which coil end portions projecting from an axial end surface of a stator core are formed in a plurality of different non-linear shapes (see, for example, Patent Document 1).
- the forming apparatus described in Patent Document 1 includes a holding mechanism that holds a rectangular conductor having a rectangular cross section, a mold that bends a rectangular conductor having a predetermined length held by the holding mechanism as a stator coil, and A moving mechanism that moves the mold toward the holding mechanism by a stroke.
- the rectangular conductor wire having a predetermined length held by the holding mechanism has a crank-shaped corresponding portion corresponding to the coil end portion of the stator coil. , Bent so as to be formed into an arc shape and a bent shape.
- a single stator coil having a coil end portion subjected to crank forming, arc forming, and edgewise forming is formed.
- Patent Document 1 since the technique described in Patent Document 1 described above is to form a single stator coil from a rectangular conductor, it is difficult to apply it to a technique in which a concentric coil is formed from a rectangular conductor that has been wound a plurality of turns. is there. Even if it is applied temporarily, it takes time and effort to form the concentric coil, and the molding accuracy may be reduced.
- the present invention has been made in view of the above points, and can easily and accurately form a concentric winding coil in which a coil end portion is formed in a plurality of different non-linear shapes.
- An object of the present invention is to provide a forming method and a forming apparatus for concentric winding coils.
- coil end portions (34, 36) protruding from the axial end surface of the stator core (12) are formed in a plurality of different non-linear shapes from a rectangular wire (28) that has been wound by a predetermined number of turns.
- the coil end portions (34, 36) are formed into a plurality of different non-linear shapes, and the corresponding portions of the flat wire (28) corresponding to the coil end portions (34, 36) are set.
- the flat conductive wire (28) is inserted into the predetermined gap.
- the machining surface (46,) of the flat conducting wire (28) set in the orthogonal direction perpendicular to the laminating direction is set.
- 50, 54, 58) is bent in the orthogonal direction using an outer shape forming mold (42, 44), and the bending of the corresponding portion of the rectangular wire (28) is performed on the corresponding portion.
- coil end portions (34, 36) protruding from the axial end surface of the stator core (12) are formed in a plurality of different non-linear shapes from a rectangular wire (28) that has been wound by a predetermined number of turns.
- a moving mechanism (100, 102, 104, 106) for moving the stroke in a predetermined direction with respect to the set flat wire (28), and bending the corresponding portion of the flat wire (28).
- the forming device (40) of the concentric winding coil (14) is advanced from the center side of the corresponding part toward both outer sides.
- FIG. 1 It is a block diagram of the stator by which the coil assembly which consists of a concentric winding coil which is one Example of this invention is mounted. It is a figure for demonstrating the method of comprising a coil assembly using the concentric winding coil of a present Example. It is a block diagram before the completion of shaping
- FIG. 1 shows a configuration diagram of a stator on which a coil assembly composed of concentric winding coils according to an embodiment of the present invention is mounted.
- FIG. 1A shows a state before completion of stator assembly
- FIG. 1B shows a state after completion of stator assembly.
- FIG. 2 is a diagram for explaining a method of forming a coil assembly using a plurality of concentric coils of the present embodiment.
- 2A shows the state before the completion of the assembly of the two concentric winding coils
- FIG. 2B shows the state after the completion of the assembly of the two concentric winding coils.
- FIG. 3 shows a configuration diagram of the concentric winding coil of this embodiment before the completion of molding.
- FIG. 4 shows the block diagram after completion
- 3A and 3B and FIGS. 4A and 4B are perspective views
- FIGS. 3C and 4C are plan views.
- the stator 10 is a stator used in a rotating electric machine such as a three-phase AC motor.
- the stator 10 is disposed radially outside the rotor as a rotor via a predetermined air gap, and generates a magnetic field that rotates the rotor when energized.
- the stator 10 includes a stator core 12 and a stator coil 14.
- the stator core 12 is a member formed in a hollow cylindrical shape.
- the stator core 12 may be formed by laminating a plurality of insulating coated steel sheets in the axial direction.
- a cylindrical yoke formed of a material obtained by compression-molding an insulating-coated soft magnetic powder may be attached to the radially outer surface of the stator core 12.
- the stator core 12 has a yoke 16 formed in an annular shape, and teeth 18 protruding from the radially inner side surface of the yoke 16 toward the radially inner side (axial center side).
- a plurality (for example, 96) of teeth 18 are provided in the circumferential direction on the radially inner side surface of the yoke 16, and are provided at regular intervals along the circumferential direction.
- a slot 20 is formed between two teeth 18 adjacent in the circumferential direction.
- the stator coil 14 is wound around each tooth 18.
- a plurality of (eg, 96) stator coils 14 are arranged in the circumferential direction on the radially inner side of the stator core 12.
- a plurality of stator coils 14 are arranged in the circumferential direction to constitute a coil assembly 22.
- the coil assembly 22 is formed in an annular shape by arranging a plurality of stator coils 14 side by side in the circumferential direction.
- the coil assembly 22 is arranged with the slots 20 accommodating the plurality of stator coils 14 being shifted one by one in the circumferential direction, and two stator coils 14 existing at a predetermined distance in the circumferential direction for each slot 20.
- the coil 14 is configured to overlap in the stacking direction (that is, the radial direction) around which the conducting wire circulates.
- Each stator coil 14 constitutes one of a U-phase coil, a V-phase coil, and a W-phase coil when the stator 10 is applied to, for example, a three-phase AC motor.
- the U-phase coil, the V-phase coil, and the W-phase coil that are the stator coils 14 are wound around the teeth 18 in that order in the circumferential direction.
- the stator core 12 includes a plurality of (for example, 48) divided cores 24 divided in the circumferential direction. That is, the stator core 12 is divided into a plurality of divided cores 24 in the circumferential direction. All the divided cores 24 have the same shape, and specifically, have a shape including the yoke 16 and the two teeth 18 corresponding to the same circumferential angle.
- the stator 10 also includes an insulating member 26 that ensures insulation between the stator core 12 and the stator coil 14.
- the insulating member 26 is provided for each divided core 24 of the stator core 12.
- the insulating member 26 has a shape that matches the shape of the split core 24.
- the insulating member 26 is made of paper or resin (for example, thermosetting resin or thermoplastic resin), and forms a thin insulating layer between the split core 24 and the stator coil 14.
- the split core 24 to which the insulating member 26 is attached is inserted into the coil assembly 22 from the outside in the radial direction so that the stator coil 14 of the coil assembly 22 is disposed in the slot 20 between the two teeth 18. .
- the stator 10 in which the stator core 12 and the stator coil 14 are assembled is configured.
- the stator coil 14 is constituted by a rectangular conducting wire having a rectangular cross section (specifically, a rectangular shape).
- Each of the stator coils 14 disposed in the circumferential direction is a concentric coil that is formed by bending a rectangular conductor wire that has been wound by a predetermined number of turns (for example, 5 turns).
- the rectangular conducting wire before the completion of the molding of the stator coil 14 is referred to as a rectangular conducting wire 28, and the stator coil 14 after the completion of the molding is referred to as a concentric winding coil 14, respectively.
- the flat conductive wire 28 is formed in a substantially elliptical shape that is wound around a predetermined number of turns by winding a single straight wire around an elliptical mold of an elliptical winding device.
- the flat conducting wire 28 is made of a highly conductive metal such as copper or aluminum.
- the concentric winding coil 14 is bent into a substantially hexagonal shape with a predetermined number of turns as shown in FIG. 4 by bending a substantially elliptical rectangular wire 28 using a molding device described in detail later. It is formed.
- the concentric winding coil 14 has slot portions 30 and 32 and coil end portions 34 and 36.
- the slot portions 30 and 32 are portions accommodated in the slots 20 of the stator core 12.
- the coil end portions 34 and 36 are portions that protrude outward in the axial direction from both axial end portions of the stator core 12.
- the slot portions 30 and 32 extend substantially linearly so as to penetrate different slots 20 that are separated by a predetermined distance in the circumferential direction of the stator core 12 in the axial direction.
- the coil end portions 34 and 36 are curved so as to connect the two circumferential slot portions 30 and 32 to each other on the axially outer side with respect to both axial end portions of the stator core 12.
- the flat conductor 28 before forming is formed so that the slot-corresponding portions corresponding to the slot portions 30 and 32 of the concentric winding coil 14 are substantially linear and correspond to the coil end portions 34 and 36 of the concentric winding coil 14.
- the coil end corresponding parts are configured so that the slot corresponding parts on both sides are connected substantially in a straight line, and the conducting wires arranged in the stacking direction are arranged in parallel.
- the conducting wires arranged in the stacking direction of the flat conducting wires 28 are formed on the same plane.
- the coil end corresponding portions corresponding to the coil end portions 34 of each step among the conductive wires arranged in the stacking direction of the flat conductive wires 28 are obliquely connected between the slot corresponding portions on both sides, thereby crossing the flat conductive wires 28 in the stacking direction.
- Both ends of the concentric winding coil 14 project to the same axial direction side (hereinafter referred to as an axial lead side) in order to connect to other concentric winding coils 14 or terminals among the axial end of the stator core 12. Yes.
- the coil end portion 34 is provided on the axial lead side, and the coil end portion 36 is provided on the axially opposite lead side opposite to the axial lead side.
- the coil end portion 34 is referred to as a lead side coil end portion 34
- the coil end portion 36 is referred to as an anti-lead side coil end portion 36.
- the slot portion 30 is provided on one side in the circumferential direction, and the slot portion 32 is provided on the other side in the circumferential direction.
- the slot portion 30 is referred to as the one-side slot portion 30, and the slot portion 32 is referred to as the other-side slot portion 32, respectively.
- the slot portions 30 and 32 are separated from each other in the circumferential direction orthogonal to the axial direction by a predetermined angular distance.
- the concentric coil 14 is configured such that a plurality of conductors are laminated in the direction of the short side of the flat conductor 28.
- the concentric winding coil 14 is configured such that a predetermined gap is formed between conductive wires adjacent in the stacking direction.
- the concentric coil 14 is formed in a trapezoidal cross section so that the distance between the slot portions 30 and 32 changes according to the position in the stacking direction. The formation of the trapezoidal cross section is performed in order to properly accommodate the slot portions 30 and 32 of the concentric coil 14 in the slot 20.
- the concentric winding coil 14 is assembled to the stator core 12 so that the lamination direction of the conductive wires coincides with the radial direction orthogonal to the axial direction of the stator core 12.
- the lead-side coil end portion 34 has four layers of conductive wires.
- the coil end portions 34 and 36 of the concentric winding coil 14 are each formed in a plurality of different non-linear shapes. Specifically, each of the coil end portions 34 and 36 is formed in three types of non-linear shapes, and is formed into a crank shape that is bent stepwise toward the radial direction of the stator core 12 (crank forming). ) And is formed into an arc shape that is curved in accordance with the arc of the annular stator core 12 (arc forming), and is also formed into a bent shape that is bent in the longitudinal direction of the cross section of the flat wire 28 (edgewise forming).
- Crank forming and arc forming are bending in the radial direction toward the lamination direction of the flat conductors 28, and edgewise forming is bending in the orthogonal direction perpendicular to the lamination direction of the flat conductors 28.
- Crank forming is a bending process performed for lane change between conductors in the stacking direction of the flat conductors 28.
- Arc forming is a bending process performed to efficiently accommodate the concentric coil 14 in the slot 20.
- the edgewise molding is a bending process performed to efficiently arrange the plurality of concentric winding coils 14 when the coil assembly 22 is configured.
- FIG. 5 shows a perspective view of a forming apparatus for the concentric winding coil 14 of the present embodiment.
- FIG. 5 shows a state before the concentric winding coil 14 is completely formed.
- FIG. 6 shows a plan view of a molding apparatus for the concentric coil 14 of this embodiment.
- FIG. 7 shows a configuration diagram of the concave shape of the outer shape forming die provided in the forming apparatus for the concentric coil 14 of this embodiment.
- FIG. 8 shows a configuration diagram of the convex shape of the outer shape forming die provided in the forming apparatus for the concentric coil 14 of the present embodiment.
- FIG. 9 shows a configuration diagram of a fin-shaped mold provided in the forming apparatus for the concentric winding coil 14 of the present embodiment.
- FIGS. 7A, 8A, and 9A are perspective views, and FIGS. 7B, 8B, and 9B are plan views. Are shown respectively.
- FIG. 10 shows a perspective view of the concentric winding coil 14 of this embodiment after it has been formed by the forming apparatus.
- FIG. 11 shows a plan view of the concentric winding coil 14 of this embodiment after the molding by the molding apparatus.
- the concentric winding coil 14 is formed by bending a substantially elliptic rectangular wire 28 that has been wound by a predetermined number of turns by a forming device 40.
- the molding apparatus 40 includes an inner mold 42 and an outer mold 44.
- the inner mold 42 is a mold that is disposed in the circumference of the set flat conducting wire 28 and is capable of holding the flat conducting wire 28 set on the outer peripheral surface side.
- the outer metal mold 44 is a metal mold that is disposed outside the circumference of the flat conducting wire 28 to be set.
- the direction (axial direction) connecting the coil end corresponding portions on both sides of the flat wire 28 set in the inner mold 42 is defined as the first direction X, and the flat wire set in the inner mold 42.
- the direction in which the slot-corresponding portions on both sides of 28 are separated from each other is referred to as a second direction Y, and the stacking direction of the flat conducting wires 28 set in the inner mold 42 is referred to as a third direction Z.
- the first direction X, the second direction Y, and the third direction Z are orthogonal to each other.
- the inner mold 42 includes a first inner mold 42-1 and a second inner mold 42-2.
- the first inner mold 42-1 and the second inner mold 42-2 are spaced apart in the first direction X.
- the first inner mold 42-1 and the second inner mold 42-2 are each formed in a pentagonal mountain shape when viewed from the third direction Z.
- the first inner mold 42-1 is a mold provided on the axial lead side of the flat rectangular wire 28 to be set
- the second inner mold 42-2 is an axial direction of the flat rectangular wire 28 to be set. This is a mold provided on the side opposite to the lead.
- the first inner mold 42-1 includes a processed surface 46 formed by imitating the shape of the lead-side coil end portion 34 of the concentric winding coil 14 after molding, and a slot portion of the concentric winding coil 14. This is a convex type having a processed surface 47 formed to imitate the vicinity of the boundary (shoulder) between the lead side coil end portion 34 of 30 and 32.
- the processing surface 46 is a surface facing the first direction X, and is formed on the convex surface 48 of the first inner mold 42-1 facing the lead side coil end portion 34 of the concentric winding coil 14.
- the processed surface 46 is a surface with which the inner peripheral surface of the short-side cross-section side of the lead-side coil end corresponding portion corresponding to the lead-side coil end portion 34 of the lead wire coil end portion 34 of the concentric winding coil 14 is in contact. It is.
- the processed surface 46 has an outer shape along the inner peripheral surface on the short side of the cross section of the lead-side coil end portion 34 of the concentric coil 14.
- the processing surface 47 is a processing surface facing in the direction between the first direction X and the second direction Y, and the slot portions 30 and 32 of the concentric winding coil 14 of the first inner mold 42-1. It is formed so as to face each other.
- the processed surface 47 is a surface where the slot portions 30 and 32 of the concentric winding coil 14, that is, the inner peripheral surface on the short side of the cross section of the portion corresponding to the slot corresponding to the slot portions 30 and 32 of the flat wire 28 contacts.
- the processed surface 47 has an outer shape along the inner peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric coil 14.
- the second inner mold 42-2 has a processed surface 50 formed by imitating the shape of the non-lead-side coil end portion 36 of the concentric winding coil 14 after completion of molding, and the concentric winding coil 14 thereof. It is a convex type which has the processed surface 51 formed imitating the boundary (shoulder part) vicinity with the non-lead side coil end part 36 of the slot parts 30 and 32.
- the processing surface 50 is a surface facing the first direction X, and is formed on the convex surface 52 of the second inner mold 42-2 facing the counter lead side coil end portion 36 of the concentric winding coil 14. .
- the processed surface 50 is the inner peripheral surface on the short side of the cross-section of the portion corresponding to the anti-lead side coil end corresponding to the anti-lead side coil end portion 36 of the flat lead wire 28, that is, the flat lead wire 28. Is the surface that touches.
- the processed surface 50 has an outer shape along the inner peripheral surface on the short side of the cross-section of the counter lead-side coil end portion 36 of the concentric coil 14.
- the processing surface 51 is a processing surface facing in the direction between the first direction X and the second direction Y, and the slot portions 30 and 32 of the concentric winding coil 14 of the second inner mold 42-2. It is formed so as to face each other.
- the processed surface 51 is a surface where the slot portions 30 and 32 of the concentric winding coil 14, that is, the inner peripheral surface on the short side of the cross section of the portion corresponding to the slot corresponding to the slot portions 30 and 32 of the flat wire 28 contacts.
- the processing surface 51 has an outer shape along the inner peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric winding coil 14.
- the outer mold 44 includes a first outer mold 44-1 and a second outer mold 44-2.
- the first outer mold 44-1 and the second outer mold 44-2 are arranged apart from each other in the first direction X.
- the first outer mold 44-1 is a mold provided on the axial lead side of the flat rectangular wire 28 to be set
- the second outer mold 44-2 is an axial direction of the flat rectangular wire 28 to be set. This is a mold provided on the side opposite to the lead.
- the first inner mold 42-1 and the second inner mold 42-2 are arranged side by side. It is arranged with. That is, the first outer mold 44-1, the first inner mold 42-1, the second inner mold 42-2, and the second outer mold 44-2 are arranged in series in that order in the first direction X. Be placed. The first outer mold 44-1 and the first inner mold 42-1 are spaced apart in the first direction X, and the second outer mold 44-2, the second inner mold 42-2, Are spaced apart in the first direction X.
- the first outer mold 44-1 includes a processed surface 54 formed by imitating the shape of the lead-side coil end portion 34 of the concentric winding coil 14 after molding, and a slot portion of the concentric winding coil 14. It is a concave mold having a processed surface 55 that is formed in the vicinity of the boundary (shoulder) between the lead-side coil end section 34 of 30 and 32, and is paired with the first inner mold 42-1.
- the processing surface 54 is a surface facing the first direction X, and is formed on the concave surface 56 of the first outer mold 44-1 facing the lead-side coil end portion 34 of the concentric coil 14.
- the processed surface 54 is a surface that is in contact with the outer peripheral surface of the lead-side coil end portion 34 of the concentric winding coil 14, that is, the short-side cross-section side of the portion corresponding to the lead-side coil end of the flat wire 28.
- the processing surface 54 has an outer shape along the outer peripheral surface on the short side of the cross section of the lead-side coil end portion 34 of the concentric winding coil 14.
- the processing surface 55 is a processing surface facing in the direction between the first direction X and the second direction Y, and the slot portions 30 and 32 of the concentric winding coil 14 of the first outer mold 44-1. It is formed so as to face each other.
- the processed surface 55 is a surface with which the outer peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric winding coil 14, that is, the slot corresponding portion of the flat wire 28 is in contact.
- the processed surface 55 has an outer shape along the outer peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric coil 14.
- the second outer mold 44-2 includes a processed surface 58 formed by imitating the shape of the non-lead side coil end portion 36 of the concentric winding coil 14 after the completion of molding, and the concentric winding coil 14 thereof.
- a concave mold having a machining surface 59 formed in the vicinity of the boundary (shoulder) between the slot portions 30 and 32 and the non-lead-side coil end portion 36, and is paired with the second inner mold 42-2. There is no.
- the processing surface 58 is a surface facing the first direction X, and is formed on the concave surface 60 of the second outer mold 44-2 facing the counter lead side coil end portion 36 of the concentric winding coil 14. .
- the processed surface 58 is a surface with which the outer peripheral surface on the short side of the cross-section of the portion corresponding to the anti-lead side coil end of the flat lead wire 28 is in contact with the anti-lead side coil end portion 36 of the concentric winding coil 14.
- the processed surface 58 has an outer shape along the outer peripheral surface on the short side of the cross-section of the counter lead-side coil end portion 36 of the concentric coil 14.
- the processing surface 59 is a processing surface facing in a direction between the first direction X and the second direction Y, and the slot portions 30 and 32 of the concentric winding coil 14 of the second outer mold 44-2. It is formed so as to face each other.
- the processed surface 59 is a surface with which the outer peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric coil 14, that is, the slot corresponding portion of the flat wire 28 contacts.
- the processed surface 59 has an outer shape along the outer peripheral surface on the short side of the cross section of the slot portions 30 and 32 of the concentric coil 14.
- the processing surface 46 of the first inner mold 42-1 and the processing surface 54 of the first outer mold 44-1 are formed in a shape suitable for edgewise forming the portion corresponding to the lead side coil end of the flat wire 28.
- the first inner mold 42-1 and the first outer mold 44-1 are molds for edgewise forming the portion corresponding to the lead side coil end of the flat conducting wire 28.
- the processing surface 50 of the second inner mold 42-2 and the processing surface 58 of the second outer mold 44-2 are suitable for edgewise forming the portion corresponding to the coil end on the side opposite to the lead side of the flat wire 28. It is formed into a shape.
- the second inner mold 42-2 and the second outer mold 44-2 are molds for edgewise molding of the portion corresponding to the coil end on the side opposite to the lead of the flat wire 28.
- the first outer mold 44-1 has a plurality of fins 62.
- the first outer mold 44-1 having a plurality of fins 62 is a mold for crank-forming and arc-forming the portion corresponding to the lead-side coil end of the flat conducting wire 28.
- a plurality of fins 62 are arranged side by side in the third direction Z and are divided in the second direction Y.
- the fin 62 includes a first fin 62-1 and a second fin 62-2 that are divided in the second direction Y.
- a gap 64 is formed in the second direction Y between the first fin 62-1 and the second fin 62-2. The same number of first fins 62-1 and second fins 62-2 are provided.
- the number of fins 62 arranged side by side in the third direction Z (that is, the number of first fins 62-1 and the number of second fins 62-2) is the portion corresponding to the lead-side coil end of the flat wire 28. “1” more than the number of conductors stacked. For example, when the number of turns of the flat conductor 28 is “5”, that is, when the number of laminated conductors at the lead-side coil end corresponding portion of the flat conductor 28 is “4”, the conductors are arranged in the third direction Z.
- the number of fins 62, the number of first fins 62-1 and the number of second fins 62-2 are each “5”.
- Each of the first fins 62-1 and each of the second fins 62-2 is formed in a substantially rectangular plate shape, and is curved in an arc shape along the arc of the annular stator core 12 toward the out-of-plane direction. is doing. All the first fins 62-1 are arranged so that the curved surfaces thereof face each other in the third direction Z. Further, all the second fins 62-2 are arranged so that the curved surfaces thereof face each other in the third direction Z.
- All the first fins 62-1 and all the second fins 62-2 of the first outer mold 44-1 have a gap between the first fins 62-1 and a gap between the second fins 62-2. It arrange
- FIG. The concentric arrangement of the first fin 62-1 and the second fin 62-2 is based on the gap between the first fins 62-1 and the gap between the second fins 62-2. This is performed so that a shape suitable for arc-forming the end corresponding portion is formed.
- all the first fins 62-1 and all the second fins 62-2 are arranged so that the end portions on the gap 64 side are opposed to each other obliquely in the second direction Y.
- the diagonal arrangement of the first fin 62-1 and the second fin 62-2 corresponds to the lead-side coil end of the flat conductor 28 by the gap 64 between the first fin 62-1 and the second fin 62-2. This is performed so that a shape suitable for cranking the part is formed. Specifically, the approximate center in the second direction Y of the lead-side coil end portion 34 of the concentric winding coil 14 is formed in a crank shape by the gap 64 between the first fin 62-1 and the second fin 62-2.
- the lane change of 0.5 stage can be performed between the slot portions 30 and 32 on both sides.
- the first fins 62-1 and the second fins 62-2 are attached and fixed to the main body 66 of the first outer mold 44-1.
- a fin hole 68 for attaching the fin 62 is formed in the main body 66 of the first outer mold 44-1.
- the fin hole 68 is an insertion hole penetrating in the first direction X for inserting the first fin 62-1 and the second fin 62-2 from the outside, and faces the first direction X in which the processed surface 54 is formed.
- the concave surface 56 is open.
- the fin hole 68 is provided for each first fin 62-1 and each second fin 62-2.
- Each fin hole 68 is formed in an appropriate shape at a position where all the first fins 62-1 and all the second fins 62-2 of the main body 66 are appropriately arranged as described above. For example, it is opened so as to be curved in the third direction Z.
- the processed surface 54 is formed between the fin holes 68.
- the main body 66 of the first outer mold 44-1 is formed with take-out holes 70 and 72 for taking out both ends of a substantially straight line formed integrally with the slot corresponding portion of the flat wire 28 to the outside.
- the extraction holes 70 and 72 are insertion holes penetrating in the first direction X into which both ends of the flat conducting wire 28 set in the first inner mold 42-1 are inserted.
- the take-out holes 70 and 72 are formed in appropriate shapes at positions where both ends of the flat conducting wire 28 can be taken out properly when the flat conducting wire 28 is properly set in the first inner mold 42-1.
- the take-out hole 70 is a hole for taking out the end portion on the one side slot portion 30 side of the flat wire 28, and the take-out hole 72 is for taking out the end portion on the other side slot portion 32 side of the flat wire 28. Is a hole.
- the main body 66 of the first outer mold 44-1 also has a bolt hole 74 for bolting the first fin 62-1 and a bolt hole 76 for bolting the second fin 62-2. Is formed. Each first fin 62-1 is formed with a bolt hole 78 for fixing the bolt. Each second fin 62-2 has a bolt hole 80 for fixing the bolt.
- Each first fin 62-1 is inserted into the fin hole 68 of the main body 66 of the first outer mold 44-1, and then the bolt hole 74 of the main body 66 and the bolt hole 78 of the first first fin 62-1 are inserted. By being fastened by a bolt inserted into the main body 66, it is attached and fixed to the main body 66 of the first outer mold 44-1.
- Each second fin 62-2 is inserted into the fin hole 68 of the main body 66 of the first outer mold 44-1, and then the bolt hole 76 of the main body 66 and the bolt of the second fin 62-2. By being fastened by a bolt inserted into the hole 80, it is attached and fixed to the main body 66 of the first outer mold 44-1.
- the first inner mold 42-1 extends from the concave surface 56 of the main body 66, respectively. Projects to the side.
- Each first fin 62-1 has a first direction facing the second fin Y2-2 and the front end of the second direction Y facing the second fin 62-2 through the gap 64 and the first inner mold 42-1 side.
- Each of the X-side tips is tapered.
- each of the second fins 62-2 faces the first fin 62-1 facing the first fin 62-1 through the gap 64 on the second direction Y side and the first inner mold 42-1 side.
- the tip portions on the one-direction X side are each formed in a tapered shape.
- the taper shape of the fin 62 is such that the lead wire coil end corresponding portion of the flat wire 28 is subjected to crank forming and arc forming in the third direction Z, and each lead wire in the stacking direction of the flat wire 28 is arranged between the fins 62. Has a function to facilitate insertion into the gap.
- the first inner mold 42-1 has a through hole 82 penetrating in the first direction X.
- the through hole 82 opens in the second direction Y together with the first direction X.
- the fin 62 projecting from the concave surface 56 of the first outer mold 44-1 toward the first inner mold 42-1 side in the process of forming the concentric winding coil 14 from the rectangular conducting wire 28. It is an escape hole to be inserted.
- the through hole 82 is provided for each fin 62 (for each first fin 62-1 and each second fin 62-2). Each through hole 82 is formed in an appropriate shape at a position where all the fins 62 provided in the first outer mold 44-1 of the first inner mold 42-1 are properly inserted.
- the first inner mold 42-1 has a fin-like portion 83 formed in a fin shape due to the presence of the plurality of through holes 82.
- the same number of fin-shaped portions 83 as the number of steps of the flat conducting wire 28 in the stacking direction are provided.
- the processed surface 46 is formed between the through holes 82.
- the processed surface 46 is a surface facing the first direction X of the fin-shaped portion 83 formed in the first inner mold 42-1.
- the second outer mold 44-2 has a plurality of fins 84.
- the second outer mold 44-2 having a plurality of fins 84 is a mold for crank-forming and arc-forming the portion corresponding to the non-lead-side coil end of the flat conducting wire 28.
- a plurality of fins 84 are arranged side by side in the third direction Z, and are divided into two in the second direction Y.
- the fin 84 includes a third fin 84-1 and a fourth fin 84-2 divided in the second direction Y.
- a gap 86 is formed in the second direction Y between the third fin 84-1 and the fourth fin 84-2. The same number of the third fins 84-1 and the fourth fins 84-2 are provided.
- the number of fins 84 arranged side by side in the third direction Z (that is, the number of third fins 84-1 and the number of fourth fins 84-2) is the portion corresponding to the coil end of the flat conductor 28 on the opposite lead side. It is “1” more than the number of conductors in the stack. For example, when the number of turns of the flat conductor 28 is “5”, that is, when the number of laminated conductors in the portion corresponding to the coil end of the flat conductor 28 is “5”, they are aligned in the third direction Z.
- the number of fins 84, the number of third fins 84-1 and the number of fourth fins 84-2 are each “6”.
- Each of the third fins 84-1 and each of the fourth fins 84-2 is formed in a substantially rectangular plate shape, and is curved in an arc shape along the arc of the annular stator core 12 toward the out-of-plane direction. is doing. All the third fins 84-1 are arranged so that the curved surfaces thereof face each other in the third direction Z. Further, all the fourth fins 84-2 are arranged so that the curved surfaces thereof face each other in the third direction Z.
- All the third fins 84-1 and all the fourth fins 84-2 of the second outer mold 44-2 have a gap between the third fins 84-1 and a gap between the fourth fins 84-2. It arrange
- the concentric arrangement of the third fins 84-1 and the fourth fins 84-2 is based on the gap between the third fins 84-1 and the gap between the fourth fins 84-2.
- the coil end corresponding portion is formed so as to have a shape suitable for arc forming.
- all the third fins 84-1 and all the fourth fins 84-2 are arranged such that the end portions on the gap 86 side are obliquely opposed to each other in the second direction Y.
- the oblique arrangement of the third fins 84-1 and the fourth fins 84-2 is caused by the gap 86 between the third fins 84-1 and the fourth fins 84-2, so that the coil end on the opposite lead side of the flat wire 28 is removed. This is performed so that a shape suitable for cranking the corresponding portion is formed.
- the center in the second direction Y of the non-lead side coil end portion 36 of the concentric winding coil 14 is formed in a crank shape by the gap 86 between the third fin 84-1 and the fourth fin 84-2.
- the third fins 84-1 and the fourth fins 84-2 are attached and fixed to the main body 88 of the second outer mold 44-2.
- a fin hole 90 for attaching the fin 84 is formed in the main body 88 of the second outer mold 44-2.
- the fin hole 90 is an insertion hole penetrating in the first direction X for inserting the third fin 84-1 and the fourth fin 84-2 from the outside, and faces the first direction X in which the machining surface 58 is formed.
- the concave surface 60 is open.
- the fin holes 90 are provided for each of the third fins 84-1 and each of the fourth fins 84-2.
- Each fin hole 90 is formed in an appropriate shape at a position where all the third fins 84-1 and all the fourth fins 84-2 of the main body 88 are appropriately arranged as described above. For example, it is opened so as to be curved in the third direction Z.
- the processed surface 58 is formed between the fin holes 90 in the concave surface 60 of the second outer mold 44-2.
- the main body 88 of the second outer mold 44-2 also has a bolt hole 92 for bolting the third fin 84-1 and a bolt hole 94 for bolting the fourth fin 84-2. Is formed.
- Each third fin 84-1 is formed with a bolt hole (not shown) for fixing the bolt.
- Each fourth fin 84-2 is formed with a bolt hole (not shown) for fixing the bolt.
- Each third fin 84-1 is inserted into the fin hole 90 of the main body 88 of the second outer mold 44-2, and then is inserted into the bolt hole 92 of the main body 88 and the bolt hole of the third fin 84-1. By being fastened by the inserted bolt, it is fixedly attached to the main body 88 of the second outer mold 44-2.
- the fourth fins 84-2 are inserted into the fin holes 90 of the main body 88 of the second outer mold 44-2, and then the bolt holes 94 of the main body 88 and the bolts of the self fourth fin 84-2. By being fastened by a bolt inserted into the hole, it is attached and fixed to the main body 88 of the second outer mold 44-2.
- the second inner mold 42-2 is formed from the concave surface 60 of the main body 88. Projects to the side.
- Each of the third fins 84-1 is opposed to the fourth fin 84-2 through the gap 86 in the second direction Y side and the first direction facing the second inner mold 42-2 side.
- Each of the X-side tips is tapered.
- the tip portions on the one-direction X side are each formed in a tapered shape.
- the taper shape of the fin 84 is such that each of the conductors in the stacking direction of the flat conductor 28 is connected between the fins 84 when cranking and arc-forming in the third direction Z are performed on the portion corresponding to the coil end on the opposite lead side of the flat conductor 28. It has a function to facilitate insertion.
- a through hole 96 penetrating in the first direction X is formed in the second inner mold 42-2.
- the through hole 96 opens in the second direction Y together with the first direction X.
- the through-hole 96 has a fin 84 that protrudes from the concave surface 60 of the second outer mold 44-2 toward the second inner mold 42-2 in the process of forming the concentric coil 14 from the flat wire 28. It is an escape hole to be inserted.
- the through hole 96 is provided for each fin 84 (for each third fin 84-1 and for each fourth fin 84-2).
- Each through hole 96 is formed in an appropriate shape at a position where all the fins 84 provided in the second outer mold 44-2 of the second inner mold 42-2 are properly inserted.
- the second inner mold 42-2 has a fin-shaped portion 97 formed in a fin shape due to the presence of the plurality of through holes 96.
- the fin-shaped portions 97 are provided in the same number as the number of steps of the flat conducting wire 28 in the stacking direction.
- the processed surface 50 is formed between the through holes 96.
- the processed surface 50 is a surface facing the first direction X of the fin-shaped portion 97 formed in the second inner mold 42-2.
- the first outer mold 44-1, the first inner mold 42-1, the second inner mold 42-2, and the second outer mold 44-2 are the They are arranged in series in that order in one direction X.
- the first outer mold 44-1, the first inner mold 42-1, the second inner mold 42-2, and the second outer mold 44-2 are each in the first direction X with respect to the base. It is attached so that the stroke can be moved.
- the first outer mold 44-1 is moved by the moving mechanism 100, the first inner mold 42-1 is moved by the moving mechanism 102, the second inner mold 42-2 is moved by the moving mechanism 104, and the second outer mold 44 is moved.
- -2 is moved by the moving mechanism 106 in the first direction X with respect to the base.
- a controller 110 mainly composed of a microcomputer is electrically connected to each of the moving mechanisms 100, 102, 104, and 106.
- the controller 110 is a control device that causes the forming device 40 to perform an operation necessary for forming the concentric winding coil 14 by bending the rectangular conducting wire 28 set in the forming device 40, and moves the operation command. This is performed for the mechanisms 100, 102, 104, and 106. Such an operation command may be issued when a predetermined switch operation is performed after the flat wire 28 is set in the molding apparatus 40. Each moving mechanism 100, 102, 104, 106 strokes the molds 44-1, 42-1, 42-2, 44-2 in the first direction X with respect to the base in accordance with a command from the controller 110. Move.
- the first inner mold 42-1, the second inner mold 42-2, the first outer mold 44-1 and the second outer mold 44-2 are all moved by the moving mechanism 100.
- 102, 104, 106 are moved in the first direction X, but any of the molds 42-1, 42-2, 44-1 and 44-2 may be fixed to the base. .
- the first outer mold 44-1 and the second outer mold 44-2 have both predetermined molds 44-1 and 44-2.
- the first inner mold 42-1 and the second inner mold 42-2 are moved so that the two molds 42-1 and 42-2 are separated by a predetermined minimum distance. Moved. At this time, between the first outer mold 44-1 and the first inner mold 42-1 and between the second outer mold 44-2 and the second inner mold 42-2, respectively. A gap sufficient to set the flat conductor 28 in the first direction is formed.
- the substantially elliptical rectangular conducting wire 28 is set in the inner mold 42.
- the flat conducting wire 28 is held on the outer peripheral surface side of the first inner mold 42-1 and the second inner mold 42-2.
- the flat conducting wire 28 is held so that the position in the third direction Z is optimal for bending the flat conducting wire 28 with the inner mold 42 and the outer mold 44.
- the first inner mold 42-1 and the second inner mold 42-2 are next directed in the first direction X so as to be separated from each other.
- the first outer mold 44-1 is moved in the first direction X so as to approach the first inner mold 42-1 and the second outer mold 44-2 is moved. Is moved in the first direction X so as to approach the second inner mold 42-2.
- the first inner die 42-1 and the first outer die 44-1 are close to each other and sandwich the corresponding portion on the lead side coil end of the flat wire 28 in the first direction.
- the second inner mold 42-2 and the second outer mold 44-2 are moved toward each other in the direction of X and the second outer mold 44-2 approaches each other so as to sandwich the portion corresponding to the coil end on the opposite lead side of the flat wire 28.
- the stroke is moved in one direction X.
- the stroke movement of the first inner mold 42-1 and the stroke movement of the second inner mold 42-2 are performed substantially simultaneously, and the stroke movement of the first outer mold 44-1 and the second outer mold 42-1 are performed.
- the stroke movement of the mold 44-2 is performed substantially simultaneously. Furthermore, the stroke movement of the first inner mold 42-1 and the stroke movement of the first outer mold 44-1 are performed in synchronization, and the stroke movement of the second inner mold 42-2 and the second outer mold 42-1 are performed.
- the stroke movement of the mold 44-2 is performed in synchronization.
- the lead side of the flat wire 28 held by the inner mold 42 The lead wires of each step aligned in the third direction Z at the coil end corresponding portion enter the gap between the fins 62 of the first outer mold 44-1.
- the fins 62 of the first outer mold 44-1 are inserted into the through holes 82 of the first inner mold 42-1.
- each of the front end portions on the first direction X side facing the first inner mold 42-1 side is formed in a tapered shape. For this reason, the lead wires of each step at the lead-side coil end corresponding portion of the flat lead wire 28 smoothly enter the gap between the fins 62 due to the tip tapered surface of the fin 62 of the first outer mold 44-1. It is easy to be inserted into the gap.
- the lead of each step at the lead-side coil end corresponding portion of the flat lead 28 enters the gap between the fins 62 of the first outer mold 44-1 first of all in the second direction Y of the lead of each step.
- the process starts when the approximate center enters the gap 64 between the first fin 62-1 and the second fin 62-2. And after that, the approach is performed so that it may approach in the clearance gap between the fins 62 in order from the approximate center of the 2nd direction Y to both outer sides.
- the lead wire of each step in the lead side coil end corresponding portion of the flat lead wire 28 is formed so as to change the lane in one step by crossing the slot corresponding portions on both sides diagonally.
- the fins 62 are arranged by the gap 64 between the first fin 62-1 and the second fin 62-2 in the lead-side coil end portion 34 of the concentric winding coil 14.
- the approximate center in the second direction Y of the lead wire of each step at the portion corresponding to the lead-side coil end of the flat lead wire 28 is the tip corner portion of the first fin 62-1.
- the approximate center in the second direction Y of each step of the lead wire 28 at the portion corresponding to the lead-side coil end is bent into a crank shape so that a step is generated in the third direction Z (crank Molding).
- the fins 62 are attached and fixed to the first outer mold 44-1 so as to be arranged concentrically with each other while being curved in the third direction Z. For this reason, when the above-mentioned approach proceeds by moving the first outer mold 44-1 toward the first direction X so as to approach the first inner mold 42-1, the lead of the flat conducting wire 28 is moved. The entire portion corresponding to the side coil end fits into the gap between the first fins 62-1 adjacent in the third direction Z and the gap between the second fins 62-2 adjacent in the third direction Z. It is bent into an arc shape so as to curve in accordance with the arc of the annular stator core 12 (arc forming).
- the processing surface 46 of the first inner mold 42-1 and the processing surface 54 of the first outer mold 44-1 are shapes suitable for edgewise forming the portion corresponding to the lead-side coil end of the flat wire 28. Is formed. For this reason, the above-described approach has proceeded to a state where the lead-side coil end corresponding portion of the flat wire 28 is in contact with both the convex surface 48 of the first inner mold 42-1 and the concave surface 56 of the first outer mold 44-1.
- the short side of the cross-section of the portion corresponding to the lead-side coil end of the flat lead wire 28 is first processed by the processing surface 46 of the first inner mold 42-1 and the processing surface 54 of the first outer mold 44-1. It is pressed and clamped in the direction X (FIG. 10). In this case, the entire lead-side coil end corresponding portion of the flat conducting wire 28 is bent in an XY plane orthogonal to the third direction Z (edgewise molding).
- the rectangular conductive wire held by the inner mold 42 is used.
- the lead wires at the respective stages arranged in the third direction Z at the portion 28 corresponding to the coil end on the opposite lead side enter the gap between the fins 84 of the second outer mold 44-2.
- the fins 84 of the second outer mold 44-2 are inserted into the through holes 96 of the second inner mold 42-2.
- Each of the front end portions on the first direction X side facing the second inner mold 42-2 side is formed in a tapered shape. For this reason, the lead wires of each step at the portion corresponding to the coil lead end of the flat lead wire 28 smoothly enter the gap between the fins 84 by the tip tapered surface of the fin 84 of the second outer mold 44-2. It is easy to insert into such a gap.
- the lead of each step at the portion corresponding to the coil end of the flat lead wire 28 opposite to the coil end first enters the gap between the fins 84 of the second outer mold 44-2.
- the second direction Y of the lead of each step Is started by entering the gap 86 between the third fin 84-1 and the fourth fin 84-2.
- the approach is performed so that it may approach in the clearance gap between the fins 84 in order from the approximate center of the 2nd direction Y to both outer sides.
- the lead wires of each step at the portion corresponding to the coil end on the opposite side of the flat lead wire 28 are formed on the same plane as between the slot corresponding portions on both sides.
- the fins 84 are arranged by the clearance 86 between the third fins 44-1 and the fourth fins 84-2 in the coil end portion 36 on the opposite lead side of the concentric winding coil 14.
- the center of the second direction Y is formed in a crank shape so that a lane change of 0.5 steps can be performed between the slot portions 30 and 32 on both sides.
- the approximate center in the second direction Y of the conductor of each step at the portion corresponding to the coil end of the flat conductor 28 is the tip corner of the third fin 84-1.
- the substantially center in the second direction Y of each step of the lead wire 28 at the portion corresponding to the coil end opposite to the lead end is bent into a crank shape so that a step is generated in the third direction Z ( Crank molding).
- the fins 84 are attached and fixed to the second outer mold 44-2 so as to be arranged concentrically with each other while being curved in the third direction Z. For this reason, when the above-mentioned approach proceeds by moving the second outer mold 44-2 toward the first direction X so that the second outer mold 44-2 approaches the second inner mold 42-2, the flat conductive wire 28 becomes opposite.
- the entire lead side coil end corresponding part fits into the gap between the third fins 84-1 adjacent in the third direction Z and the gap between the fourth fins 84-2 adjacent in the third direction Z. It is bent into an arc shape so as to curve in accordance with the arc of the annular stator core 12 (arc forming).
- the processing surface 50 of the second inner mold 42-2 and the processing surface 58 of the second outer mold 44-2 are suitable for edgewise forming the portion corresponding to the coil end on the side opposite to the lead side of the flat wire 28. It is formed into a shape. For this reason, the above-described approach proceeds to a state where the portion corresponding to the coil end of the flat lead wire 28 is in contact with both the convex surface 52 of the second inner mold 42-2 and the concave surface 60 of the second outer mold 44-2. Then, when the process proceeds further, the short side of the cross-section of the portion corresponding to the non-lead side coil end of the flat wire 28 is formed by the processing surface 50 of the second inner mold 42-2 and the processing surface 58 of the second outer mold 44-2.
- the first outer die 44-1 is moved to the first inner die 42-1.
- the second outer mold 44-2 is moved in the first direction X so as to be separated from the second inner mold 42-2.
- the first inner mold 42-1 and the second inner mold 42-2 are stroked in the first direction X so as to approach each other. It should be noted that the stroke movement of the first outer mold 44-1 and the stroke movement of the second outer mold 44-2 may be performed substantially simultaneously.
- the coil end corresponding portion is crank-shaped bent in the third direction Z, arc-shaped bent in the third direction Z, and in the XY plane orthogonal to the third direction Z. Since the holding of the flat lead wire 28 that has been subjected to the bending process in FIG. 1 to the outer peripheral surface side of the first inner mold 42-1 and the second inner mold 42-2 is released, the molding is completed thereafter. The subsequent concentric winding coil 14 can be removed.
- the coil end of the substantially elliptical rectangular conducting wire 28 in which a plurality of conducting wires are laminated by moving the inner die 42 and the outer die 44 constituting the molding device 40 by stroke. Crank forming, arc forming, and edgewise forming can be performed on the corresponding part, and as a result, a plurality of coil wires 34 and 36 are laminated to form a plurality of different non-linear shapes.
- the substantially hexagonal concentric winding coil 14 can be formed.
- the conductors at each stage in the stacking direction of the coil end portions 34 and 36 of the concentric winding coil 14 can be formed into a plurality of different non-linear shapes substantially simultaneously, and each of the conductors has a plurality of differences. In forming a non-linear shape, it is sufficient to move the inner mold 42 and the outer mold 44 of the molding apparatus 40 in the first direction X by one stroke.
- each step in the stacking direction of the portion corresponding to the coil end of the substantially elliptical rectangular conducting wire 28 is obtained.
- the substantially hexagonal concentric winding in which the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes from the substantially elliptical rectangular conductor wire 28 it is not necessary to prepare separate molds and jigs for forming each of these non-linear shapes (specifically, a crank shape, an arc shape, and a bent shape). Therefore, it is not necessary to provide a plurality of steps and to separately provide a transfer facility between the steps.
- the number and cost of equipment such as molds and jigs increase when the coil end portions 34 and 36 of the concentric winding coil 14 are formed into a plurality of different non-linear shapes. Can be prevented, and an increase in installation space of equipment can be prevented. Therefore, according to the present embodiment, it is possible to realize the molding of the concentric winding coil 14 in which the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes with a simple configuration.
- the coil end portions 34 and 36 of the concentric winding coil 14 can be formed into a plurality of different non-linear shapes at substantially the same time. Therefore, when forming the concentric winding coil 14 in which the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes, the processing time of the rectangular conductor 28 to be formed can be shortened.
- the edge-wise forming of the coil end portions 34 and 36 of the concentric winding coil 14 is performed after the crank forming and the arc forming, and the flat conductors 28 at the respective stages in the stacking direction are the fins 62, It is performed in a state sandwiched between 84.
- turns number of turns was carried out are a plurality different.
- the two coil end portions 34 and 36 of the concentric coil 14 can be formed into a plurality of different non-linear shapes almost simultaneously. For this reason, when forming both the coil end portions 34 and 36 of the concentric winding coil 14 into a plurality of different non-linear shapes, the processing time of the rectangular wire 28 to be formed can be shortened, and both coils It is possible to suppress deformation of the slot portions 30 and 32 that connect both the coil end portions 34 and 36 due to the molding of the end portions 34 and 36 being performed at different timings.
- the concentric winding coil 14 when forming the substantially hexagonal concentric coil 14 in which a plurality of conductors are laminated and the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes.
- the processing time for the flat rectangular wire 28 to be molded can be greatly shortened. Therefore, the concentric winding coil 14 can be formed in a short time, and the productivity of the concentric winding coil 14 can be improved.
- the process of forming the substantially hexagonal concentric winding coil 14 in which the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes from the substantially elliptical rectangular conductor wire 28 It is not necessary to repeat attachment / detachment of the flat conducting wire 28 to be formed from a mold or a jig between forming steps of a plurality of different non-linear shapes. For this reason, it is possible to prevent the flat rectangular wire 28 to be molded from being easily damaged due to repeated attachment / detachment from the mold or jig, and as a result, the quality of the concentric winding coil 14 is deteriorated. Can be suppressed.
- the lead wires of each step at the coil end corresponding portion of the flat lead wire 28 enter between the fins 62 and the fins 84 of the outer mold 44 first. It starts when the approximate center of the two directions Y enters the gap 64 of the fin 62 and the gap 86 of the fin 84. Then, the approach is performed so as to enter the gap between the fins 62 and the gap between the fins 84 in order from the approximate center in the second direction Y to both outer sides.
- the bending process of the portion corresponding to the coil end of the flat wire 28 proceeds from the center side in the second direction Y of the portion corresponding to the coil end toward both outer sides.
- the substantially center in the second direction Y of the coil end corresponding portion of the flat conducting wire 28 is formed in a crank shape.
- the coil end portions 34 and 36 are formed in a plurality of different non-linear shapes. 14 can be easily and accurately performed in a short time.
- the inner mold 42 and the outer mold 44 are the “mold” described in the claims, the coil end portions 34, 36 of the concentric winding coil 14 of the flat conductor 28. Corresponding coil end corresponding parts are described in the “corresponding part” described in the claims, and the outer mold 44 having the fins 62 and 84 is included in the “fin-shaped mold” described in the claims.
- the first inner mold 42-1, the second inner mold 42-2, the first outer mold 44-1 and the second outer mold 44-2 having 50, 54, 58 are described in the claims.
- the first outer mold 44-1 and the second outer mold 44-2 are the "concave mold", “first concave mold”, and “second concave mold” described in the claims.
- the first inner mold 42-1 and the second inner mold 42-2 are described in the claims. Convex ", the" first convex "and” second convex ", corresponds respectively.
- the first inner mold 42-1 and the first outer mold 44-1 are moved closer to each other so that the lead-side coil end corresponding portion of the flat wire 28 is sandwiched in the first direction X (inside and outside).
- the coil is moved toward one direction X (normal direction), and the second inner die 42-2 and the second outer die 44-2 are moved closer to each other, and the non-lead-side coil of the rectangular lead wire 28 is moved.
- the stroke is moved in the first direction X (normal direction) so as to sandwich the end corresponding part in the first direction X (inside and outside). Further, the first outer mold 44-1 and the second outer mold 44-2 are moved by the stroke almost simultaneously.
- the first outer mold 44-1 and the second outer mold 44-2 are moved by the moving mechanisms 100 and 106 in the normal direction of the first direction X so as to approach each other.
- the coil end corresponding portions on both sides of the flat wire 28 are located between the fins 62 attached to the first outer mold 44-1 and the fins 84 attached to the second outer mold 44-2.
- crank forming is performed at the center in the second direction Y of the lead wire of each step for each of the coil end corresponding portions on both sides of the flat lead wire 28, and arc forming is performed. Is called.
- the coil end corresponding portions on both sides of the flat wire 28 are placed in the first direction X so as to approach each other due to friction with the outer fins. It is pressed toward.
- the slot corresponding portions sandwiched between the coil end corresponding portions on both sides of the flat conducting wire 28 may be deformed in the second direction Y and swell. is there.
- the first outer mold 44-1 and the second outer mold 44-2 are directed inward in the first direction X by the moving mechanisms 100 and 106 so as to approach each other.
- the strokes toward the outside in the first direction X so that the first inner mold 42-1 and the second inner mold 42-2 are separated from each other by the moving mechanisms 102, 104. Moved.
- both sides of the flat wire 28 are moved.
- Coil end corresponding parts (particularly, substantially in the center in the second direction Y) and slot corresponding parts (particularly near the boundary with the coil end corresponding part) are the machining surfaces 46, 47 of the inner molds 42-1, 42-2. , 50, 51 while being in contact with each other, the coil end corresponding portions on both sides of the flat wire 28 are extended outward in the first direction X so as to be separated from each other.
- the rectangular conducting wire 28 having a rectangular cross section is not curved toward the stacking direction of each step conducting wire before the start of arc forming, the conducting wires at each step corresponding to the slot corresponding portions on both sides are in the second direction Y.
- the conductors at the respective steps corresponding to the slots on both sides are inclined with respect to the second direction Y. It will be a thing. That is, when the rectangular conducting wire 28 having a rectangular cross section is formed into an arc shape, the rectangular conducting wire 28 is moved from the state in which the conducting wires at the respective stages corresponding to the slots on both sides are kept horizontal with respect to the second direction Y. It moves slightly in the direction Z (upper side in the figure) and deforms into a tilted state.
- the inner molds 42-1 and 42-2 are separated from each other, that is, approach the paired outer molds 44-1 and 44-2. Assuming that the movement of the stroke continues toward the outside, the following inconvenience occurs. Specifically, the deformation of the flat conducting wire 28 due to the above-mentioned arc forming causes the coil end corresponding portions and the slot corresponding portions on both sides of the flat conducting wire 28 to be processed surfaces 46, 47, 50 of the inner molds 42-1 and 42-2. , 51 while being stretched outward in the first direction X.
- the inner peripheral side of the flat wire 28 is formed on the processing surfaces 46, 47, 50, 51 of the inner molds 42-1 and 42-2 (in particular, the coil end corresponding portion and the slot corresponding portion of the flat wire 28).
- the rectangular conductor 28 is scratched or peeled off by moving relative to the third direction Z and rubbing against corners formed in the vicinity of the corners (that is, corners of the fin-like portions 83 and 97). May occur.
- FIG. 12 is a diagram showing a forming procedure by the forming apparatus 40 of the concentric winding coil 14 which is a modified example of the present invention.
- the number of the rectangular wire 28 at each point (specifically, point A, point B, point C, point D, and point E) from the start of forming to the end of forming by the forming apparatus 40 is shown.
- 44-2 and the positional relationship between the inner mold 42 and the flat wire 28 are shown.
- “50”, “52”, “52.5”, “54”, “131”, and “135” without lead lines are the molds 42-1, 42-2, The stroke positions 44-1 and 44-2 are shown.
- stroke movement is performed such that the inner molds 42-1 and 42-2 are separated from each other, that is, approach the paired outer molds 44-1 and 44-2.
- the inner molds 42-1 and 42-2 approach each other at a midway timing (point C shown in FIG. 12) from the start to the completion of arc forming of the flat conducting wire 28 until the completion. That is, a stroke movement (reverse movement) in the direction opposite to the normal direction is performed so as to be separated from the pair of outer molds 44-1 and 44-2.
- the stroke movement in the direction opposite to the normal direction of the inner molds 42-1 and 42-2 is performed as described above, the first molds such that the outer molds 44-1 and 44-2 approach each other.
- the stroke movement in the direction X may be continued as usual.
- the amount of movement of the stroke movement in the opposite direction described above is sufficient if at least the contact between the inner molds 42-1 and 42-2 and the flat wire 28 is eliminated. Further, the midway timing at which the stroke movement in the opposite direction is started after the slot-corresponding portion sandwiched between the coil end corresponding portions on both sides of the flat wire 28 is prevented from being deformed and bulging in the second direction Y,
- the flat conductor 28 may be at any timing as long as the conductors at the respective stages corresponding to the slots on both sides are deformed from a state in which the conductor is kept horizontal with respect to the second direction Y, and is more preferably inclined. The timing is most likely to cause deformation.
- the flat rectangular wire 28 is inclined in the third direction Z from the state in which the conductive wires at the respective stages of the slot-corresponding portions on both sides are kept horizontal with respect to the second direction Y during arc forming.
- the inner peripheral side of the flat wire 28 is a corner near the processing surfaces 46, 47, 50, 51 of the inner molds 42-1 and 42-2.
- the processing surfaces 46, 47, 50, 51 of the inner molds 42-1 and 42-2 can be separated from each other, and the inner peripheral side of the flat wire 28 is the processing surface 46 of the inner molds 42-1 and 42-2. , 47, 50, 51 to avoid contact and rub against the corners That. Therefore, according to the configuration of this modified example, the flat conductive wire 28 is prevented from being damaged or peeled off due to rubbing against the corners of the inner molds 42-1 and 42-2 at the time of arc forming of the flat conductive wire 28. be able to.
- the stroke movement in the opposite direction described above may be temporary.
- the inner molds 42-1 and 42-2 are again separated from each other, that is, approach the paired outer molds 44-1 and 44-2.
- Such stroke movement in the normal direction may be performed.
- the inner metal If the stroke movement in the normal direction such that the molds 42-1 and 42-2 are separated from each other, that is, approaches the paired outer molds 44-1 and 44-2, is resumed, the rectangular conductor 28 and the inner mold Although the molds 42-1 and 42-2 come into contact with each other, the flat conductor 28 is hardly deformed by the arc forming thereafter, so that the flat conductor 28 is prevented from being damaged or peeled off. It becomes possible to appropriately perform edgewise molding of the above.
- a concentric coil 14 in which coil end portions 34 and 36 projecting from the axial end surface of the stator core 12 are formed in a plurality of different non-linear shapes is formed from a rectangular wire 28 that has been wound by a predetermined number of turns.
- the coil ends 34 and 36 are formed in a plurality of different non-linear shapes in one step by moving the molds 42 and 44 in a predetermined direction with respect to the set flat wire 28.
- corresponding portions of the flat wire 28 corresponding to the coil end portions 34 and 36 are arranged side by side with a predetermined gap in the circumferential lamination direction of the flat wire 28 to be set.
- the fin-shaped mold 44 having the fins 62 and 84 is bent into the stacking direction by being inserted into the predetermined gap, and is aligned with the fin-shaped mold 44.
- the outer shape forming dies 42, 44 having the processing surfaces 46, 50, 54, 58 which are configured and set and are oriented in the orthogonal direction perpendicular to the laminating direction of the flat wire 28 to be set, it is directed in the orthogonal direction.
- a method of forming the concentric winding coil 14 by bending and bending the corresponding portion of the flat conducting wire 28 from the center side of the corresponding portion toward both outer sides.
- the coil end portion can be formed into a plurality of different non-linear shapes in one step of moving the mold in a predetermined direction with respect to the set flat wire. In such a configuration, it is not necessary to separately prepare a mold and a jig for forming each of these non-linear shapes, and therefore, the concentric winding coil can be easily formed.
- the coil end portions can be formed into a plurality of different non-linear shapes substantially simultaneously, and the substantially hexagonal concentric coil 14 is formed from a substantially elliptical rectangular conductor wire that has been wound a plurality of turns.
- the concentric coil can be formed in a short time. Furthermore, when forming a concentric winding coil from a rectangular conducting wire, the bending process of the coil end corresponding
- the flat conductor is bent in the orthogonal direction of the corresponding portion corresponding to the coil end portion after the bending in the stacking direction, and the flat conductor at each step in the stacking direction is formed. It is performed in a state of being sandwiched between fins. For this reason, it is possible to suppress deformation of the part where the bending process in the laminating direction has been completed during bending in the orthogonal direction of the part corresponding to the coil end of the flat wire, and to accurately form the concentric winding coil. Can do.
- the plurality of different non-linear shapes in the coil end portions 34, 36 are the centers of the coil end portions 34, 36.
- the arc shape of the stator core 12 formed in an annular shape and arranged on both sides across the center, and bending toward the laminating direction includes: A forming method of the concentric winding coil 14 which is a crank forming for forming the crank shape and an arc forming for forming the arc shape.
- the two coil end portions 34, 36 on both sides in the axial direction of the stator core 12 are at least in the crank shape and the arc shape.
- the forming method of the concentric winding coil 14 which is formed and the forming of the two coil end portions 34 and 36 proceeds simultaneously.
- each of the coil end portions of the concentric winding coil can be formed into a plurality of different non-linear shapes substantially simultaneously, so that the concentric winding coil can be formed in a short time.
- the concentric winding coil 14 in which the coil end portions 34 and 36 projecting from the axial end surface of the stator core 12 are formed in a plurality of different non-linear shapes is formed from the rectangular conductor wire 28 that has been wound by a predetermined number of turns.
- the forming device 40 includes a plurality of fins 62 and 84 arranged in a stacked manner in a circumferential lamination direction of the flat rectangular wire 28 to be set with a predetermined gap, and the coil end of the flat rectangular wire 28 The corresponding portions corresponding to the portions 34 and 36 are inserted into the gaps to bend the fin-shaped mold 44 in the laminating direction, and the flat conductive wire is configured integrally with the fin-shaped mold 44 and set. 28.
- the coil end portion can be formed into a plurality of different non-linear shapes in one step of moving the mold in a predetermined direction with respect to the set flat wire. In such a configuration, it is not necessary to separately prepare a mold and a jig for forming each of these non-linear shapes, and therefore, the concentric winding coil can be easily formed.
- the coil end portions can be formed into a plurality of different non-linear shapes substantially simultaneously, and the substantially hexagonal concentric coil 14 is formed from a substantially elliptical rectangular conductor wire that has been wound a plurality of turns.
- the concentric coil can be formed in a short time. Furthermore, when forming a concentric winding coil from a rectangular conducting wire, the bending process of the coil end corresponding
- the rectangular conductor is bent in the orthogonal direction of the corresponding portion corresponding to the coil end portion after the bending in the stacking direction, and the flat conductor at each step in the stacking direction is formed. It is performed in a state of being sandwiched between fins. For this reason, it is possible to suppress deformation of the part where the bending process in the laminating direction has been completed during bending in the orthogonal direction of the part corresponding to the coil end of the flat wire, and to accurately form the concentric winding coil. Can do.
- the fin-shaped mold 44 molds the center of the corresponding portion of the rectangular conducting wire 28 into a crank shape
- the fin-shaped mold 44 includes at least two coil end portions 34 and 36 on both sides in the axial direction of the stator core 12.
- An apparatus for forming a concentric coil which is formed into the crank shape and the arc shape, and advances the forming of the two coil end portions 34 and 36 simultaneously.
- each of the coil end portions of the concentric winding coil can be formed into a plurality of different non-linear shapes almost simultaneously, so that the concentric winding coil can be formed in a short time.
- the number of the fins 62 and 84 arranged side by side in the stacking direction is equal to the rectangular conductor. 28.
- the forming apparatus 40 of the concentric winding coil 14 which is larger by “1” than the number of lamination steps of the portion bent by 28 in the lamination direction using the fins 62.
- the plurality of fins 62 and 84 have gaps between the fins, the concentric winding coil. 14.
- the fin-shaped mold 44 is formed in a tapered shape of the fins 62 and 84.
- a forming apparatus 40 for the concentric winding coil 14 that bends the corresponding portion of the flat conducting wire 28 in the laminating direction by using a tapered surface at the tip.
- the outer shape forming dies 42 and 44 may be configured such that the corresponding portion of the flat wire 28 is the corresponding portion.
- the outer shape forming dies 42 and 44 are disposed on the outer periphery of the flat wire 28.
- the first and second concave molds 44-1 and 44-2 which are formed by simulating the shape of the coil end portions 34 and 36 of the concentric winding coil 14, and the inner circumference of the rectangular conductive wire 28,
- First and second convex molds 42 simulating the shape of the coil end portions 34, 36 of the concentric winding coil 14 paired with the first and second concave molds 44-1, 44-2.
- the fin-shaped mold 44 is a mold in which a plurality of the fins 62 and 84 are integrally formed in the first concave mold 44-1 and the second concave mold 44-2, respectively.
- the forming apparatus 40 of the concentric winding coil 14 which is.
- the moving mechanisms 100, 102, 104, and 106 have the shape of the coil end portion 34 on one side of the concentric winding coil 14.
- the first concave mold 44-1 and the first convex mold 42-1 forming a pair formed by imitating each other in a direction opposite to each other so as to sandwich the corresponding portion on one side of the set flat wire 28
- the second concave mold 44-2 and the second convex mold 42-2 forming a pair formed by simulating the shape of the coil end portion 36 on the other side of the concentric winding coil 14.
- the forming device 40 of the concentric winding coil 14 that moves the stroke in opposite directions so as to sandwich the corresponding portion on the other side of the set flat wire 28.
- the movement of the first concave mold 44-1 and the first convex mold 42-1 by the moving mechanisms 100, 102, 104, and 106 is performed.
- the stroke movement of the second concave mold 44-2 and the second convex mold 42-2 is started, bending forming of the corresponding portion of the flat conducting wire 28 toward the stacking direction is started, At a midway timing until the bending is completed, the moving mechanisms 100, 102, 104, and 106 are configured so that only the first convex mold 42-1 and the second convex mold 42-2 are not connected to the flat conductor 28, respectively.
- the forming device 40 of the concentric winding coil 14 that moves the stroke in a direction opposite to the direction at which the stroke movement is started in order to make contact.
- the inner peripheral side of the rectangular conductive wire is prevented from contacting and rubbing against the corners of the first convex shape and the second convex shape when bending the flat conductive wire in the stacking direction. As a result, it is possible to prevent the flat conductor wire from being scratched or peeled off.
- the moving mechanisms 100, 102, 104, and 106 include the fin-shaped mold 44 and the outer shape.
- Stator 12 Stator Core 14 Stator Coil (Concentric Winding Coil) 28 Flat conductor 30, 32 Slot part 34, 36 Coil end part 40 Molding device 42, 42-1, 42-2 Inner mold 44, 44-1, 44-2 Outer mold 62, 62-1, 62-2 , 84, 84-1, 84-2 Fins 46, 50, 54, 58 Work surface 100, 102, 104, 106 Moving mechanism 110 Controller
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Abstract
Description
12 ステータコア
14 ステータコイル(同芯巻コイル)
28 平角導線
30,32 スロット部
34,36 コイルエンド部
40 成形装置
42,42-1,42-2 内側金型
44,44-1,44-2 外側金型
62,62-1,62-2,84,84-1,84-2 フィン
46,50,54,58 加工面
100,102,104,106 移動機構
110 コントローラ
Claims (16)
- 所定複数巻数だけ周回された平角導線から、ステータコアの軸方向端面から突出するコイルエンド部が複数の相異なる非直線形状に形成される同芯巻コイルを成形する成形方法であって、
セットされた前記平角導線に対して金型を所定方向にストローク移動させることにより一工程で、前記コイルエンド部を前記複数の相異なる非直線形状に成形し、
前記平角導線の、前記コイルエンド部に対応する対応部位を、セットされる前記平角導線の周回の積層方向に所定の隙間を介して並んで配置される複数のフィンを有するフィン状金型を用いて、前記所定の隙間に挿入することで前記積層方向に向けて曲げ加工し、かつ、前記フィン状金型と一体構成され、セットされる前記平角導線の前記積層方向に直交する直交方向に向いた加工面を有する外形成形用金型を用いて前記直交方向に向けて曲げ加工し、
前記平角導線の前記対応部位の曲げ加工を、該対応部位の中央側から両外側に向けて進行させることを特徴とする同芯巻コイルの成形方法。 - 前記直交方向に向けた曲げ加工は、前記積層方向に向けた曲げ加工が行われた後に行われることを特徴とする請求項1記載の同芯巻コイルの成形方法。
- 前記コイルエンド部における前記複数の相異なる非直線形状は、該コイルエンド部の中央に配置されるクランク形状と、該中央を挟んで両側に配置される、円環状に形成される前記ステータコアの円弧に合わせた円弧形状と、を含み、
前記積層方向に向けた曲げ加工は、前記クランク形状を成形するクランク成形、及び、前記円弧形状を成形する円弧成形であることを特徴とする請求項1又は2記載の同芯巻コイルの成形方法。 - 前記ステータコアの軸方向両側にある2つの前記コイルエンド部は共に、少なくとも前記クランク形状と前記円弧形状とに成形され、
該2つの前記コイルエンド部の成形は同時に進行することを特徴とする請求項3記載の同芯巻コイルの成形方法。 - 所定複数巻数だけ周回された平角導線から、ステータコアの軸方向端面から突出するコイルエンド部が複数の相異なる非直線形状に形成される同芯巻コイルを成形する成形装置であって、
セットされる前記平角導線の周回の積層方向に所定の隙間を介して並んで配置される複数のフィンを有し、前記平角導線の、前記コイルエンド部に対応する対応部位を前記隙間に挿入することで前記積層方向に向けて曲げ加工するフィン状金型と、
前記フィン状金型と一体構成され、セットされる前記平角導線の前記積層方向に直交する直交方向に向いた加工面を有し、前記平角導線の前記対応部位を前記直交方向に向けて曲げ加工する外形成形用金型と、
前記フィン状金型及び前記外形成形用金型を、セットされた前記平角導線に対して所定方向にストローク移動させる移動機構と、
を備え、
前記平角導線の前記対応部位の曲げ加工を、該対応部位の中央側から両外側に向けて進行させることを特徴とする同芯巻コイルの成形装置。 - 前記フィン状金型が前記平角導線の前記対応部位を前記積層方向に向けて曲げ加工した後に、前記外形成形用金型が前記平角導線の前記対応部位を前記直交方向に向けて曲げ加工することを特徴とする請求項5記載の同芯巻コイルの成形装置。
- 前記フィン状金型は、前記平角導線の前記対応部位の中央をクランク形状に成形すると共に、該中央を挟んだ両側を円環状に形成される前記ステータコアの円弧に合わせて円弧形状に成形することを特徴とする請求項5又は6記載の同芯巻コイルの成形装置。
- 前記フィン状金型は、前記ステータコアの軸方向両側にある2つの前記コイルエンド部を共に、少なくとも前記クランク形状と前記円弧形状とに成形し、該2つの前記コイルエンド部の成形を同時に進行させることを特徴とする請求項7記載の同芯巻コイルの成形装置。
- 前記積層方向に並んで配置される前記フィンの数が、前記平角導線の、該フィンを用いて前記積層方向に向けて曲げ加工される部位の積層段数よりも“1”だけ多いことを特徴とする請求項5乃至8の何れか一項記載の同芯巻コイルの成形装置。
- 複数の前記フィンは、フィン同士の間の隙間が前記同芯巻コイルの前記積層方向に積層される複数の導線を転写した形状に形成されるように、互いに同芯上に配置されることを特徴とする請求項5乃至9の何れか一項記載の同芯巻コイルの成形装置。
- 前記フィン状金型は、前記フィンの、テーパ状に形成された先端のテーパ面を利用して、前記平角導線の前記対応部位を前記積層方向に向けて曲げ加工することを特徴とする請求項5乃至10の何れか一項記載の同芯巻コイルの成形装置。
- 前記外形成形用金型は、前記平角導線の前記対応部位を前記直交方向に向けてエッジワイズ成形することを特徴とする請求項5乃至11の何れか一項記載の同芯巻コイルの成形装置。
- 前記外形成形用金型は、前記平角導線の周回外側に配置され、前記同芯巻コイルの前記コイルエンド部の形状を模して形成された第1及び第2凹型と、前記平角導線の周回内側に配置され、前記第1及び第2凹型と対をなす、前記同芯巻コイルの前記コイルエンド部の形状を模して形成された第1及び第2凸型とであり、
前記フィン状金型は、複数の前記フィンが前記第1凹型及び前記第2凹型のそれぞれに一体構成された金型であることを特徴とする請求項5乃至12の何れか一項記載の同芯巻コイルの成形装置。 - 前記移動機構は、前記同芯巻コイルの一方側の前記コイルエンド部の形状を模して形成された対をなす前記第1凹型と前記第1凸型とをそれぞれ、セットされた前記平角導線の一方側の前記対応部位を挟むように相対する方向にストローク移動させると共に、前記同芯巻コイルの他方側の前記コイルエンド部の形状を模して形成された対をなす前記第2凹型と前記第2凸型とをそれぞれ、セットされた前記平角導線の他方側の前記対応部位を挟むように相対する方向にストローク移動させることを特徴とする請求項13記載の同芯巻コイルの成形装置。
- 前記移動機構による前記第1凹型及び前記第1凸型のストローク移動並びに前記第2凹型及び前記第2凸型のストローク移動が開始されることにより前記平角導線の前記対応部位の前記積層方向に向けた曲げ成形が開始された後、該曲げ成形が完了するまでの中途タイミングで、前記移動機構は、前記第1凸型及び前記第2凸型のみをそれぞれ、前記平角導線と非接触とすべく、前記ストローク移動が開始された際の方向とは反対方向にストローク移動させることを特徴とする請求項14記載の同芯巻コイルの成形装置。
- 前記移動機構は、前記フィン状金型及び前記外形成形用金型を、セットされた前記平角導線の両側の前記対応部位を結ぶ方向にストローク移動させることを特徴とする請求項5乃至15の何れか一項記載の同芯巻コイルの成形装置。
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JP2014209833A (ja) | 2014-11-06 |
JP6146219B2 (ja) | 2017-06-14 |
DE112014000852T5 (de) | 2015-11-05 |
CN105052022B (zh) | 2017-05-10 |
US20150372573A1 (en) | 2015-12-24 |
US9859775B2 (en) | 2018-01-02 |
CN105052022A (zh) | 2015-11-11 |
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