Coil forming device

Abstract

The present invention provides a coil forming device which can easily form a coil wire into a U shape without deteriorating the forming accuracy due to winding marks. A coil forming device (1) forms a coil wire (10) into a U-shape, and comprises: a coil wire holding portion (2) which winds and holds the coil wire (10); a winding drum (4) having one or more storage portions (451, 462) on its outer periphery (4a) for storing the coil wire (10) supplied from the coil wire holding portion (2); a cutting member (5) which cuts the coil wire (10) stored in the storage portions (451, 462) and wound on the winding drum (4) at a portion of the outer periphery (4a) of the winding drum (4); a pulling member (6) which pulls the coil wire (10) cut by the cutting member (5) outward in the radial direction of the winding drum (4) from a position away from the cutting member (5); and a forming portion (7) which forms the coil wire (10) pulled out by the pulling member (6) into a U-shape.

Description

Technical Field

[0001] The invention relates to a coil forming device. Background Art

[0002] Generally, a coil constituting a stator of a rotating electric machine such as a motor or a generator is obtained by forming a coil wire unwound from a bobbin and cut into a predetermined length into a predetermined shape. For example, in the case of a wave coil, after forming a coil wire of a predetermined length into a U-shaped formed body, the U-shaped formed body is folded multiple times to form a wave coil.

[0003] Sometimes, a coil is formed by bundling a plurality of coil wires into one collective conductor. As a method for forming a collective conductor, the following method is known: coil wires are unwound from a number of unwinding rollers (winding frames) corresponding to the number of coil wires constituting the collective conductor, bundled into one, and then wound onto one winding roller (for example, see Patent Document 1).

[0004] Prior art literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2007-227266

[0006] However, when a plurality of coil wires are unwound from separate winding frames to form a collective conductor, there is a problem of poor forming accuracy of the collective conductor. This is because the winding marks are different for each coil wire. Moreover, when forming a U-shaped formed body, the collective conductor must be unwound again from the winding roller on which the collective conductor is wound and cut into a specified length before being formed into a U shape. Therefore, there is a problem of complicated forming process. Such problems of winding marks of coil wires and the complexity of the forming process are also problems found when a plurality of U-shaped formed bodies of the same shape are formed using a single-wire coil wire. Summary of the invention

[0007] An object of the present invention is to provide a coil forming device capable of easily forming a coil wire into a U-shape without causing deterioration in forming accuracy due to winding marks.

[0008] (1) The coil forming device according to the present invention is a coil forming device (e.g., coil forming device 1 described below) that forms a coil wire (e.g., coil wire 10 described below) into a U-shape, and includes: a coil wire holding portion (e.g., bobbin 2 described below) that winds and holds the coil wire; and a winding drum (e.g., winding drum 4 described below) having one or more storage portions (e.g., first storage portion 4 described below) on its outer periphery (e.g., outer periphery 4a described below) for storing the coil wire supplied from the one coil wire holding portion. 51, a second storage portion 462); a cutting member (for example, a cutting member 5 described later) which cuts the coil wire stored in the storage portion and wound on the winding drum at a portion of the outer periphery of the winding drum; a pulling member (for example, a pulling member 6 described later) which pulls the coil wire cut by the cutting member outward from a position away from the cutting member toward the radially outer side of the winding drum; and a forming portion (for example, a forming portion 7 described later) which forms the coil wire pulled out by the pulling member into a U-shape.

[0009] According to the above (1), the coil wire is supplied from one coil wire holding portion and wound on the winding drum, so it can be formed into a U-shape without deteriorating the forming accuracy due to the winding mark. In addition, after the coil wire is wound around the outer circumference of the winding drum and cut, the coil wire can be easily formed into a U-shape by simply pulling it out radially outward of the winding drum.

[0010] (2) In the coil forming device described in (1), a plurality of the storage portions may be provided in the axial direction of the winding drum (for example, in the Z direction described below).

[0011] According to the above (2), the coil wire is wound around the plurality of storage portions to form a plurality of coil wires after cutting, so that the plurality of coil wires can be collectively formed into a U-shape.

[0012] (3) In the coil forming device described in (1) or (2), the storage section may have a size capable of storing the coil wire stacked a plurality of times on the winding drum.

[0013] According to the above (3), the collective conductor composed of a plurality of coil wires may be formed simply by winding the coil wires around the outer circumference of a winding bobbin.

[0014] (4) In the coil forming device described in any one of (1) to (3), the forming portion may include a pull-out passage portion (for example, a pull-out passage portion 71 described below), the pull-out passage portion extending radially outward from the winding drum to form a passage for the coil wire pulled out by the pull-out member, and the pull-out passage portion includes a pair of guide members (for example, a guide member 711 described below), the pair of guide members sandwiching the coil wire pulled out from the winding drum by the pull-out member from both sides to guide the coil wire so as to prevent the coil wire from expanding.

[0015] According to the above (4), when the coil wire is pulled out, it can be smoothly pulled out to the molding portion without expanding from the outer periphery of the winding drum.

[0016] (5) In the coil forming device described in any one of (1) to (4), the pulling-out component may be configured to pull the coil wire cut by the cutting component from the radial inner side to the outer side of the winding drum, and the forming portion may include a mold (for example, the mold 72 described later), which molds the coil wire into a U shape near the terminal end of the pulling-out direction of the pulling-out component, and the pulling-out component constitutes a part of the mold.

[0017] According to the above (5), the pull-out member for pulling out the coil wire from the outer periphery of the winding drum can be directly used to form the coil wire into a U shape by a mold. Therefore, there is no need to transfer the coil wire from the pull-out member, and the pulling and forming of the coil wire can be achieved in one step.

[0018] (6) In the coil forming device described in any one of (1) to (5), the winding drum may be configured to wind the coil wire around the outer circumference by rotating around a rotation axis (for example, a rotation axis 41 described below).

[0019] According to the above (6), the coil wire can be easily wound around the outer circumference of the winding drum only by rotating the winding drum.

[0020] Effects of the Invention

[0021] According to the present invention, it is possible to provide a coil forming device capable of easily forming a coil wire into a U-shape using a coil wire without causing deterioration in forming accuracy due to winding marks. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a front view of a U-shaped coil formed by a coil forming device.

[0023] Figure 2 It is a top view of a U-shaped coil formed by a coil forming device.

[0024] Figure 3 is along Figure 1 Cross-sectional view along line A-A in FIG.

[0025] Figure 4 It is a top view showing one embodiment of the coil forming device.

[0026] Figure 5 It is a side view showing one embodiment of the coil forming device.

[0027] Figure 6 It is a perspective view showing a correcting portion of a coil wire.

[0028] Figure 7 It is a side view showing the first outer peripheral member of the winding drum.

[0029] Figure 8 It is a perspective view showing the second outer peripheral member of the take-up drum.

[0030] Fig. 9 It is a side view showing the second outer peripheral member of the winding drum.

[0031] Fig.10 This is a diagram for explaining the coil wire guide member.

[0032] Fig.11 It is a three-dimensional diagram showing a mold.

[0033] Fig.12 This is a front view showing a portion of the coil wire after being wound around the outer circumference of the winding drum.

[0034] Fig.13 This is a side view showing the first outer peripheral member in which all the coil wires are stored in the first storage portions.

[0035] Fig.14 It is a top view of the coil forming device showing a state in which the coil wire is cut.

[0036] Fig.15 This is a diagram for explaining a case where a pull-out member is arranged inside the coil wire wound around a winding drum.

[0037] Fig.16 This is a plan view of the coil forming device showing how the coil wire wound on the winding drum is pulled out by the pulling member.

[0038] Fig.17 This is a perspective view showing a state in which a pull-out member passes between a pair of guide members.

[0039] Fig.18 It is a perspective view showing the state of convex bending by a die.

[0040] Fig.19It is a three-dimensional view showing how the shoulder is bent using a mold.

[0041] Fig. 20 It is a perspective view showing how crank bending is performed using a die.

[0042] Fig.21 This is a front view showing a state where a plurality of U-shaped coils formed by a coil forming device are arranged.

[0043] Fig. 22 It is a plan view showing a state where a plurality of U-shaped coils formed by a coil forming device are arranged.

[0044] Description of symbols

[0045] 1: Coil forming device;

[0046] 2: Winding frame (coil wire holding part);

[0047] 4: winding drum;

[0048] 4a: outer circumference (of winding drum);

[0049] 41: Rotation axis;

[0050] 451: 1st storage section;

[0051] 452: Second storage section;

[0052] 5: Cut off the parts;

[0053] 6: Pull out the parts;

[0054] 7: Forming department;

[0055] 71: Pull out the passage portion;

[0056] 711: guide component;

[0057] 72: Mould;

[0058] 10: Coil wire. DETAILED DESCRIPTION

[0059] Hereinafter, one embodiment of the coil forming device will be described in detail with reference to the drawings.

[0060] First, refer to Figure 1 to Figure 3 The coil formed by the coil forming device 1 of the present disclosure is described. The coil forming device 1 forms a U-shaped coil 20 by bending the coil wire 10 into a U-shape. The U-shaped coil 20 has a top 21 at the top, a pair of oblique portions 22, 22 extending obliquely from the top 21, a pair of shoulders 23, 23 bent at each end of the oblique portions 22, 22, and a pair of straight portions 24, 24 extending in parallel from the shoulders 23, 23.

[0061] like Figure 2 As shown, the right oblique portion 22 of the pair of oblique portions 22, 22 of the U-shaped coil 20 is inclined relative to the left oblique portion 22 and the straight portions 24, 24 in the thickness direction of the U-shaped coil 20 ( Figure 2 In the vertical direction), the U-shaped coil 20 is offset by the thickness. That is, the top 21 of the U-shaped coil 20 and the shoulder 23 on the right side are formed into a crank shape in the thickness direction, whereby only the oblique portion 22 on the right side is offset in the thickness direction.

[0062] The U-shaped coil 20 shown in this embodiment is a conductor assembly obtained by laminating a plurality of (three in this embodiment) coil wires 10 made of rectangular wires made of a conductor such as copper or aluminum. The three coil wires 10 are arranged in the width direction ( Figure 1 in the left and right direction).

[0063] like Figure 4 and Figure 5 As shown, the coil forming device 1 has: a winding frame 2 for supplying a coil wire 10; a correction section 3 for correcting the winding marks of the coil wire 10 supplied from the winding frame 2; a winding drum 4 for winding the coil wire 10; a cutting member 5 for cutting the coil wire 10 wound on the winding drum 4; a pulling member 6 for pulling the coil wire 10 outward in the radial direction of the winding drum 4; and a forming section 7 for forming the coil wire 10 into a U shape. In addition, Figure 5 In the figure, the cutting member 5 is omitted.

[0064] The bobbin 2 is a coil wire holding portion that winds and holds the coil wire 10. In the coil forming device 1, only one bobbin 2 is provided. The coil wire 10 is unwound from the one bobbin 2 and supplied to the winding drum 4.

[0065] The correction unit 3 corrects the winding trace of the coil wire 10 wound and held on the bobbin 2, and is therefore arranged on the supply path of the coil wire 10 from the bobbin 2 toward the winding drum 4. Figure 6 As shown, the correction part 3 has: a pair of introduction rollers 31, 31 for introducing the coil wire 10; a plurality of correction rollers 32; and a delivery roller 33 for delivering the coil wire 10 that has passed through the plurality of correction rollers 32 toward the winding drum 4. The plurality of correction rollers 32 apply tension to the coil wire 10 in the same radial direction as the winding frame 2 to correct the winding marks of the coil wire 10.

[0066] The winding drum 4 has: a rotating shaft 41, which is arranged in a direction (Z direction) perpendicular to the ground 100; twelve radial frame portions 42, which extend radially from the periphery of the rotating shaft 41 at equal intervals; and twelve connecting frame portions 43, which connect the adjacent radial frame portions 42, 42 near their ends.

[0067] A first peripheral member 45 is attached to each of the ends of the twelve radiating frame portions 42. The first peripheral member 45 is formed of a metal block, which is longer in the axial direction (Z direction) than in the circumferential direction (X direction) of the winding drum 4, and forms a part of the outer periphery 4a of the winding drum 4 for winding the coil wire 10.

[0068] like Figure 7 As shown, a first storage portion 451 for storing the coil wire 10 is provided on the distal end surface 45a of the first peripheral member 45 facing the radially outer side of the winding drum 4. In the first peripheral member 45 of the present embodiment, six first storage portions 451 are arranged at regular intervals along the axial direction of the winding drum 4. The six first storage portions 451 have the same structure and are composed of grooves extending along the circumferential direction of the winding drum 4. The coil wire 10 supplied from the winding frame 2 via the correcting portion 3 is stored in the first storage portions 451 of the twelve first peripheral members 45, and is thereby wound around the outer periphery 4a of the winding drum 4.

[0069] Figure 7 The solid line shows that the coil wire 10 wound on the winding drum 4 for the first round is stored in the first storage section 451 at the bottom. Figure 7 The dotted lines have a size (depth) that can stack and store three turns of the winding drum 4 in the radial direction of the winding drum 4. Therefore, the winding drum 4 of this embodiment can wind 18 turns of the coil wire 10 around the outer periphery 4a.

[0070] The second peripheral member 46 is mounted on each of the twelve connecting frame portions 43 disposed between the adjacent radiating frame portions 42, 42. Figure 8 and Fig. 9 As shown, the second peripheral member 46 is formed of a metal plate having a height substantially equal to that of the first peripheral member 45 (height along the Z direction). The second peripheral member 46 and the first peripheral member 45 together constitute a portion of the outer periphery 4a of the winding drum 4 around which the coil wire 10 is wound.

[0071] The second peripheral member 46 is mounted on the connecting frame portion 43 so as to protrude radially outward from the winding drum 4, and forms a surface substantially identical to the end surface 45a of the first peripheral member 45 on the outer periphery 4a of the winding drum 4. The end surface 46a of the second peripheral member 46 facing radially outward from the winding drum 4 is curved along the arc shape of the outer periphery 4a of the winding drum 4.

[0072] Seven cylindrical or cylindrical roller members 461 are mounted at regular intervals on the distal end surface 46a of the second outer peripheral member 46 along the axial direction of the winding drum 4. The axial direction of each roller member 461 is along the radial direction of the winding drum 4. Thus, six second storage portions 462 for storing the coil wire 10 are formed between the roller members 461, 461 adjacent in the axial direction of the winding drum 4. The positions of the six first storage portions 451 of the first outer peripheral member 45 and the positions of the six second storage portions 462 along the axial direction of the winding drum 4 are the same. Therefore, the coil wire 10 wound on the outer periphery 4a of the winding drum 4 is stored in the first storage portion 451 of the first outer peripheral member 45 and the second storage portion 462 of the second outer peripheral member 46.

[0073] Fig. 9 The solid line shows that the coil wire 10 wound on the winding drum 4 for the first round is stored in the second storage section 462 at the bottom. The second storage section 462 of this embodiment is also shown as Fig. 9 As shown by the dashed line in the middle, each has such a size (protruding height of the roller member 461) that the coil wires 10 for three turns of the winding drum 4 can be stacked and stored in the radial direction of the winding drum 4.

[0074] Figure 8 The second peripheral member 46 shown is formed into an elongated strip in the circumferential direction of the winding drum 4. Only one elongated second peripheral member 46 is arranged between adjacent first peripheral members 45, 45, and the second peripheral member 46 has two groups of seven roller members 461 arranged in the axial direction of the winding drum 4. The two groups of roller members 461 are arranged to be spaced apart in the circumferential direction of the winding drum 4. However, the number of groups of roller members 461 provided in one second peripheral member 46 can be appropriately increased or decreased according to the length of the second peripheral member 46. For example, in Figure 4 In the winding drum 4 shown, two short second peripheral members 46, 46 are respectively arranged between adjacent first peripheral members 45, 45 at the locations where the cutting member 5 and the pulling member 6 are arranged. Such a short second peripheral member 46 may have only one set of roller members 461.

[0075] The winding drum 4 can be driven by a driving motor 47 connected to the rotating shaft 41 to rotate in a direction around the rotating shaft 41. Figure 4The winding drum 4 is configured to automatically wind the coil wire 10 supplied from the winding frame 2 via the straightening unit 3 by rotating.

[0076] A plurality of pressing rollers 48 are arranged at fixed intervals in the circumferential direction of the winding drum 4 on the radially outer side of the winding drum 4. The pressing rollers 48 are rotatably arranged on an annular support stand 481 arranged on the radially outer side of the winding drum 4 in a manner that contacts the outer periphery 4a of the winding drum 4. Therefore, when the winding drum 4 rotates, the end surface 45a of the first peripheral member 45 and the pressing rollers 48 are respectively in contact and move relatively, thereby preventing the coil wire 10 from falling off from the first storage portion 451 and the second storage portion 462.

[0077] like Figure 4 As shown, a coil wire introduction member 49 for introducing the coil wire 10 into the winding drum 4 is provided on the support platform 481 corresponding to the portion where the coil wire 10 from the winding frame 2 through the correction unit 3 contacts the outer periphery 4a of the winding drum 4. Fig.10 As shown, the coil wire introduction member 49 is provided with a first support roller 492 and a second support roller 493 on a base plate portion 491 extending in the axial direction of the winding drum 4, wherein the first support roller 492 abuts against the coil wire 10 from below to support it, and the second support roller 493 abuts against the coil wire 10 from the radially outer side of the winding drum 4 to support it. Thus, the coil wire 10 supplied from the winding frame 2 via the correction unit 3 abuts against the first support roller 492 and the second support roller 493 in sequence to be supported, and is smoothly introduced into the outer periphery 4a of the winding drum 4.

[0078] The first support roller 492 and the second support roller 493 of the coil wire introduction member 49 are provided to be movable up and down by the drive of a motor (not shown) or the like relative to the base plate portion 491. The coil wire introduction member 49 operates in synchronization with the rotation of the winding drum 4 to raise the first support roller 492 and the second support roller 493. Specifically, the first storage portion 451 of the first peripheral member 45 and the second storage portion 462 of the second peripheral member 46 shown in this embodiment respectively store three turns of the coil wire 10, so that the coil wire introduction member 49 raises the first support roller 492 and the second support roller 493 by a fixed distance each time the winding drum 4 rotates three times. The fixed distance corresponds to the interval between the two first storage portions 451, 451 adjacent to each other in the axial direction of the winding drum 4 on the first peripheral member 45. Thus, the coil wire 10 wound on the winding drum 4 automatically moves to a height corresponding to the first storage section 451 and the second storage section 462 located one above each time the winding drum 4 rotates three times (each time the winding drum 4 rotates three times).

[0079] The diameter of the winding drum 4 can be appropriately set according to the length of the U-shaped coil 20 to be formed. For example, when the length of the U-shaped coil 20 is about 6m (the length of the U-shaped coil 20 when stretched straight is about 12m), the diameter of the winding drum 4 is set to about 4m. However, it is desirable that the diameter of the winding drum 4 is set to a diameter that does not exceed the elastic range of the coil wire 10. As a result, when the coil wire 10 is wound around the winding drum 4, it is difficult for the coil wire 10 to have a winding mark.

[0080] The cutting member 5 is composed of a wire cutter capable of cutting the coil wire 10, for example. Figure 4 As shown, the cutting member 5 is arranged near the coil wire introduction member 49 on the radially outer side of the winding drum 4. After the coil wire 10 is wound around the outer periphery 4a of the winding drum 4, the cutting member 5 cuts the coil wire 10 at a part of the outer periphery 4a.

[0081] The pull-out member 6 is formed of a metal block. The pull-out member 6 has a planar shape with a Figure 1 The inner surface shape of the U-shaped coil 20 shown is convex toward the radial outside of the winding drum 4. The height of the pull-out member 6 along the axial direction of the winding drum 4 is substantially equal to the height of the first peripheral member 45, and is configured to be able to pull all the coil wires 10 wound on the winding drum 4 out of the winding drum 4.

[0082] The pull-out member 6 is disposed above the winding drum 4. The pull-out member 6 is provided so as to be movable up and down and to be movable linearly in one direction along the radial direction of the winding drum 4 by the drive of a motor (not shown). Figure 5 As shown, a guide rail 61 is provided, which extends straightly from the upper side of the winding drum 4 at the position farthest from the cutting member 5 toward the radially outer side of the winding drum 4, sandwiching the winding drum 4. The guide rail 61 is arranged parallel to the ground 100 at a position higher than the winding drum 4.

[0083] The pull-out member 6 before starting the pull-out operation is arranged on the lower surface side of the end portion 61a on the guide rail 61 close to the winding drum 4. This position is a position inside the coil wire 10 wound on the outer periphery 4a of the winding drum 4. Therefore, when the pull-out member 6 is lowered, it is arranged inside the coil wire 10 wound on the winding drum 4. The pull-out member 6 moves along the guide rail 61 from this position to pull out the coil wire 10 cut by the cutting member 5 toward the radially outer side of the winding drum 4.

[0084] The forming part 7 is disposed below the guide rail 61. In detail, the forming part 7 is as follows. Figure 4 and Figure 5 As shown, it has: a pull-out passage portion 71 that constitutes a passage for the coil wire 10 pulled out from the winding drum 4 by the pull-out member 6; and a die 72 that molds the pulled-out coil wire 10 into a U-shape.

[0085] The pull-out passage 71 is formed in a long tray shape extending from the outer periphery 4a of the winding drum 4 along the guide rail 61 toward the radially outer side of the winding drum 4. The pull-out passage 71 supports the lower side of the coil wire 10 pulled out from the winding drum 4 by the pull-out member 6.

[0086] A pair of plate-shaped guide members 711, 711 are provided at the end 71a of the pull-out passage portion 71 on the side close to the winding drum 4. The guide members 711, 711 are bent so as to gradually approach the pull-out passage portion 71 from the outer periphery 4a of the winding drum 4. The guide members 711, 711 sandwich the coil wire 10 pulled out from the winding drum 4 by the pull-out member 6 from both sides to guide the coil wire 10 so as to prevent the coil wire 10 from expanding in the lateral direction. The mutually opposing surfaces of the guide members 711, 711 are smoothly bent to a degree that does not exceed the elastic region of the coil wire 10 so as to avoid causing winding marks on the coil wire 10 when guiding the coil wire 10.

[0087] The die 72 is disposed at an end 71b of the pull-out passage portion 71 on the side away from the winding drum 4. The end 71b corresponds to the vicinity of the terminal end portion in the pull-out direction of the pull-out member 6 pulling out the coil wire 10. Fig.11 As shown, the mold 72 has a convex bending mold 721 for molding the top 21 and a pair of oblique portions 22, 22 of the U-shaped coil 20, and a pair of shoulder bending molds 722, 722 for molding a pair of shoulders 23, 23 of the U-shaped coil 20. The convex bending mold 721 has a crank bending portion 721a, which is used to shape the top 21 and one shoulder 23 of the U-shaped coil 20 into a crank shape so that one oblique portion 22 is offset. The crank bending portion 721a is composed of a portion of the convex bending mold 721 corresponding to one oblique portion 22. The crank bending portion 721a is arranged to be movable downward relative to the convex bending mold 721.

[0088] The convex bending mold 721 and the shoulder bending molds 722, 722 are both female molds, each having six grooves 723, 724, and the grooves 723, 724 accommodate the coil wire 10 (coil wire bundle 11 described later) pulled out by the pull-out member 6. The male mold of the mold 72 of this embodiment is composed of the pull-out member 6. Therefore, the pull-out member 6 that pulls out the coil wire 10 from the winding drum 4 is assembled as a male mold to the convex bending mold 721 and the shoulder bending molds 722, 722 and molded, thereby, the mold 72 molds the U-shaped coil 20.

[0089] Next, a series of operations of the coil forming device 1 for forming the U-shaped coil 20 will be described. The coil wire 10 straightened from the bobbin 2 via the straightening section 3 is guided by the coil wire introduction member 49, thereby being stored in the first storage section 451 at the bottom of the first peripheral member 45 of the winding drum 4 and the second storage section 462 at the bottom of the second peripheral member 46, and is wound up by the rotation of the winding drum 4. The coil wire introduction member 49 guides the first support roller 492 and the second support roller 493 to rise a fixed distance each time the winding drum 4 rotates three times, and the coil wire 10 is stored in the first storage section 451 and the second storage section 462 at the top.

[0090] Fig.12 The state in which the coil wire 10 is stored in all the first storage parts 451 and the second storage parts 462 by rotating the winding drum 4 18 times is shown. The coil wire 10 wound on the winding drum 4 for 18 turns has five inclined parts 10a, and the inclined parts 10a are obliquely wound toward the first storage part 451 and the second storage part 462 one above each time the winding drum 4 rotates 3 times.

[0091] Fig.13 The state in which the coil wire 10 is stored in all the first storage portions 451 of the first outer peripheral member 45 after the winding drum 4 rotates 18 times is shown. The coil wire 10 for three turns of the winding drum 4 is stored in each first storage portion 451 in a stacked manner in the radial direction of the winding drum 4. Although not shown, similarly, the coil wire 10 for three turns of the winding drum 4 is also stored in all the second storage portions 462 of the second outer peripheral member 46 in a stacked manner.

[0092] like Figure 4 As shown, the winding drum 4 has a receiving portion 51 for the cutting member 5 between any two adjacent first peripheral members 45, 45 among the twelve first peripheral members 45. The receiving portion 51 shown in this embodiment is provided between two short second peripheral members 46, 46 (arranged between the first peripheral members 45, 45). After winding the coil wire 10 for 18 turns, the winding drum 4 is positioned so that the position of the receiving portion 51 coincides with the position of the cutting member 5 and stops.

[0093] After the winding drum 4 stops, Fig.14 As shown, the cutting member 5 moves toward the receiving portion 51, thereby cutting 18 turns of the coil wire 10 at a portion of the outer periphery 4a. As a result, the 18 turns of the coil wire 10 are divided into six coil wire bundles 11, each of which is composed of three coil wires 10 stored in the first storage portion 451 and the second storage portion 462. The coil wire bundle 11 is pressed from the outside by a plurality of pressing rollers 48 arranged on the outer periphery 4a of the winding drum 4, so that it does not fall off the winding drum 4.

[0094] After cutting the coil wire 10, Fig.15 As shown in FIG. 1 , the pull-out member 6 is lowered and arranged inside the coil wire bundle 11. Fig.16 As shown, in the winding drum 4, a storage space S for the pull-out member 6 is formed at a position inside the coil wire bundle 11 on the opposite side of the cutting member 5. After the pull-out member 6 is arranged in the storage space S, it moves along the guide rail 61 to pull out the six coil wire bundles 11 on the outer circumference 4a of the winding drum 4 to the radially outer side of the winding drum 4. At this time, the six coil wire bundles 11 are arranged at a fixed interval in the height direction of the pull-out member 6.

[0095] Since the pull-out member 6 pulls out the coil wire bundle 11 on the opposite side of the cutting member 5 while sandwiching the rotating shaft 41 of the winding drum 4, the coil wire bundle 11 has a bilaterally symmetrical length with the pull-out member 6 as the vertex. Therefore, the pull-out member 6 can pull out the coil wire bundle 11 from the outer periphery 4a of the winding drum 4 in a well-balanced and stable manner. The coil wire bundle 11 pulled out from the winding drum 4 is supported from the bottom by the pull-out passage portion 71 of the forming portion 7.

[0096] like Fig.17 As shown, the pull-out member 6 passes straightly between the pair of guide members 711, 711 when pulling out the coil wire bundle 11. The interval between the guide members 711, 711 gradually narrows along the moving direction of the pull-out member 6. Therefore, the guide members 711, 711 form the six coil wire bundles 11 into a substantially U-shape along the two side surfaces of the pull-out member 6 as the pull-out member 6 passes.

[0097] A plurality of protrusions 711b, 711b are provided on the opposing side surfaces 711a, 711a of the guide members 711, 711, respectively. The protrusions 711b, 711b are provided seven by seven at regular intervals along the axial direction of the winding drum 4 so that the coil wire bundles 11 can pass between the protrusions 711b, 711b adjacent to each other in the vertical direction, respectively. The six coil wire bundles 11 pass between the protrusions 711b, 711b when being pulled out by the pulling member 6, and therefore, are not entangled with each other.

[0098] When the pull-out component 6 moves to the end of the guide rail 61, Fig.18 As shown, the convex bending mold 721 of the mold 72 of the molding unit 7 is abutted. Then, the convex bending mold 721 as the female mold is molded with the pull-out member 6 as the male mold to mold the top 21 and a pair of oblique parts 22, 22 on each coil wire bundle 11. Next, as shown in Fig.19 As shown in FIG. 1 , a pair of left and right shoulder bending molds 722, 722 are molded together to form a pair of shoulder portions 23, 23 on each coil wire bundle 11. Fig. 20As shown, when the male bending mold 721, the shoulder bending molds 722, 722 and the pull-out member 6 are molded together, the crank bending portion 721a is moved downward, thereby forming six U-shaped coils 20 with an offset oblique portion 22. The six U-shaped coils 20 are taken out of the coil forming device 1 after the mold is opened.

[0099] With respect to the six U-shaped coils 20 formed, one oblique portion 22 is offset in the thickness direction by the thickness of the U-shaped coil 20. Fig.21 and Fig. 22 As shown, when the straight line portions 24 are overlapped with each other at equal intervals, all twelve straight line portions 24 are arranged on the same plane along the Y direction.

[0100] As described above, the coil forming device 1 of the present embodiment includes: a bobbin 2 that winds and holds the coil wire 10; a winding drum 4 that has a plurality of first storage portions 451 and second storage portions 462 on the outer periphery 4a for storing the coil wire 10 supplied from the bobbin; a cutting member 5 that cuts the coil wire 10 stored in the first storage portion 451 and the second storage portion 462 and wound on the winding drum 4 at a portion of the outer periphery 4a of the winding drum 4; a pulling member 6 that pulls the coil wire 10 cut by the cutting member 5 outward from a position away from the cutting member 5 in the radial direction of the winding drum 4; and a forming section 7 that forms the coil wire 10 pulled out by the pulling member 6 into a U-shape. Thus, the coil wire 10 is supplied from the bobbin 2 and wound on the winding drum 4, and can be formed into a U-shape without deteriorating the forming accuracy due to the winding mark. Furthermore, after the coil wire 10 is wound around the outer circumference of the winding drum 4 and cut, the coil wire 10 can be easily formed into a U-shape simply by pulling it outward in the radial direction of the winding drum 4 .

[0101] A plurality of first storage portions 451 and second storage portions 462 are provided in the axial direction of the winding drum 4. Thus, by winding the coil wire 10 around the plurality of first storage portions 451 and second storage portions 462, a plurality of coil wire bundles 11 are formed after cutting, so that the plurality of coil wires 10 can be collectively formed into a U-shape.

[0102] The first storage portion 451 and the second storage portion 462 are sized to store the coil wires 10 stacked multiple times on the winding drum 4. Thus, a collective conductor composed of multiple coil wires 10 can be formed simply by winding the coil wires 10 around the outer periphery 4a of the winding drum 4.

[0103] The forming portion 7 has a pull-out passage portion 71 extending radially outward from the winding drum 4 to form a passage for the coil wire 10 pulled out by the pulling member 6, and the pull-out passage portion 71 has a pair of guide members 711, 711, which sandwich the coil wire bundle 11 pulled out from the winding drum 4 by the pulling member 6 from both sides and guide it to prevent the coil wire bundle 11 from expanding. Thus, when the coil wire bundle 11 is pulled out, it can be smoothly pulled out to the forming portion 7 without expanding from the outer periphery 4a of the winding drum 4.

[0104] The pull-out member 6 is configured to pull out the coil wire bundle 11 cut by the cutting member 5 from the radially inner side to the outer side of the winding drum 4, and the molding section 7 has a die 72, which molds the coil wire bundle 11 into a U-shape near the terminal portion of the pull-out direction of the pull-out member 6, and the pull-out member 6 constitutes a part of the die 72. Thus, the pull-out member 6 for pulling out the coil wire bundle 11 from the outer periphery 4a of the winding drum 4 can be directly used to mold the coil wire bundle 11 into a U-shape through the die 72, so there is no need to transfer the coil wire bundle 11 from the pull-out member 6, and the pulling and molding of the coil wire bundle 11 can be achieved in one process.

[0105] The winding drum 4 is configured to wind the coil wire 10 around the outer periphery 4a by rotating about the rotation axis 41. Thus, the coil wire 10 can be easily wound around the outer periphery 4a of the winding drum 4 only by rotating the winding drum 4.

[0106] The winding drum 4 of the coil forming device 1 may have only one storage portion for storing the coil wire 10 on the outer periphery 4a. That is, in this case, the winding drum 4 forms only one coil wire bundle 11. In addition, each of the plurality of storage portions may store the coil wire 10 for only one circumference.

[0107] In the coil forming device 1 shown in the above embodiment, the pull-out component 6 constitutes a part (male mold) of the mold 72 which is arranged on the inner side of the coil wire bundle 11 and forms the coil wire bundle 11 into a U shape, but the mold arranged on the inner side of the coil wire bundle 11 can also be composed of a component separate from the pull-out component 6.

Claims

1. A coil forming device, which forms a coil wire into a U shape, comprising: a coil wire holding portion, which is wound around and holds the coil wire; a correcting section that corrects a winding mark of the coil wire supplied from the coil wire holding section; a winding drum having one or more storage portions on an outer periphery for storing the coil wire supplied from the one coil wire holding portion; a cutting member for cutting the coil wire stored in the storage portion and wound around the winding drum in a manner that does not cause winding marks, at a portion of the outer circumference of the winding drum; a pulling member that pulls the coil wire cut by the cutting member out from a position away from the cutting member toward the radially outer side of the winding drum; as well as A forming section forms the coil wire material drawn out by the drawing member into a U shape.

2. The coil forming device according to claim 1, wherein: A plurality of the storage portions are provided in the axial direction of the winding drum.

3. The coil forming device according to claim 1 or 2, wherein: The storage portion has a size capable of storing the coil wire stacked a plurality of times on the winding drum.

4. The coil forming device according to claim 1 or 2, wherein: The forming portion includes a pull-out passage portion extending radially outward from the winding drum and constituting a passage for the coil wire pulled out by the pulling member. The pull-out passage portion includes a pair of guide members that sandwich the coil wire pulled out from the winding drum by the pull-out member from both sides and guide the coil wire so as to prevent the coil wire from spreading.

5. The coil forming device according to claim 1 or 2, wherein: The pulling member is configured to pull out the coil wire cut by the cutting member from the radially inner side to the outer side of the winding drum, The molding unit includes a mold, and the mold molds the coil wire into a U-shape near a terminal end portion of the pull-out direction of the pull-out member. The pull-out member forms a part of the mold.

6. The coil forming device according to claim 1 or 2, wherein: The winding drum is configured to wind the coil wire around the outer circumference by rotating around a rotation axis.

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