JP5699928B2 - Stator coil molding apparatus and molding method - Google Patents

Description

  The present invention relates to a stator coil forming apparatus and a forming method for processing a conductor wire to form a slot accommodating portion and a coil end portion.

  Conventionally, an example of a technique related to a manufacturing method of a circumferentially-deployed stator coil in which an insulation covering conductor wire is bent to alternately produce a slot accommodating conductor portion and a coil end conductor portion has been disclosed (see, for example, Patent Document 1). According to this technique, after arranging at least three mold pairs, the mold pairs are moved in a direction approaching each other to form a coil end conductor portion, and the mold pairs are moved in the longitudinal direction of the insulated conductor wire. The operation of moving in the longitudinal direction of the insulation-coated conductor wire while moving in the direction perpendicular to the direction is performed simultaneously with the operation of forming the slot accommodating conductor portion.

JP 2009-194994 A

  However, as shown in FIG. 5 to FIG. 8 of Patent Document 1, the technique of the document is a method of mainly bending the insulating coated conductor wire at a right angle to form the slot accommodating conductor portion. Therefore, the coil end conductor portion shown in FIG. 3 of the same document needs to be formed in a separate process. Further, as shown in paragraph [0020] and FIG. 3, the coil end conductor portion needs to be formed into a crank shape (thickness direction step 3A) or a staircase shape (corner portions C1 to C7). Furthermore, as shown in FIG. 2, the coil end conductor portion needs to be formed into an arc shape matching the circumference of the stator core (12).

  In order to form the four types of shapes described above, it is necessary to perform molding in four steps using a mold pair corresponding to each shape. In this case, not only the number of equipment (that is, the number of mold pairs) is increased and the cost is increased, but also the pitch accuracy is increased because it is necessary to change the insulated conductor wire for each process (or mold pair). There is concern that it will get worse.

  Moreover, it is possible to form the processed surface which shape | molds an insulation coating conductor wire in step shape with respect to the intermediate metal mold | die pair (102) shown by FIGS. 5-8 of patent document 1. FIG. In this case, the stepped coil end conductor portion can be formed at a time together with the slot accommodating conductor portion. However, there are cases where the direction in which the step shape is formed (for example, the XY plane) and the direction in which the step is formed into a crank shape or an arc shape (for example, the YZ plane) are different. When a machining surface having a shape obtained by combining the crank shape and the arc shape with the staircase shape is formed, the machining surface of the mold pair becomes a three-dimensional shape. If an edge-covered conductor wire is to be inserted as shown in FIG. 5 of Patent Document 1, it cannot even be inserted because it interferes with the three-dimensional machining surface of the mold pair.

  This invention is made | formed in view of such a point, and the 1st objective is to reduce the number of facilities, and to reduce cost. The second purpose is to reduce the processing time by reducing the number of steps. The third purpose is to improve pitch accuracy.

The invention according to claim 1, which has been made to solve the above-mentioned problems, is a slot accommodating portion that processes a conductor wire and accommodates it in a slot of a stator core, and a portion that protrudes from an axial end surface of the stator core. In a stator coil forming apparatus that forms a plurality of different non-linearly shaped coil end portions, a processing surface that is processed into the shape of the slot housing portion and a plurality of different processing surfaces that are processed into the shape of the coil end portion One or more molds having a composite processed surface obtained by combining two or more processed surfaces, a mold moving mechanism for moving the mold in a predetermined stroke direction, and the conductor wire temporarily A conductor wire holding mechanism that is released after being held, and an interlocking mechanism that interlocks the movement of the mold by the die moving mechanism and the holding and releasing by the conductor wire holding mechanism. By processing the conductor line by moving the mold by the mold moving mechanism, molding the plurality of shape corresponding to the synthesis processing surface to the conductor wire, the interlocking mechanism, the die moving mechanism The power generated with the movement of the mold due to the is transmitted to the conductor wire holding mechanism, the conductor wire holding mechanism from the direction intersecting the stroke direction before the start of molding based on the transmitted power The conductor wire is held, and the conductor wire is released after the molding by one or more of the dies is finished .

  According to this configuration, the conductor wire is formed into a plurality of shapes corresponding to the composite processed surface by one mold. That is, when the die is moved by one stroke (that is, relative movement between the die portion and the punch portion), a plurality of shapes corresponding to the composite processed surface are formed on the conductor wire. Therefore, the number of necessary dies (equipment) can be reduced as a whole, and the cost can be reduced. Since the number of molds is reduced, the number of times of changing the conductor wire is reduced, and the pitch accuracy can be improved.

  The “conductor wire” may be any material as long as it is a conductive wire, and may or may not have an insulating coating. The “insulation coating” is an arbitrary coating member that includes an insulating film and can be insulated so that the conductor wire does not conduct (including short circuit) with other conductive members. “A plurality of different non-linear shapes” in which the coil end portion is processed includes two or more non-linear shapes among the above-described step shape, crank shape, arc shape, and other non-linear shapes. The “synthesized processed surface” includes all processed surfaces to be combined. Depending on the shape of the processed surface to be combined, it becomes a two-dimensional processed surface or a three-dimensional processed surface. For example, when the machining surface of the slot accommodating portion and the step-like machining surface of the coil end portion are synthesized, the machining direction is the same, so that a two-dimensional machining surface is obtained. On the other hand, when the staircase-shaped and crank-shaped processed surfaces applied to the coil end portion are combined, the processing directions are different, so that a three-dimensional processed surface is obtained. The “plurality of shapes” may include a linear shape in addition to the above-described different non-linear shapes.

The conductor wire holding mechanism is actuated in the direction intersecting the movement direction of the mold, or to free or hold the conductor wires. Since the operating directions are different, the conductor wire holding mechanism and the mold do not interfere with each other. Therefore, not only can the conductor wire be held and released reliably, but also the conductor wire can be prevented from being damaged due to interference (for example, deformation of the conductor wire or peeling of the insulation coating).

Further , since the power generated with the movement of the mold is transmitted to the conductor wire holding mechanism to hold and release the conductor wire, a drive source for operating the conductor wire holding mechanism becomes unnecessary. Therefore, the cost can be further reduced.

The invention according to claim 2 is characterized in that the interlocking mechanism includes a cam. According to this configuration, since the power generated with the movement of the mold is reliably transmitted to the conductor wire holding mechanism by the cam, the conductor wire can be reliably held and released with a simple configuration.

The invention according to claim 3 is characterized in that the mold moving mechanism and the conductor wire holding mechanism operate based on power transmitted from separate drive sources. According to this configuration, it is possible to reliably hold and release the conductor wire even when power associated with the movement of the mold does not occur.

According to a fourth aspect of the present invention, when processing into the shape of the slot accommodating portion, the invention has a pressing portion that includes at least an expansion region that is a corner portion of the slot accommodating portion and can swell with processing. Features. According to this configuration, it is possible to prevent the pressing portion from expanding when bending the conductor wire, and to reduce the difference in bending stress distribution. Therefore, it is possible to suppress the spring back accompanying the bending process and improve the processing accuracy (bending accuracy).

According to a fifth aspect of the present invention, there is provided a corner portion processing portion that performs a process of bending a corner portion of the slot housing portion to a predetermined angle when processing into the shape of the slot housing portion. According to this configuration, the corner of the slot accommodating portion is bent at a predetermined angle by the corner processing portion. The “predetermined angle” can be arbitrarily set as long as the tips of the stator coils after processing do not contact each other. For example, when the angle of the linear conductor wire before processing is 0 degree, it is desirable to set within a range of 30 to 150 degrees.

According to a sixth aspect of the present invention, the composite processed surface of the mold is gradually changed so that the surface shape gradually changes so that the processed surfaces are smoothly connected between the processed surfaces having different shapes. It has a processing surface. The “gradual change processed surface” is a connection surface that changes gradually (continuously) between the processed surfaces. According to this configuration, the composite processed surface of the mold includes a plurality of processed surfaces so as to be processed into a target shape, but the gradually changing processed surface is interposed between the processed surfaces. As the mold moves, the conductor wire is gradually deformed according to the gradual change processed surface, so that an unreasonable stress is not generated and the target processed shape can be surely finished. In addition, since the load necessary for processing each shape can be dispersed, low-rigidity device parts can be applied, and the device cost can be kept low.

According to the seventh aspect of the present invention, the plurality of different machining surfaces to be machined into the shape of the coil end portion are a machining surface to be machined into a staircase shape, a machining surface to be machined into a crank shape, and a machining surface to be machined into an arc shape. Among them, it includes two or more processed surfaces. According to this structure, the synthetic | combination process surface of a metal mold | die contains two or more process surfaces for processing a coil end part. Therefore, a plurality of shapes corresponding to the coil end portions are formed on the conductor wire in one stroke.

According to an eighth aspect of the present invention, the conductor wire is processed and processed into a plurality of different non-linear shapes which are different from the slot accommodating portion accommodated in the slot of the stator core and the portion protruding from the axial end surface of the stator core. Two or more of a machining surface processed into the shape of the slot housing portion and a plurality of different machining surfaces processed into the shape of the coil end portion. One or more molds having a composite processed surface obtained by combining the processed surfaces, a mold moving mechanism that moves the mold in a predetermined stroke direction, and a conductor wire holding that is released after temporarily holding the conductor wire A holding step of holding the conductor wire from a direction crossing the stroke direction before the start of molding by the conductor wire holding mechanism, and a mold movement. After finishing the molding step, one or more molding steps for molding a plurality of shapes corresponding to the synthetic processing surface on the conductor wire by processing the conductor wire by moving the mold according to the structure, A release step of releasing the conductor wire held by the conductor wire holding mechanism, and a plurality of different processing surfaces to be processed into the shape of the coil end portion are processed surfaces to be processed into a staircase shape, a crank Two or more processed surfaces are included among a processed surface processed into a shape and a processed surface processed into an arc shape .

According to this configuration, after the conductor wire is held by the holding step, the mold is moved in the stroke direction by the molding step, and the conductor wire is formed into a plurality of shapes corresponding to the composite processed surface, and the release step after molding The conductor wire is released by. Since the conductor wire is formed in a plurality of shapes in one forming step, the number of steps can be reduced and the processing time can be shortened. As the number of processes is reduced, the number of times of changing the conductor wire is also reduced, so that the pitch accuracy can be improved. Also, a plurality of shapes corresponding to the coil end portions are formed on the conductor wire in one stroke.

According to the ninth aspect of the invention, the conductor wire is processed and processed into a plurality of different non-linear shapes which are different from the slot accommodating portion accommodated in the slot of the stator core and the portion protruding from the axial end surface of the stator core. Two or more of a machining surface processed into the shape of the slot housing portion and a plurality of different machining surfaces processed into the shape of the coil end portion. One or more molds having a composite processed surface obtained by combining the processed surfaces, a mold moving mechanism that moves the mold in a predetermined stroke direction, and a conductor wire holding that is released after temporarily holding the conductor wire A holding step of holding the conductor wire from a direction crossing the stroke direction before the start of molding by the conductor wire holding mechanism, and a mold movement. After finishing the molding step, one or more molding steps for molding a plurality of shapes corresponding to the synthetic processing surface on the conductor wire by processing the conductor wire by moving the mold according to the structure, A release step of releasing the conductor wire held by the conductor wire holding mechanism, and a composite processed surface of the mold is processed into a shape of the slot accommodating portion, and the coil end portion A plurality of different processed surfaces to be processed into a shape of the same, and the forming step forms a plurality of shapes corresponding to the combined processed surface on the conductor wire by one stroke. And According to this configuration, since a plurality of shapes of the conductor wire are formed in one forming step, the number of steps can be reduced and the processing time can be shortened. As the number of processes is reduced, the number of times of changing the conductor wire is also reduced, so that the pitch accuracy can be improved. Further, when the mold is moved by one stroke, a plurality of shapes relating to the slot accommodating portion and the coil end portion are formed at a time. Therefore, the number of dies (equipment) can be minimized, and the cost can be reduced. Since the number of molds is reduced, there is no need to change the conductor wire, and pitch accuracy can be improved.

In a tenth aspect of the present invention, the plurality of different machining surfaces to be machined into the shape of the coil end portion are a machining surface to be machined into a staircase shape, a machining surface to be machined into a crank shape, and a machining surface to be machined into an arc shape. Among them, it includes two or more processed surfaces. According to this configuration, a plurality of shapes corresponding to the coil end portions are formed on the conductor wire in one stroke.

The invention according to claim 11 is characterized in that in the forming step, the slot accommodating portion and the coil end portion are processed in parallel. According to this configuration, part or all of the slot accommodating portion and the coil end portion are processed in parallel in the molding step, so that the processing time of the stator coil can be shortened.

It is a perspective view which shows the structural example of the shaping | molding apparatus of a stator coil. It is a perspective view which shows the 1st structural example of a metal mold | die (die | dye part). It is a perspective view which shows the structural example of a metal mold | die (punch part). It is a side view which shows the structural example of a metal mold | die (punch part). It is a top view which shows an example of a process shape. It is a perspective view which shows an example of a holding process. It is the top view and side view which show an example of a holding process. It is a perspective view which shows an example of a holding process. It is a perspective view which shows an example of a formation process (arc shape processing). It is a side view which shows an example of a formation process (arc shape processing). It is a perspective view which shows an example of a formation process (arc shape processing). It is a perspective view which shows an example of a shaping | molding process (a process of a crank shape and staircase shape). It is a side view which shows an example of a shaping | molding process (working of a crank shape and staircase shape). It is a perspective view which shows an example of a shaping | molding process (a process of a crank shape and staircase shape). It is a figure which shows the expansion area | region at the time of bending shape process, and the press part which suppresses expansion. It is a perspective view which shows an example of a formation process (bending shape process). It is a side view which shows an example of a shaping | molding process (bending shape process). It is a perspective view which shows an example of a formation process (bending shape process). It is a perspective view which shows an example of a releasing process. It is a side view which shows an example of a releasing process. It is a perspective view which shows an example of a releasing process. It is a figure which shows the example of a change of the shape of the conductor wire accompanying progress of a process. It is a perspective view which shows an example of the stator coil assembled using the conductor wire. It is a perspective view which shows an example of the stator using a stator coil. It is a perspective view which shows the 2nd structural example of a metal mold | die (die | dye part). It is a perspective view which shows an example of a holding process. It is the top view and side view which show an example of a holding process. It is a perspective view which shows an example of a holding process. It is a perspective view which shows the example of a change of the shape of the conductor wire accompanying progress of a process. It is a top view which shows the example of a change of the shape of the conductor wire accompanying progress of a process. It is a side view which shows the example of a change of the shape of the conductor wire accompanying progress of a process. It is a figure which shows the structural example of a corner | angular part processed body. It is a figure which shows the 3rd structural example of a metal mold | die (die | dye part). It is a figure which shows the state of the corner | angular part processed body at the time of a process. It is a perspective view which shows an example of a holding process. It is a perspective view which shows an example of a formation process (arc shape processing). It is a perspective view which shows the progress in the middle of a shaping | molding process (a process of a crank shape, step shape, and bending shape process). It is a perspective view which shows the time of completion of a formation process. It is a perspective view which shows an example of a releasing process. It is a top view which shows an example of a holding process. It is a top view which shows an example of a formation process (arc shape processing). It is a top view which shows the progress in the middle of a formation process (a process of a crank shape, a staircase shape, and a bending shape process). It is a top view which shows the time of completion of a formation process. It is a top view which shows an example of a releasing process.

  Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. Each figure shows elements necessary for explaining the present invention, and does not show all actual elements. When referring to directions such as up, down, left and right, the description in the drawings is used as a reference.

[Embodiment 1]
The first embodiment is an example in which a stator coil is formed by processing a conductor wire having a predetermined length, and will be described with reference to FIGS. Note that a drive source for operating a predetermined element (for example, a punch portion or a bent portion) is not shown. As the drive source, for example, an electric motor (motor), a cylinder, or the like can be used, and includes a power transmission mechanism (for example, a cam, a rack and pinion, a gear (gear), or the like) that transmits generated power.

  FIG. 1 is a perspective view showing a configuration example of a stator coil molding apparatus (hereinafter simply referred to as a “molding apparatus”). The molding apparatus 10 includes a base 11, a conductor wire holding mechanism 20, a mold 30, a mold moving mechanism 40, a bending portion 50, and the like. The processing conductor wire Cw may be of any material as long as it is a conductive wire, and may or may not have an insulating coating. In this embodiment, an example will be described in which processing is performed using a flat wire whose surface is covered with an insulating coating and whose cross-sectional shape is a rectangle.

  First, the configuration example shown in FIG. 1 will be briefly described, and the configuration and function of each element will be described later. On the base 11, a die part 31 and a rail 41 are provided. That is, it may be fixed using a fixing member (for example, a bolt or a screw), fixed by a fixing means (for example, welding or adhesion), or may be integrally formed as a part of the base 11. The rail 41 formed in a straight line is configured such that the moving body 42 can reciprocate. The movement of the moving body 42 may be realized by receiving power transmitted from an external driving source, or may be realized by a driving source provided in the moving body 42. The moving body 42 is provided with a punch portion 32. The conductor wire holding mechanism 20 is rotatably supported at a predetermined position of the die portion 31 (see FIG. 2).

  The conductor wire holding mechanism 20 has a function of releasing the conductor wire Cw after temporarily holding it. The conductor wire holding mechanism 20 includes a holding body 21 and a pressing portion 22. The holding body 21 is formed in a “U” shape when viewed from above, and has a portion that is rotatable with respect to the die portion 31 and two arm-shaped portions that are formed in parallel. The conductor wire Cw is held or released by using a part of the arm-shaped portion (specifically, the pressing portion 22). In order to hold and release the conductor wire Cw, the conductor wire Cw is supported so as to be rotatable around a predetermined central axis set in the die portion 31. However, it is urged by an elastic member (such as a spring or rubber) (not shown) so that the postures shown in FIGS. 1, 6, 8, 19, and 21 become the reference posture (release posture). . The pressing portion 22 has a function of pressing at least an expansion region Ex that may be generated when the conductor wire Cw is bent (see FIG. 15). The circular arc processing portion 22a provided as a part of the pressing portion 22 has a function of processing the conductor wire Cw into an arc shape (see FIGS. 4 and 11).

  The mold 30 has a function of processing the conductor wire Cw into a target shape, and includes a die portion 31, a punch portion 32, and the like. The die portion 31 and the punch portion 32 are opposed to each other so as to be processed with the conductor wire Cw interposed therebetween, and a processed surface is formed. That is, a gap corresponding to the thickness and width of the conductor wire Cw is secured between the processed surface of the die portion 31 and the processed surface of the punch portion 32. The die portion 31 will be described with reference to FIG. 2, and the punch portion 32 will be described with reference to FIGS.

  A die portion 31 shown in a perspective view in FIG. 2 has a conductor wire holding mechanism 20, a bent portion 50, and the like as well as a synthetic processing surface 31a. The composite processed surface 31a is used to process the conductor wire Cw into a plurality of shapes together with a composite processed surface 32a (see FIG. 3A) described later. The composite processed surface 31a and the composite processed surface 32a have a relationship between a convex shape and a concave shape that are processed into a plurality of shapes while ensuring a gap corresponding to the thickness and width of the conductor wire Cw. As described above, since the composite processed surface 31a and the composite processed surface 32a are opposed to each other, a specific example of the composite processed surface 31a will be described later on behalf of the composite processed surface 32a (see FIG. 3A).

  The bending portion 50 receives power transmitted from a drive source (not shown) and bends the conductor wire Cw by a predetermined angle to form a slot accommodating portion Cb. That is, the bent portion 50 has a flat surface for bending in contact with the conductor wire Cw. The bending process part 50 of this form uses a block body of a predetermined shape, and is provided rotatably on the left and right side parts (or the vicinity thereof) of the die part 31 (especially the synthetic processing surface 31a). The “predetermined angle” can be arbitrarily set as long as the tips of the stator coils after processing do not contact each other. For example, assuming that the angle of the linear conductor line Cw before processing is 0 degree, it may be set at 90 degrees (or within an allowable angle range based on 90 degrees), or set within a range of 30 to 150 degrees. May be.

  The punch portion 32 shown in FIGS. 3A and 4 has a composite processed surface 32a, a guide groove 32b, a cam 32c, and the like. 3A is a perspective view, FIG. 4A is a side view seen from the direction of arrow Da in FIG. 3A, and side view seen from the direction of arrow Db in FIG. Indicates.

  The composite processed surface 32a is a processed surface for processing the conductor wire Cw into a plurality of shapes. The plurality of shapes are an arc-shaped machining surface Sa, a crank-shaped machining surface Sb, and a staircase-shaped machining surface Sc. The arc-shaped machining surface Sa processes the conductor wire Cw into an arc shape Pa shown in FIG. The crank shape processed surface Sb processes the conductor wire Cw into a crank shape Pb shown in FIG. The staircase-shaped processed surface Sc processes the conductor line Cw into a staircase shape Pc shown in FIG. The processing by the bending processing unit 50 processes the conductor wire Cw into a bent shape Pd shown in FIG. The bent shape Pd corresponds to the “corner portion” of the slot accommodating portion Cb. Note that a surface (for example, YZ plane) that processes the arc shape Pa and the crank shape Pb is different from a surface that processes the staircase shape Pc and the bent shape Pd (for example, XY plane).

  Between the arc-shaped processed surface Sa, the crank-shaped processed surface Sb, and the staircase-shaped processed surface Sc, there is a gradually changing processed surface Sd. The gradually changing processed surface Sd is a processed surface formed such that the surface shape gradually changes so that two or more processed surfaces are smoothly connected to each other. In other words, it is a connection surface that gradually (continuously) changes between the processed surfaces.

  The guide groove 32b guides the convex portion 21d (see FIG. 2) of the holding body 21 when the conductor wire Cw is processed. The cam 32c is planarly connected to a part of the guide groove 32b. The cam 32 c first contacts the inclined surface 21 a of the holding body 21 to rotate the holding body 21. When the convex portion 21d enters the guide groove 32b, the arc processing portion 22a of the pressing portion 22 processes the conductor wire Cw into an arc shape. As the convex portion 21d moves in the guide groove 32b, the conductor wire Cw gradually forms both a crank shape and a staircase shape by the crank shape processed surface Sb, the stepped shape processed surface Sc, and the gradual change processed surface Sd. Processed.

  The conductor wire Cw is processed by the relative movement of the die portion 31 and the punch portion 32. However, since the composite processed surfaces 31a and 32a have a complicated surface shape, there is a possibility that the conductor wire Cw receives a drag force. Therefore, since the punch portion 32 moves straight so that it does not wobble during processing, the left and right side surfaces where the guide grooves 32b are formed are sandwiched by the guide portions 21c (see FIG. 2) of the conductor wire holding mechanism 20 and guided. Is done.

  Here, the combined machining surfaces 31a and 32a include the crank-shaped machining surface Sb. When processing the conductor wire Cw on the crank-shaped processed surface Sb, the insulating coating of the conductor wire Cw may be damaged depending on the thickness of the insulating coating and the radius of the crank-shaped processed surface Sb. An experiment was conducted to determine whether or not the insulation coating is damaged depending on the relationship between the thickness of the insulation coating and the radius of the crank-shaped processed surface Sb. A graph summarizing this relationship is shown in FIG.

  The curve shown in FIG. 3B represents the relationship between the thickness of the insulating coating and the radius of the crank-shaped processed surface Sb. When the insulating coating is thinner than the thickness Tb (for example, 90 [μm] or the like) or smaller than the radius Rb (for example, 13.5 [mm] or the like) of the crank-shaped processed surface Sb, the conductor line Cw is locally In particular, damage (for example, peeling of the insulation coating) occurred on the processed surface. On the other hand, when the insulating coating was not less than the thickness Tb or when the radius was not less than the radius Rb of the crank-shaped processed surface Sb, the insulating coating was not damaged. Therefore, it is desirable to use the conductor wire Cw whose insulation coating is equal to or greater than the thickness Tb, or to form the composite processed surfaces 31a and 32a with a radius Rb or greater of the crank-shaped processed surface Sb.

  A process of forming the conductor wire Cw using the forming apparatus 10 including the mold 30 of the first configuration example configured as described above will be described with reference to FIGS. 6, 9, 12, 16, and 19 are perspective views seen from the punch portion 32 side. 7A, FIG. 10A, FIG. 13A, FIG. 17A, and FIG. 20A are plan views seen from above. FIG. 7B, FIG. 10B, FIG. 13B, FIG. 17B, and FIG. 20B are side views as viewed from the right side of FIG. 8, 11, 14, 18, and 21 are perspective views seen from the die portion 31 side. FIG. 15A is a perspective view showing an example of a region that expands during bending shape processing. FIG. 15B is a plan view showing an example of a pressing portion that suppresses expansion. FIG. 22 is a plan view showing an example of the conductor wire Cw whose shape changes with the progress of processing. However, the plane (for example, YZ plane) in FIGS. 22A to 22C is different from the plane in FIG. 22D (for example, XY plane).

  The forming step (that is, continuous processing of arc shape processing, crank shape processing, staircase shape processing, and bending shape processing) may be performed in a fixed order or may be performed in two or more steps. In this embodiment, a single mold 30 is used to perform a holding process, a molding process (arc-shaped machining), a molding process (crank shape and staircase machining), a molding process (bending shape machining), and a release process in this order. Each case will be described individually. Although the moving body 42 receives power transmitted from the drive source, the punch unit 32 also moves with the movement of the moving body 42. Therefore, the following description will be made simply as the movement of the punch unit 32.

[Holding process]
The holding step is a step of holding the unprocessed conductor wire Cw before the start of molding. This will be described with reference to FIGS. 6 to 8 showing the state immediately before holding. The unprocessed conductor wire Cw is transported to a position shown in FIGS. 6 to 8 by a predetermined transport mechanism (for example, a belt conveyor, a gripping device, etc., and the same applies hereinafter). Thereafter, when the punch portion 32 moves in the processing direction (arrow D1 direction), the tip portion of the cam 32c comes into contact with the inclined surface 21a of the holding body 21. This machining direction corresponds to the “stroke direction”. As the punch part 32 continues to move, the holding body 21 is pushed along the inclination of the cam 32c and rotates in the holding direction (arrow D2 direction). Since the holding direction is different from the machining direction, it corresponds to a “direction intersecting the stroke direction”. When the holding body 21 rotates in the holding direction in this way, the arc processing portion 22a shown in FIG. 7B presses and holds the conductor wire Cw against the die portion 31.

[Molding process (arc shape processing)]
The forming step (arc shape processing) is a step of processing the conductor wire Cw held in the holding step into an arc shape. This will be described with reference to FIGS. 9 to 11 and FIG. 22 (A) showing the state after being processed into an arc shape. As the punch portion 32 continues to move further in the processing direction (arrow D1 direction), the holding body 21 also continues to rotate in the holding direction (arrow D2 direction). In this state, the conductor wire Cw held by the arc processing portion 22a further passes the arc-shaped processing surface Sa (FIG. 3 (A) or FIG. 4 (A)) of the die 30 (that is, the die portion 31 and the punch portion 32). To be pressed). By this pressing, the conductor line Cw is processed into an arc shape along the arc-shaped processing surface Sa. FIG. 22A shows an example of a conductor line Cw having an arc shape Pa.

[Molding process (crank shape processing, staircase shape processing)]
The forming step (crank shape processing, staircase shape processing) is a step of further processing the conductor wire Cw having the arc shape Pa by adding a crank shape and a staircase shape. This will be described together with the changes from FIG. 9 to FIG. 11 to FIG. As described above, FIGS. 9 to 11 show the state of the conductor line Cw processed into an arc shape. If the punch portion 32 continues to move further in the processing direction (arrow D1 direction) from this state, the cam 32c stops against the inclined surface 21b of the holding body 21, or the convex portion 21d of the holding body 21 (see FIG. 2). (See) hits the end face of the guide groove 32b and stops. Since the convex portion 21d moves while being guided by the guide groove 32b during the movement of the punch portion 32, the drag from the conductor wire Cw accompanying the deformation can be suppressed to prevent wobble.

  As shown in FIG. 3 (A) and FIG. 4 (A), the mold 30 has a gradually changing processed surface Sd between the arc-shaped processed surface Sa and the crank-shaped processed surface Sb and the stepped processed surface Sc. Is formed. The shape of the conductor wire Cw gradually changes along the gradually changing processed surface Sd. When the conductor line Cw is pressed against the crank-shaped processed surface Sb, the conductor line Cw is processed into the shape of the conductor line Cw shown in FIG. That is, it has a shape having a crank shape Pb in addition to the arc shape Pa in FIG. When the conductor line Cw is pressed against the staircase-shaped processed surface Sc, the conductor line Cw is processed into the shape of the conductor line Cw shown in FIGS. 22 (C) and 22 (D). That is, in addition to the arc shape Pa and the crank shape Pb, the shape further has a staircase shape Pc.

[Molding process (bending shape processing)]
The forming step (bending shape processing) is a step of bending the conductor wire Cw to a predetermined angle, and will be described with reference to FIGS. 15 to 18 together with FIGS. When the process of bending the rectangular conductor wire Cw from the straight line (two-dot chain line) to the bent state (solid line) is performed, the expansion region Ex shown by the hatched hatch in FIG. 15A expands. This is because a compressive stress acts on the inner diameter side of the conductor wire Cw and a tensile stress acts on the outer diameter side during bending. Therefore, a pressing portion 22 is formed on the holding body 21 so as to press the conductor wire Cw in at least a wide range of the expansion region Ex (see FIG. 1).

  With respect to the conductor wire Cw in which the arc shape Pa, the crank shape Pb, and the staircase shape Pc are processed, the pair of bending portions 50 are rotated in the bending direction by receiving power transmitted from the drive source. As shown in FIGS. 12-14, one bending process part 50 rotates in a 1st bending direction (arrow D3 direction), and the other bending process part 50 rotates in a 2nd bending direction (arrow D4 direction). Bending is performed. In the bending process, the pressing portion 22 presses the conductor wire Cw with a flat surface, so that it can be bent at a predetermined angle while suppressing expansion. Thus, a conductor line Cw further having a bent shape Pd is shown in FIG.

[Release process]
The releasing step is a step of releasing the conductor wire Cw processed into the target shape by the forming step. This will be described together with the changes from FIGS. 16 to 18 to FIGS. As described above, the state shown in FIGS. 16 to 18 holds the conductor wire Cw in which the arc shape Pa, the crank shape Pb, the step shape Pc, and the bent shape Pd are processed. From this state, the punch part 32 and the pair of bending parts 50 are each operated in the retracting direction. That is, the punch portion 32 is moved in the direction of arrow D5, one bending portion 50 is rotated in the direction of arrow D7, and the other bending portion 50 is rotated in the direction of arrow D8. When the cam 32c and the holding body 21 are separated with the movement of the punch portion 32, the holding body 21 receives a drag force from an elastic member (not shown) and rotates in the release direction (arrow D6 direction). When the arcuate part 22a is separated from the conductor line Cw, the holding of the conductor line Cw is released. The state in which the conductor line Cw is released in this way is shown in FIGS. Since the released conductor line Cw is formed into a predetermined shape, it is transported by a predetermined transport mechanism.

  In the holding step and the releasing step described above, when the cam 32c comes into contact with the holding body 21 (particularly the inclined surface 21a) with the movement of the punch portion 32, it operates to hold the conductor wire Cw (FIGS. 6 to 6). 8), when the cam 32c moves away from the holding body 21, it operates to release the conductor wire Cw (see FIGS. 16 to 18). According to these operations, the cam 32c, the holding body 21 and the like correspond to the “interlocking mechanism”.

  The conductor wire Cw processed by the holding process, the forming process, and the releasing process described above includes a coil end portion Ca and a slot accommodating portion Cb as shown in FIG. When a plurality of conductor wires Cw formed in this way are used to assemble the slot accommodating portion Cb into the slot 202 of the stator core 201, the stator coil 200 shown in a perspective view in FIG. 23 can be configured. Furthermore, when the conductor wires Cw are connected to each other and the terminals 301 to 303 are connected to the end portions, the stator 300 shown in a perspective view in FIG. 24 can be manufactured.

According to the first embodiment described above, the following effects can be obtained .
(1) In the molding apparatus 10, a machining surface (bending portion 50) to be machined into the shape of the slot accommodating portion Cb and a plurality of different machining surfaces (arc-shaped machining surface Sa, crank) to be machined into the shape of the coil end portion Ca. Among the shape processing surface Sb and the staircase shape processing surface Sc), the mold 30 having the composite processing surfaces 31a and 32a obtained by synthesizing two or more processing surfaces, and the mold 30 in a predetermined stroke direction (processing direction and retraction) And moving the mold 30 by the mold moving mechanism 40 to process the conductor wire Cw, a plurality of conductor wires Cw corresponding to the composite processed surfaces 31a and 32a. (Arc shape Pa, crank shape Pb, staircase shape Pc, bent shape Pd) is formed (see FIGS. 1 to 3 and 22). According to this configuration, when the mold 30 is moved by one stroke, a plurality of shapes (see FIG. 22D) corresponding to the composite processed surfaces 31a and 32a are formed on the conductor wire Cw. Therefore, the number of molds 30 (equipment number) required as a whole can be reduced, and the cost can be reduced. Since the number of molds 30 is reduced, the number of times of changing the conductor wire Cw is reduced, and the pitch accuracy can be improved.

(2) A conductor wire holding mechanism 20 that temporarily holds the conductor wire Cw and then releases the conductor wire Cw is provided, and the conductor wire holding mechanism 20 (particularly the holding body 21) intersects the stroke direction before the start of molding (FIGS. 6 to 6). The configuration in which the conductor wire Cw is held from the direction of the arrow D2 shown in FIG. 8 and the conductor wire Cw is released by rotating in the release direction (the direction of arrow D6 shown in FIGS. 16 to 18) after the molding by the mold 30 is finished. (See FIGS. 6 to 8 and FIGS. 16 to 18). According to this configuration, since the operation direction is different, such as the moving direction of the mold 30 and the rotation direction of the holding body 21, the mold 30 and the holding body 21 do not interfere with each other. Therefore, not only can the conductor wire Cw be held and released reliably, but also the conductor wire Cw can be reliably prevented from being damaged due to interference.

(3) The structure includes an interlocking mechanism (such as the cam 32c and the holding body 21) that interlocks the movement of the mold 30 by the mold moving mechanism 40 and the holding and releasing by the conductor wire holding mechanism 20 (FIGS. 6 to 8). FIG. 16 to FIG. 18). According to this configuration, the power generated with the movement of the mold 30 is transmitted to the conductor wire holding mechanism 20 to hold and release the conductor wire Cw, so that a drive source for operating the conductor wire holding mechanism 20 is provided. It becomes unnecessary. Therefore, the cost can be further reduced.

(4) The interlocking mechanism includes a cam 32c (see FIGS. 6 to 8 and FIGS. 16 to 18). According to this configuration, the power generated with the movement of the mold 30 is reliably transmitted to the conductor wire holding mechanism 20 by the cam 32c, so that the conductor wire Cw can be reliably held and released with a simple configuration. it can.

(5) When processing into the shape of the slot accommodating portion Cb, the corner portion of the slot accommodating portion Cb is configured to include a pressing portion 22 that presses at least including an expansion region Ex that can expand with processing (FIG. 1). See). According to this configuration, it is possible to prevent the pressing portion 22 from expanding when the conductor wire Cw is bent, and to reduce the difference in bending stress distribution. Therefore, it is possible to suppress the spring back accompanying the bending process and improve the processing accuracy (bending accuracy).

(6) The composite processed surfaces 31a and 32a of the mold 30 have a gradually changing processed surface Sd whose surface shape gradually changes so that the processed surfaces are smoothly connected to each other between the processed surfaces having different shapes. The configuration was adopted (see FIGS. 3A and 4). According to this configuration, as the mold 30 moves, the conductor wire Cw is gradually deformed according to the gradual change processed surface Sd, so that excessive stress is not generated and the target processed shape can be surely finished. . In addition, since the load necessary for processing each shape can be dispersed, apparatus parts with low rigidity can be applied, and the apparatus cost can be kept low.

(7) A plurality of different machining surfaces to be machined into the shape of the coil end portion Ca include a step-like machining surface Sc to be machined into a staircase shape, a crank-shaped machining surface Sb to be machined into a crank shape, and an arc shape machining to be machined into an arc shape. The configuration includes the surface Sa (see FIGS. 3A and 4). According to this structure, the synthetic | combination process surfaces 31a and 32a of the metal mold | die 30 include the process surface for processing the coil end part Ca. Therefore, a plurality of shapes corresponding to the coil end portion Ca (that is, the arc shape Pa, the crank shape Pb, and the step shape Pc shown in FIGS. 5 and 22) are formed on the conductor wire Cw in one stroke.

(8) In the stator coil forming method, the conductor 10 is used to form the conductor wire Cw from the direction (arrow D2 direction shown in FIGS. 6 to 8) intersecting the stroke direction before the start of molding by the conductor wire holding mechanism 20. A holding step of holding and a forming step of forming a plurality of shapes corresponding to the composite processed surfaces 31a and 32a on the conductor wire Cw by processing the conductor wire Cw by moving the die 30 by the die moving mechanism 40. (Continuous machining of arc shape machining, crank shape machining, staircase shape machining, and bending shape machining) and the conductor wire Cw held by the conductor wire holding mechanism 20 after finishing the molding process is released (see FIGS. 16 to 18). And a release step of releasing by rotating in the direction of arrow D6 (see FIGS. 6 to 22). According to this configuration, since the conductor wire Cw is formed in a plurality of shapes in one forming step, the number of steps can be reduced and the processing time can be shortened. As the number of processes is reduced, the number of times of changing the conductor wire Cw is also reduced, so that the pitch accuracy can be improved.

(9) The composite processed surfaces 31a and 32a of the mold 30 are obtained by combining all of the processed surfaces processed into the shape of the slot accommodating portion Cb and a plurality of different processed surfaces processed into the shape of the coil end portion Ca. (See FIG. 3A and FIG. 4), the forming process is configured to form a plurality of shapes corresponding to the composite processed surfaces 31a and 32a on the conductor wire Cw by one stroke (FIGS. 6 to 22). See). According to this configuration, when the mold 30 is moved by one stroke, a plurality of shapes relating to the slot accommodating portion Cb and the coil end portion Ca are formed at a time. Therefore, the number of molds 30 (equipment number) can be minimized, and the cost can be reduced. Since the number of molds 30 is reduced, there is no need to change the conductor wire Cw, and the pitch accuracy can be improved.

[Embodiment 2]
The second embodiment is an example in which a stator coil is formed in the same manner as in the first embodiment described above, and is an example in which a corner portion is processed into the shape of a slot accommodating portion. The second embodiment will be described with reference to FIGS. 25 to 32 and FIGS. 9 to 14. In the first embodiment described above, the slot accommodating portion Cb is processed after finishing the processing of the coil end portion Ca, whereas in the second embodiment, the processing of the coil end portion Ca and the processing of the slot accommodating portion Cb are performed in parallel. Do it.

  FIG. 25 is a perspective view showing a second configuration example of the mold (die part), which is used instead of the first configuration example shown in FIG. A die portion 31 shown in FIG. 25 includes a corner processing convex portion 21f and a corner processing concave portion 31b in addition to the first configuration example of the mold of FIG. The corner processing convex portion 21f corresponding to the “engaging portion” and the corner processing concave portion 31b corresponding to the “engaged portion” constitute a “corner processing portion”. Specifically, the pressing portion 22 and the composite processed surface 31a are respectively provided on the opposing surfaces. That is, the corner processing convex portion 21f is provided on the lower surface side of the pressing portion 22, and the corner processing concave portion 31b is provided on the synthetic processing surface 31a. The corner processing convex portion 21f and the corner processing concave portion 31b are formed in a corresponding concave-convex relationship shape. However, after the corner processing convex portion 21f enters the corner processing concave portion 31b, a predetermined gap is formed between the lower surface of the pressing portion 22 and the surface of the synthetic processing surface 31a. The predetermined gap is preferably substantially the same as the thickness of the conductor wire Cw in order to press the expansion region Ex shown in FIG. Note that “substantially the same as the thickness” is not limited to the same thickness, but includes an allowable thickness of about ± several percent associated with expansion of the expansion region Ex in the stator coil after processing.

  The three-dimensional shape of the corner processing convex portion 21f and the corner processing concave portion 31b is arbitrary as long as it can be processed into the bent shape Pd at a predetermined position of the conductor wire Cw. For example, although it is formed in a rectangular parallelepiped shape in the configuration example of FIG. 25, it may be formed in a cubic shape or other three-dimensional shape. For example, if the example of FIG. 25 is an I-shape, the other three-dimensional shape corresponds to a rectangular parallelepiped such as an L shape or a polyhedron of tetrahedron or more. Although not shown, the corner processing convex portion 21f and the corner processing concave portion 31b may be configured in the opposite form. That is, the corner processing convex portion 21f is formed in a concave shape, and the corner processing concave portion 31b is formed in a convex shape. In addition, when the rigidity of the corner processing convex portion 21f exceeds the rigidity necessary for processing (formation of the slot accommodating portion Cb), the formation of the corner processing concave portion 31b performed on the die portion 31 may be omitted. In this case, the die portion 31 has the same shape as that shown in FIG.

  The shape of the composite processed surface 32a is the same as that of the first embodiment described above. For this reason, a point to be processed into an arc shape Pa shown in FIGS. 29 (A), 30 (A), and 31 (A), which will be described later, and FIGS. 29 (B), 30 (B), and 31 (B). This is also the same as processing into the crank shape Pb shown. On the other hand, in this embodiment, from FIG. 29 (B), FIG. 30 (B), and FIG. 31 (B) to FIG. 29 (C), FIG. 30 (C), and FIG. As shown in FIGS. 29D, 30D, and 31D, the crank shape Pb, the staircase shape Pc, and the bent shape Pd are processed in parallel with the first embodiment. Is different. According to the specifications of the forming apparatus 10 and the required accuracy of the conductor wire Cw, the “parallel” may be performed in parallel for each processing of the crank shape Pb, the staircase shape Pc, and the bent shape Pd. Some may be parallel. In this embodiment, after the processing of the bent shape Pd starts, the processing of the crank shape Pb and the staircase shape Pc is further performed in parallel.

  When processing the crank shape Pb, the staircase shape Pc, and the bent shape Pd in parallel, the corner processing convex portion 21f and the corner processing concave portion 31b are engaged before the bending shape Pd is processed. In the molding process, when the process proceeds to the formation of the crank shape Pb, the conductor wire Cw has a shape as shown in FIGS. 29B, 30B, and 31B. In Embodiment 1, since there is no member that forms the corner of the bent shape Pd, the bent shape Pd is formed after the crank shape Pb and the staircase shape Pc are formed. In this embodiment, since there is a corner processing convex portion 21f that forms a corner portion of the bent shape Pd, the movement of the punch portion 32 (see the change from FIG. 11 to FIG. 12) and the operation of the bending processing portion 50 (FIG. 14). To FIG. 16). That is, the crank shape Pb and the staircase shape Pc are formed by the movement of the punch portion 32, and the bent shape Pd is formed by the operation of the bending portion 50.

  FIG. 26 to FIG. 31 and FIG. 31 illustrate the process of forming the conductor wire Cw using the molding apparatus 10 including the mold 30 of the second configuration example configured as described above (that is, the holding process, the molding process, and the releasing process). This will be described with reference to FIGS. 9 to 14 and FIGS. 19 to 21.

[Holding process]
The holding process will be described with reference to FIGS. The unprocessed conductor line Cw is transported to a position shown in FIGS. 26 to 28 by a predetermined transport mechanism. Thereafter, when the punch portion 32 moves in the machining direction (the direction of the arrow D1 in FIG. 1 and the like), the tip of the cam 32c comes into contact with the inclined surface 21a of the holding body 21, and the holding body 21 moves along the inclination of the cam 32c. It is pushed and rotates in the holding direction (the direction of arrow D2 in FIG. 1 and the like). When the holding body 21 rotates in the holding direction in this way, the arc processing portion 22a shown in FIG. 27B presses and holds the conductor wire Cw against the die portion 31. The shape (unprocessed shape) of the conductor wire Cw in the state held in this way is shown in FIGS. 29 (A), 30 (A), and 31 (A).

[Molding process (arc shape processing)]
The forming step (arc shape processing) will be described with reference to FIGS. As the punch portion 32 continues to move further in the processing direction, the holding body 21 also continues to rotate in the holding direction, and the corner processing convex portion 21f of the holding body 21 is engaged with the corner processing concave portion 31b of the die portion 31. Match. The conductor wire Cw held by the arc machining portion 22a is further held while the arc-shaped machining surface Sa (FIG. 3 (A) and FIG. 4 (A)) of the die 30 (that is, the die portion 31 and the punch portion 32). To be pressed). By this pressing, the conductor line Cw is processed into an arc shape along the arc-shaped processing surface Sa. An example of the conductor line Cw having the arc shape Pa processed in this way is shown in FIGS. 29 (B), 30 (B), and 31 (B).

[Molding process (crank shape processing, staircase shape processing, bending shape processing)]
The forming step (crank shape processing, staircase shape processing, bent shape processing) is a step of further processing the crank shape Pb, the staircase shape Pc, and the bent shape Pd in parallel. As shown in FIGS. 12 to 14, in order for the bending portion 50 to bend the conductor wire Cw at the predetermined angle, one bending portion 50 is rotated in the direction of arrow D3, and the other bending portion 50 is moved to arrow D4. Rotate in the direction. The bending shape Pd starts to be processed with the start of the operation of the bending portion 50, and the crank portion Pb and the staircase shape Pc are processed in parallel as the punch portion 32 continues to move further in the processing direction. An example of the conductor line Cw in the middle of processing is shown in FIGS. 29 (C), 30 (C), and 31 (C). When the conductor line Cw is finally pressed against the staircase-shaped machining surface Sc, the operation of the bending portion 50 and the movement of the punch portion 32 are finished. An example of the conductor wire Cw having the arc shape Pa, the crank shape Pb, the staircase shape Pc, and the bent shape Pd processed in this way is shown in FIGS. 29 (D), 30 (D), and 31 (D).

[Release process]
The release process is performed in the same manner as in the first embodiment. That is, the punch portion 32 is moved in the retracting direction (the arrow D5 direction shown in FIG. 16 and the like), the one bending portion 50 is rotated in the arrow D7 direction, and the other bending portion 50 is rotated in the arrow D8 direction. In this process, the corner machining projection 21f is separated from the corner machining recess 31b and the arc machining portion 22a is separated from the conductor wire Cw. The state of the conductor wire Cw from which the holding has been released is shown in FIGS. Since the released conductor line Cw is formed into a predetermined shape (target shape), it is transported by a predetermined transport mechanism.

According to the second embodiment described above, the following effects can be obtained .

(10) A structure having a corner processing convex portion 21f and a corner processing concave portion 31b (corner processing portion) for processing to bend the corner portion of the slot storage portion Cb to a predetermined angle when processing into the shape of the slot storage portion Cb. (See FIGS. 25 to 28). According to this configuration, the corner portion of the conductor wire Cw is bent to a predetermined angle by the corner processing convex portion 21f, and the bent shape Pd (shown in FIG. 29D, FIG. 30D, and FIG. 31D is shown. Corners) are formed.

(11) The forming step is configured to process the slot accommodating portion Cb and the coil end portion Ca in parallel. Specifically, the crank shape Pb, the staircase shape Pc, and the bent shape Pd are processed in parallel (see FIGS. 29 to 31). According to this configuration, part or all of the slot accommodating portion Cb and the coil end portion Ca are processed in parallel in the forming step, so that the processing time of the stator coil 200 can be shortened.

[Embodiment 3]
The third embodiment is an example in which a part of the molding process is performed in parallel as in the second embodiment. The third embodiment will be described with reference to FIGS. In the second embodiment described above, the corner processing convex portion 21f and the corner processing concave portion 31b are provided as the corner processing portion, whereas in the third embodiment, the corner processing body is configured as a corner processing portion. Element. In addition, in order to make it easy to see, illustration of the holding body 21 which operates without interfering with the corner processed body 23 is omitted in FIG.

  A configuration example of the corner processed body 23 will be described with reference to FIG. 32A and 32B are front views, and FIG. 32C is a side view as viewed from the right side of FIG. 32B. The corner processed body 23 shown in these drawings has a stepped portion 23a, a convex portion 23b, and the like. The step portion 23 a is a part that avoids interference of the holding body 21. The convex portion 23b is formed in a shape that can be engaged with the corner processing concave portion 31b, and corresponds to an “engaging portion” used in place of the corner processing convex portion 21f shown in the second embodiment. The corner part processed body 23 shown in FIG. 32 (A) and the corner part processed body 23 shown in FIG. 32 (B) may be formed integrally or separately. A workpiece moving mechanism (not shown) is configured to be movable in the vertical direction of the drawing.

  The 3rd structural example of the metal mold | die 30 containing the corner | angular part processed body 23 is demonstrated referring FIG. 33 and FIG. FIGS. 33A and 34A are front views, and FIG. 33B and FIG. 34B are side views. In FIG. 33, the corner | angular part processed body 23 of the non-processing position (retracted position) which does not process the corner | angular part of the slot accommodating part Cb is shown. At the non-processing position, the corner processed body 23 does not contact the conductor wire Cw, so that the conductor wire Cw can be transported (carrying in and out) by the transport mechanism. In FIG. 34, the corner | angular part processed body 23 of the processing position which processes the corner | angular part of the slot accommodating part Cb is shown. Since the convex part 23b of the corner processed body 23 engages with the corner processed concave part 31b, the corner processed convex part 21f in the second embodiment is in the same state as engaged with the corner processed concave part 31b. Therefore, the corner portion of the slot accommodating portion Cb can be processed in the state shown in FIG. 34 to form the bent shape Pd.

  Regarding the process of forming the conductor wire Cw using the molding apparatus 10 including the mold 30 of the third configuration example configured as described above (that is, the holding process, the molding process, and the releasing process), refer to FIGS. While explaining. 35 to 39 are perspective views, and FIGS. 40 to 44 are plan views. In each of these drawings, elements necessary for processing using the corner processed body 23 are described for easy understanding.

[Holding process]
The holding process will be described with reference to FIGS. The unprocessed conductor line Cw is transported to a position shown in FIGS. 35 and 40 by a predetermined transport mechanism. Thereafter, when the punch portion 32 moves in the machining direction (the direction of the arrow D1 in FIG. 1 and the like), the tip of the cam 32c comes into contact with the inclined surface 21a of the holding body 21, and the holding body 21 moves along the inclination of the cam 32c. It is pushed and rotates in the holding direction (the direction of arrow D2 in FIG. 1 and the like). When the holding body 21 rotates in the holding direction in this way, the arc processing portion 22a shown in FIG. 27B presses and holds the conductor wire Cw against the die portion 31. The shape (unprocessed shape) of the conductor wire Cw in the state of being held in this way is the same as in FIGS. 29A, 30A, and 31A in the second embodiment.

[Molding process (arc shape processing)]
The forming step (arc shape processing) will be described with reference to FIGS. When the punch portion 32 continues to move further in the processing direction, the holding body 21 also continues to rotate in the holding direction, and the convex portion 23b of the corner portion processed body 23 engages with the corner portion processing concave portion 31b of the die portion 31. To do. The conductor wire Cw held by the arc machining portion 22a is further held while the arc-shaped machining surface Sa (FIG. 3 (A) and FIG. 4 (A)) of the die 30 (that is, the die portion 31 and the punch portion 32). To be pressed). By this pressing, the conductor line Cw is processed into an arc shape along the arc-shaped processing surface Sa. An example of the conductor line Cw having the arc shape Pa processed in this way is shown in FIGS.

[Molding process (crank shape processing, staircase shape processing, bending shape processing)]
The forming step (crank shape processing, staircase shape processing, bent shape processing) is a step of further processing the crank shape Pb, the staircase shape Pc, and the bent shape Pd in parallel. In order for the bent portion 50 to bend the conductor wire Cw at the predetermined angle, as shown in FIGS. 37 and 42, one bent portion 50 is rotated in the direction of arrow D3, and the other bent portion 50 is moved to arrow D4. Rotate in the direction. The bending shape Pd starts to be processed with the start of the operation of the bending portion 50, and the crank portion Pb and the staircase shape Pc are processed in parallel as the punch portion 32 continues to move further in the processing direction. 37 and 42 show an example of the conductor line Cw in the middle of processing. When the conductor line Cw is finally pressed against the staircase-shaped machining surface Sc, the operation of the bending portion 50 and the movement of the punch portion 32 are finished. An example of the conductor wire Cw having the arc shape Pa, the crank shape Pb, the staircase shape Pc, and the bent shape Pd processed in this way is shown in FIGS.

[Release process]
The release process is performed in the same manner as in the second embodiment. That is, the punch portion 32 is moved in the retracting direction (the direction of arrow D5 shown in FIG. 16 and the like), and one bending portion 50 is rotated in the direction of arrow D7 as shown in FIGS. 50 is rotated in the direction of arrow D8. In this process, the convex portion 23b of the corner portion processed body 23 is detached from the corner portion concave portion 31b, and the circular arc portion 22a is separated from the conductor wire Cw. FIGS. 39 and 44 show the state of the conductor wire Cw from which the holding has been released. Since the released conductor line Cw is formed into a predetermined shape (target shape), it is transported by a predetermined transport mechanism.

According to Embodiment 3 described above, the following effects can be obtained .

(12) When processing into the shape of the slot accommodating portion Cb, the corner processed body 23 (particularly the convex portion 23b) and the corner processed concave portion 31b (corner portion processing) for performing processing to bend the corner portion of the slot accommodating portion Cb to a predetermined angle. Part) (see FIGS. 32 to 34). According to this configuration, the corner portion of the conductor wire Cw is bent at a predetermined angle by the corner processed body 23, and a bent shape Pd (corner portion) shown in FIGS. 39 and 44 is formed.

(13) The forming step is configured to process the slot accommodating portion Cb and the coil end portion Ca in parallel. Specifically, the crank shape Pb, the staircase shape Pc, and the bent shape Pd are processed in parallel (see FIGS. 36 to 44). According to this configuration, part or all of the slot accommodating portion Cb and the coil end portion Ca are processed in parallel in the forming step, so that the processing time of the stator coil 200 can be shortened.

[Other Embodiments]
Although the form for implementing this invention was demonstrated according to Embodiment 1-3 in the above, this invention is not limited to the said form at all. In other words, various forms can be implemented without departing from the scope of the present invention. For example, the following forms may be realized.

In the first to third embodiments described above, the mold moving mechanism 40 is moved by the power transmitted from the drive source, and the conductor wire Cw is held by the conductor wire holding mechanism 20 by an interlocking mechanism (such as the cam 32c and the holding body 21). And release (see FIGS. 6 to 8 and FIGS. 16 to 18). Instead of this configuration, the mold moving mechanism 40 and the conductor wire holding mechanism 20 may be configured to operate based on power transmitted from separate drive sources. According to this arrangement, even if the power caused by the movement of the mold 30 does not occur, it can be reliably held and releasing of the conductor wires Cw.

  In the above-described first to third embodiments, the synthetic processing surfaces 31a and 32a formed on the die 30 (the die portion 31 and the punch portion 32) include an arc-shaped processing surface Sa, a crank-shaped processing surface Sb, and a staircase-shaped processing surface. It was comprised by the processed surface which synthesize | combines Sc (refer FIG. 3 (A) and FIG. 4). Instead of this form, among the arc-shaped machining surface Sa, the crank-shaped machining surface Sb, the staircase-shaped machining surface Sc, and other machining surfaces (for example, a polygonal machining surface that is machined into a polygonal shape such as a triangle), You may comprise the process surface which synthesize | combines the 2 or more process surfaces selected arbitrarily. The composite processed surfaces 31a and 32a can be formed in accordance with the target shape, and the same effects as those of the first to third embodiments can be obtained.

  In the first to third embodiments described above, the conductor wire Cw is processed with one mold 30 (see FIG. 1 and the like). Instead of this form, the conductor wire Cw may be processed with two or more molds 30. In the example constituted by the second mold 30 (the first mold and the second mold), the combined machining surface of the first mold is composed of the arc-shaped machining surface Sa and the crank-shaped machining surface Sb, and the second mold. What is necessary is just to synthesize | combine the step-shaped process surface Sc and the bending-shaped process surface as the composite process surface of a type | mold. Although the processing plane performed by the first mold is different from the processing plane performed by the second mold, each mold can be processed in the same plane, so that the combined processing surface can be simplified and the operation can be simplified. . The same applies to the case of three or more molds. In any configuration, since a plurality of shapes can be formed with a single mold by the composite processed surfaces 31a and 32a, the same effects as those of the first to third embodiments can be obtained.

  In the first to third embodiments described above, the conductor wire Cw that is insulation-coated on the rectangular wire is applied. Instead of this form, a conductor wire Cw having a shape other than a rectangular wire (for example, a circular wire having a circular cross-sectional shape or a ridged wire having a plurality of fine wires), a conductor wire Cw that is not covered with insulation, or the like The same applies to. Since the object to be processed is merely different, the same effects as those of the first to third embodiments can be obtained.

  In the second and third embodiments described above, the die portion 31 is provided with the corner processing concave portion 31b, and the corner processing convex portion 21f or the convex portion 23b of the corner processing body 23 is engaged (FIGS. 25 and 25). 34). Instead of this form, the guide portion 21c (particularly the lower surface) of the holding body 21 may be provided with a concave portion similar to the corner processing concave portion 31b and a convex portion that can be engaged with the concave portion. The said recessed part and convex part are corresponded to a "corner part processed part." A convex part is good also as a structure with which the synthetic | combination process surface 31a is equipped, and it has a columnar body (for example, convex part 23b of the corner | angular part processed body 23, and a through-hole (hole which penetrated the corner | angular part process recessed part 31b) provided in the die part 31) An equivalent member) may be moved so as to protrude from the composite processed surface 31a. In any case, the corner portion of the slot accommodating portion Cb can be processed by forming the concave portion and the convex portion to be engaged, and the bent shape Pd can be formed in the conductor wire Cw.

DESCRIPTION OF SYMBOLS 10 Stator coil shaping apparatus 20 Conductor wire holding mechanism 21 Holding body (interlocking mechanism)
21a, 21b Inclined surface 21c Guide part 21d Convex part 21e Corner part processing convex part (corner part processing part; engagement part)
22 Pressing part 22a Arc processing part 23 Corner part processed body 23b Convex part (corner part processing part; engaging part)
30 mold 31 die part (mold)
31a, 32a Composite processing surface 31b Corner processing recess (corner processing portion; engaged portion)
32 Punch part (die)
32b Guide groove 32c Cam (interlocking mechanism)
40 Die moving mechanism 50 Bending portion Cw Conductor wire Ca Coil end portion Cb Slot accommodating portion Sa Arc-shaped machining surface Sb Crank-shaped machining surface Sc Stair-shaped machining surface Sd Gradual change machining surface

Claims (11)

The conductor wire is processed to form a slot accommodating portion that is accommodated in a slot of the stator core, and a coil end portion that is a portion protruding from the axial end surface of the stator core and is processed into a plurality of different non-linear shapes. In the stator coil forming device,
One or more gold having a composite processed surface obtained by combining two or more processed surfaces among a processed surface processed into the shape of the slot housing portion and a plurality of different processed surfaces processed into the shape of the coil end portion. Type,
A mold moving mechanism for moving the mold in a predetermined stroke direction ;
A conductor wire holding mechanism for releasing the conductor wire after temporarily holding it;
An interlocking mechanism that interlocks the movement of the mold by the mold moving mechanism and the holding and releasing by the conductor wire holding mechanism;
By processing the conductor wire by moving the mold by the mold moving mechanism, to form a plurality of shapes corresponding to the composite processing surface in the conductor wire ,
The interlocking mechanism transmits the power generated with the movement of the mold by the mold moving mechanism to the conductor wire holding mechanism,
The conductor wire holding mechanism holds the conductor wire from a direction intersecting the stroke direction before the start of molding based on the transmitted power, and after the molding by one or more molds is completed, the conductor wire The stator coil forming apparatus characterized by releasing the coil. The stator coil forming apparatus according to claim 1 , wherein the interlocking mechanism includes a cam. 3. The stator coil forming apparatus according to claim 1, wherein the mold moving mechanism and the conductor wire holding mechanism operate based on power transmitted from separate drive sources. The time of processing the shape of the slot portions of claims 1 to 3, characterized in that it comprises a pressing portion that presses at least include an inflation area to obtain bulge with the machining a corner portion of the slot portion The stator coil forming apparatus according to any one of the preceding claims. The time of processing the shape of the slot portions, according to any one of claims 1 to 4, characterized in that it comprises a corner machining portion for machining to bend the corner portion of the slot portion at a predetermined angle Stator coil forming device. The composite processed surface of the mold has a gradually changing processed surface whose surface shape gradually changes so that the processed surfaces are smoothly connected to each other between the processed surfaces having different shapes. The stator coil molding apparatus according to any one of claims 1 to 5 . The plurality of different machining surfaces to be machined into the shape of the coil end portion include two or more machining surfaces among a machining surface to be machined into a staircase shape, a machining surface to be machined into a crank shape, and a machining surface to be machined into an arc shape. The stator coil forming apparatus according to any one of claims 1 to 6 , wherein The conductor wire is processed to form a slot accommodating portion that is accommodated in a slot of the stator core, and a coil end portion that is a portion protruding from the axial end surface of the stator core and is processed into a plurality of different non-linear shapes. In the stator coil forming method,
One or more gold having a composite processed surface obtained by combining two or more processed surfaces among a processed surface processed into the shape of the slot housing portion and a plurality of different processed surfaces processed into the shape of the coil end portion. Using a molding apparatus comprising: a mold; a mold moving mechanism that moves the mold in a predetermined stroke direction; and a conductor wire holding mechanism that releases the conductor wire after temporarily holding the conductor wire,
Holding the conductor wire from the direction intersecting the stroke direction before the start of molding by the conductor wire holding mechanism;
One or more forming steps for forming a plurality of shapes corresponding to the composite processed surface on the conductor wire by processing the conductor wire by moving the die by the mold moving mechanism;
And after releasing the forming step, releasing the conductor wire held by the conductor wire holding mechanism ,
The plurality of different machining surfaces to be machined into the shape of the coil end portion include two or more machining surfaces among a machining surface to be machined into a staircase shape, a machining surface to be machined into a crank shape, and a machining surface to be machined into an arc shape. A stator coil molding method characterized by the above. The conductor wire is processed to form a slot accommodating portion that is accommodated in a slot of the stator core, and a coil end portion that is a portion protruding from the axial end surface of the stator core and is processed into a plurality of different non-linear shapes. In the stator coil forming method,
One or more gold having a composite processed surface obtained by combining two or more processed surfaces among a processed surface processed into the shape of the slot housing portion and a plurality of different processed surfaces processed into the shape of the coil end portion. Using a molding apparatus comprising: a mold; a mold moving mechanism that moves the mold in a predetermined stroke direction; and a conductor wire holding mechanism that releases the conductor wire after temporarily holding the conductor wire,
Holding the conductor wire from the direction intersecting the stroke direction before the start of molding by the conductor wire holding mechanism;
One or more forming steps for forming a plurality of shapes corresponding to the composite processed surface on the conductor wire by processing the conductor wire by moving the die by the mold moving mechanism;
And after releasing the forming step, releasing the conductor wire held by the conductor wire holding mechanism ,
The composite processed surface of the mold is a combination of all of the processed surface processed into the shape of the slot accommodating portion and a plurality of different processed surfaces processed into the shape of the coil end portion,
The forming step includes forming a plurality of shapes corresponding to the composite processed surface on the conductor wire by one stroke . The plurality of different machining surfaces to be machined into the shape of the coil end portion include two or more machining surfaces among a machining surface to be machined into a staircase shape, a machining surface to be machined into a crank shape, and a machining surface to be machined into an arc shape. The method for forming a stator coil according to claim 9 . The stator coil forming method according to any one of claims 8 to 10 , wherein in the forming step, the slot accommodating portion and the coil end portion are processed in parallel.

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