JP3894004B2 - Method for forming segment for coil of rotating electrical machine and mold structure used therefor - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for forming a segment for a coil of a rotating electrical machine and a mold structure used therefor, in particular, a molding method capable of easily forming a segment having a reproducible and stable shape, and a mold structure used in the method. About.
[0002]
[Prior art]
There are various types of stator coils and rotor coils of rotating electrical machines such as motors and generators. For example, a coil is typically formed by winding a coil wire directly on a stator core or a rotor core, or a coil is wound using a separate winding mold or the like and mounted on the stator core or the rotor core. On the other hand, pine needle conductors (substantially U-shaped conductors) called segments are inserted into slots formed in the stator core and the rotor core, and the ends of each segment are sequentially joined to one end side of the core by welding or the like to form a coil as a whole. There are coils to form. In the case of this segment type coil, since the so-called coil winding process is not required, the cross section of the coil (segment) can be a rectangular cross section substantially equal to the occupied space cross section of the core slot. The rate can be easily improved, and this is effective in that a small and high-output rotating electrical machine can be obtained.
[0003]
FIG. 3 is a view for explaining the single-piece shape of a conventional substantially U-shaped segment 100 disclosed in Japanese Patent Laid-Open No. 11-75334, etc. FIG. 3 (a) is a U-shaped curved portion (a coil to be described later). FIG. 3B is a plan view, FIG. 3C is a side view, and FIG. 3D is a perspective view. The segment 100 is formed by bending a rectangular wire of a predetermined length into a U shape, thereby connecting the slot insertion portion 102 to be inserted into a core slot such as a stator (not shown) and the slot insertion portion 102 at the end surface portion of the core. A coil end forming portion (crossover portion) 104 for passing from a predetermined slot to another predetermined slot is configured. Further, as is apparent from each drawing, a twisted portion 106 obtained by twisting a rectangular wire by 180 ° is formed near the approximate center of the coil end forming portion 104.
[0004]
4A and 4B are a top view and a side view showing an annular arrangement state in which a plurality of segments 100 are inserted into slots (not shown) of the core. 4A and 4B, when the segments 100 are arranged in an annular shape, the other segments 100 must be jumped by the number of slots that the slot insertion portion 102 of the segment 100 jumps. At this time, when the segment 100 comes out of a certain slot and enters a slot that is a predetermined number of distances away from it, if it tries to enter with the same diameter, it interferes with other segments 100, so the segment 100 has two slot insertion portions 102. It is necessary to enter the slot separately in the radial direction. Therefore, a twist is applied at the coil end forming portion 104 so that the wire is displaced before and after the twisted portion 106.
[0005]
[Problems to be solved by the invention]
However, in the segment 100 with the 180 ° twisted portion 106 as described above, the twisted portion 106 is bulky when arranged in an annular shape, and the coil end portion becomes large. That is, there is a problem that the axial dimension and the radial dimension of the core such as the stator of the rotating electrical machine increase, resulting in an increase in size of the rotating electrical machine itself. Further, when the twisted portion 106 is formed, it is difficult to stabilize the shape of the twisted portion 106 because the slot insertion portions 102 at both ends are clamped and formed by a method such as twisting one of the clamps. There is. When the shape variation and shape reproducibility of each segment 100 are low, the increase in size in the axial direction and the radial direction in the above-described annular arrangement is further promoted.
[0006]
Japanese Patent Application Laid-Open No. 2000-69700 discloses a segment without the twisted portion 106, but the bending shape of the wire is complicated and it is difficult to maintain the shape reproducibility. There is a problem that the shape reproducibility must be improved while considering the stress and damage to the wire rod.
[0007]
This invention is made | formed in view of the said subject, and it aims at providing the shaping | molding die structure used for the shaping | molding method which can shape | mold the segment of a stable shape easily, and its shaping | molding method.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a method for forming a segment in which a coil is formed by sequentially connecting ends inserted into slots of a core of a rotating electrical machine, the wire forming the segment Forming a two-dimensional crank wire having a substantially crank shape on the first plane, and a crank portion of the two-dimensional crank wire 3 having a substantially apex along a second plane substantially perpendicular to the first plane. Forming a three-dimensional chevron wire having a three-dimensional chevron shape, and bending the outer portion of the three-dimensional chevron wire from the coil end formation region including the apex portion toward the slot insertion direction. And
[0009]
In order to achieve the above object, the present invention provides a method for forming a segment in which a coil is formed by sequentially connecting ends inserted into slots of a core of a rotating electrical machine. A two-dimensional molding step of sandwiching a pair of male and female molding dies on and off on one plane and molding the wire into a two-dimensional crank wire having a substantially crank shape corresponding to the male and female shape; and substantially orthogonal to the first plane A three-dimensional forming step of forming into a three-dimensional chevron-shaped three-dimensional chevron with a crank portion of the two-dimensional crank wire approximately apex by a pair of chevron male and female molds contacting and separating along the second plane; A coil end including the apex portion of the three-dimensional angle wire by a pair of bending dies that are in contact with and separated from each other along a third plane intersecting the first plane while maintaining contact with the male and female molds A slot portion molding step from forming region bent outer portion toward the insertion direction of said slot, characterized by including.
[0010]
Here, the substantially crank shape does not mean a specific one shape, but means that the wire has a continuous bend, and for example, includes a smooth bend such as an S-shape. Further, the term “substantially orthogonal” does not mean a complete right angle, but means a degree that is substantially recognized as orthogonal. Furthermore, a substantially vertex does not mean a complete point, but includes a vertex and its periphery.
[0011]
According to this configuration, the wire is first formed into a two-dimensional crank shape, and thereafter, a mountain shape in the coil end formation region and a slot insertion portion are formed. In this case, since bending is performed while releasing all stress applied to the wire, unnecessary stress and damage can be prevented from being applied to the wire.
[0012]
In addition, because each bending process is performed step by step by moving and moving away from each other, it is easy to maintain uniform shape reproducibility while maintaining a uniform shape based on the shape of the mold while releasing stress during each bending process. Can be done.
[0013]
In order to achieve the above object, the present invention provides a molding structure for a segment which is inserted into each slot of a core of a rotating electrical machine and forms a coil by sequentially connecting the end portions. A pair of detachable two-dimensionally shaped male and female molds formed on a two-dimensional crank wire rod having a substantially crank shape by sandwiching the wire to be formed on a first plane, and a second plane that is substantially perpendicular to the first plane. A pair of three-dimensional forming male and female molds formed into a three-dimensional chevron-shaped three-dimensional chevron with the crank portion of the two-dimensional crank wire approximately apex, and a third plane that intersects the first plane. And a pair of bent male and female dies that bend the outer portion of the three-dimensional angled wire rod from the coil end forming region including the apex portion toward the slot insertion direction.
[0014]
According to this configuration, each bending process of the segment is performed step by step by the male and female molds that move toward and away from each other. Therefore, a uniform segment based on the mold shape can be easily and stably released while releasing the stress during each bending process. It can be carried out.
[0015]
In order to achieve the above object, the present invention is characterized in that, in the above configuration, the bent male and female male mold is common to the three-dimensional male and female male mold.
[0016]
According to this configuration, it is possible to easily reduce the die cost for segment forming. Further, the structure of the opening / closing device can be simplified even when the mold is brought into and out of contact with an automatic opening / closing device or the like.
[0017]
In order to achieve the above object, according to the present invention, in the above configuration, the male mold of the three-dimensional molded male and female and the male mold of the bent male and female have a guide groove for guiding the wire. It is characterized by that.
[0018]
According to this configuration, the segment forming accuracy can be easily improved.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of the invention (hereinafter referred to as embodiments) will be described with reference to the drawings.
[0020]
FIG. 1 shows the shape of a segment 10 formed by the method for forming a segment for a coil of a rotating electrical machine according to this embodiment. The segment 10 has a slot insertion portion 12 inserted into a slot of a core such as a stator (not shown) by bending a rectangular wire made of a copper material or the like of a predetermined length into a U shape like the conventional one. A slot insertion portion 12 is connected to form a coil end forming portion (crossover portion) 14 for crossing from a predetermined slot to another predetermined slot at the end face portion of the core. 1A is a top view of the coil end forming portion 14 as viewed from above, FIG. 1B is a plan view of the segment 10, FIG. 1C is a side view of the segment 10, and FIG. ) Is a perspective view of the segment 10.
[0021]
As is clear from FIGS. 1A to 1D, the segment 10 does not include a twisted portion in the coil end forming portion 14. By not including the twisted portion, it is possible to suppress the bulk of the coil end forming portion 14 and to reduce the amount of protrusion in the axial direction and the radial direction of the rotating electrical machine. As shown in FIG. Sometimes, the height h of the coil end forming portion 14 can be reduced. That is, when the segments 10 are arranged in a ring shape, the axial and radial dimensions of the rotating electrical machine can be reduced.
[0022]
Hereinafter, the segment forming method of the present embodiment will be described with reference to FIG. 2 while referring to the shape of the segment 10 shown in FIG.
[0023]
As described above, the segment 10 is formed from a rectangular wire material (wire) 16 made of a copper wire having a predetermined length. As shown in FIG. 2A, the rectangular wire material 16 is first sandwiched between a pair of male and female molding dies 18 that are in contact with and separated from each other on the xy plane (first plane). A two-dimensional crank wire 20 having a substantially crank shape corresponding to the mold 18b is formed (two-dimensional forming step). The crank portion 20a of the two-dimensional crank wire 20 serves as a portion for changing the entry position into the slot for avoiding mutual interference when the plurality of segments 10 are arranged in an annular shape. Here, the substantially crank shape does not mean a specific one shape, but means that the wire has a continuous bend, for example, includes a smooth bend such as an S-shape, This means that the crank shape is appropriately selected according to 10 design specifications.
[0024]
The male mold 18a and the female mold 18b are driven toward and away from the first plane by a fluid pressure cylinder or the like (only one or both of them may be driven). At this time, since both ends of the flat wire material 16 are pressure-molded in an open state, unnecessary stress is not applied to the flat wire material 16 and the occurrence of thinning or the like can be prevented.
[0025]
Subsequently, as shown in FIGS. 2B and 2C, the two-dimensional crank wire 20 is substantially orthogonal to the first plane (not to mean a complete right angle but to be substantially orthogonal) The crank shape is appropriately selected according to the design specifications of the segment 10) and is sandwiched between a pair of chevron male and female molds 22 contacting and separating along the second plane (xz plane) (three-dimensional molding step) ). As shown in FIG. 2 (b), the male male mold 22a has a convex shape along the second plane, and its upper surface and side surfaces are bent when the two-dimensional crank wire 20 is bent. A guide groove 24 is formed to restrict the movement. Further, the upper surface portion has a three-dimensional chevron shape in which the position corresponding to the crank portion 20a of the two-dimensional crank wire 20 is substantially apex (not including a complete point but including the apex and its periphery). The two-dimensional crank wire 20 is positioned accurately. With the guide groove 24, as will be described later, reproducible molding can be performed when pressure is applied by each male and female molding die.
[0026]
As shown in FIG. 2 (c), the two-dimensional crank wire 20 is set on the male mold 22a having a convex mountain shape, and the female mold 22b having a concave mountain shape is set to the first shape as shown in FIG. 2 (d). By approaching and pressurizing along two planes, the two-dimensional crank wire 20 is formed into a three-dimensional angle wire 26 bent not only in the xy direction but also in the z direction. Also in this case, since both ends of the two-dimensional crank wire 20 remain open, unnecessary stress is not applied to the wire, and desired molding can be performed. The male and female mold 22 is also driven by a fluid pressure cylinder or the like.
[0027]
Next, as shown in FIG. 2 (d), 2 is engaged with the shoulder portion 28 of the male mold 22a as shown in FIG. 2 (e) while maintaining the contact state of the mountain-shaped male and female molds 22. The two female folding dies 30a are brought close to, in contact with, and pressurized by a fluid pressure cylinder or the like. The male mold 22a and the female folding mold 30a are used to bend the outer portion of the three-dimensional chevron wire 26 including the apex portion (the chevron portion of the male mold 22a) toward the slot insertion direction (not shown). (Slot portion forming step). Also in this case, since both ends of the three-dimensional angle wire 26 are open, it is possible to avoid applying unnecessary stress to the wire. Thereafter, the two female folding dies 30a and the mountain-shaped male and female forming dies 22 are separated from each other, whereby the completed segment 10 can be taken out from the dies, and a series of segment forming steps is completed. The contact / separation direction of the female folding die 30a may be performed along a third plane that intersects the first plane. For example, as in the present embodiment, a second plane (second) that intersects the first plane is used. 3 planes = 2nd plane), and the contact / separation direction of the female folding mold 30a can be selected so that the contact / separation operations of the male and female dies do not interfere with each other.
[0028]
In the present embodiment, an example is shown in which a male and female mold 22a and a female bending mold 30a constitute a bent male and female mold for forming a slot insertion portion. That is, the male molding die 22a is shared for three-dimensional molding and slot portion molding. This sharing can reduce the mold manufacturing cost, and can also share an actuator (such as a fluid pressure cylinder) that performs a series of mold contacting / separating operations, thereby reducing the cost and size of the equipment. Of course, separate male and female molds may be used for the three-dimensional molding and the slot molding. In any case, by performing the three-dimensional forming and the slot portion forming in two stages, unnecessary stress is not applied to the wire forming the segment 10, and the wire is partially compressed and buckled. It is possible to easily avoid damage such as winding or pulling to cause line thinning.
[0029]
The segment 10 thus molded can easily obtain a stable shape reproducibility by the shape of each male and female mold, the guide groove 24 formed in the male molding die 22a, and the contact and separation operation of each male and female mold. . In addition, as described above, the segment 10 formed in this way does not include a torsion part that is bulky or has a low shape reproducibility as in the past, and is therefore arranged in an annular arrangement when attached to a core for a rotating electrical machine. Also, an increase in the axial and radial protrusions of the coil end portion can be suppressed.
[0030]
In addition, the shape of each male and female type | mold shown by this embodiment respond | corresponds to the shape of the segment 10, and can be changed suitably.
[0031]
【The invention's effect】
According to the present invention, the wire is first formed into a two-dimensional crank shape, and thereafter, the mountain shape in the coil end formation region and the slot insertion portion are formed. As a result, since bending is performed while releasing all stress applied to the wire, unnecessary stress and damage to the wire can be prevented. In addition, because each bending process is performed step by step by moving and moving away from each other, it is easy to maintain uniform shape reproducibility while maintaining a uniform shape based on the shape of the mold while releasing stress during each bending process. Can be done.
[Brief description of the drawings]
FIG. 1 is an explanatory view illustrating the shape of a segment formed by a segment forming method according to an embodiment of the present invention.
FIG. 2 is an explanatory diagram for explaining a segment molding method and a mold used for molding according to an embodiment of the present invention.
FIG. 3 is an explanatory diagram for explaining the shape of a segment formed by a conventional method for forming a segment.
FIG. 4 is an explanatory diagram for explaining a state in which a plurality of segments are arranged in an annular shape.
[Explanation of symbols]
10 segments, 12 slot insertion portions, 14 coil end forming portions, 16 rectangular wire materials, 18, 22 male and female forming dies, 18a, 22a male forming dies, 18b, 22b female forming dies, 20 two-dimensional crank wires, 20a crank portions, 24 guide groove, 26 three-dimensional angle wire, 28 shoulder portion, 30a female folding die.

Claims (5)

A method for forming a segment, which is inserted into each slot of a core of a rotating electrical machine to form a coil by sequentially connecting ends,
Forming a wire forming a segment into a two-dimensional crank wire having a substantially crank shape on the first plane;
Forming a three-dimensional chevron shaped wire with a three-dimensional chevron shape with the crank portion of the two-dimensional crank wire approximately apex along a second plane substantially orthogonal to the first plane;
Bending a portion outside the coil end forming region including the apex portion of the three-dimensional angle wire toward the slot insertion direction;
A method for forming a segment for a coil of a rotating electrical machine, comprising: A method for forming a segment, which is inserted into each slot of a core of a rotating electrical machine to form a coil by sequentially connecting ends,
A two-dimensional molding step of sandwiching the wire rod between a pair of male and female molding dies that contact and separate on the first plane, and molding the wire rod into a two-dimensional crank wire rod having a substantially crank shape corresponding to the male and female mold shape;
The two-dimensional crank wire rod is formed into a three-dimensional chevron-shaped three-dimensional wire rod with the crank portion of the two-dimensional crank wire rod as a substantially apex by a pair of chevron male and female molds that contact and separate along a second plane substantially orthogonal to the first plane. A three-dimensional molding step;
A coil end forming region including the apex portion of the three-dimensional chevron wire by a pair of bending dies that are in contact with and separated from each other along a third plane intersecting the first plane while maintaining contact with the chevron male and female molds A slot portion forming step of bending the outer portion toward the slot insertion direction;
A method for forming a segment for a coil of a rotating electrical machine, comprising: A segment mold structure that is inserted into each slot of a core of a rotating electrical machine to form a coil by sequentially connecting end portions,
A pair of two-dimensionally formed male and female molds that are separable and formed on a two-dimensional crank wire rod that has a substantially crank shape by sandwiching a wire rod that forms a segment on the first plane;
A pair of three-dimensionally formed male and female molds that are formed into a three-dimensional chevron-shaped three-dimensional chevron that is close to and away from a second plane that is substantially perpendicular to the first plane and that has a crank portion of the two-dimensional crank wire as a substantial apex; ,
A pair of bent male and female dies that are contacted and separated along a third plane intersecting the first plane and that bend an outer portion of the three-dimensional angled wire rod from the coil end forming region including the apex portion toward the slot insertion direction. When,
A mold structure of a segment characterized by comprising: The structure of claim 3,
The segmented mold structure is characterized in that the male model of the bent male and female mold is common to the male mold of the three-dimensional molded male and female mold. In the structure of claim 3 or claim 4,
The three-dimensional male and female male mold and the bent male and female male mold each have a guide groove for guiding the wire.

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