Method for manufacturing power distribution components

Abstract

The present invention provides a metal round wire having a non-circular cross-section portion at a predetermined position without additional processing and having a three-dimensional shape with predetermined dimensional accuracy and shape accuracy. The present invention is provided with a processing machine (20) for forming the non-circular cross-section portion, which forms a non-circular cross-section portion with a non-circular cross-section shape at at least one position in the middle process of processing the metal round wire into a predetermined three-dimensional shape. During bending, the non-circular cross-section portion is held in a wire holding portion of a bending machine (30), thereby bending the metal round wire into a predetermined three-dimensional shape. By holding the non-circular cross-section portion, the relative rotation between the non-circular cross-section portion and the wire holding portion is suppressed compared to the case of a circular cross-section. Therefore, the bending accuracy of the metal round wire into a three-dimensional shape is improved.

Description

Technical Field

[0001] The present invention relates to a method and apparatus for processing a metal round wire to be installed as a conductor at a predetermined position of an electrical device, and a method for manufacturing a power distribution component in which a resin member and the metal round wire are integrated. Background Art

[0002] As conductors for various electrical devices, metal round wires consisting of single wires with a circular cross-section are used. Compared to square wires with a square cross-section, metal round wires are cheaper, have superior tensile and bending strength, and are easier to bend in the desired direction when installed in electrical equipment than square wires. With these advantages in mind, for example, Patent Document 1 describes the use of metal round wires as power lines for supplying power to three-phase rotating electrical machines such as motors. On the other hand, when three power lines are connected individually to terminals, there are problems such as positional shifts when fastened to the terminals due to the flexibility of the power lines. To prevent such positional shifts, Patent Document 1 proposes the use of a power line fixing member with three insertion holes for the three power lines to pass through. While the use of such a power line fixing member reliably suppresses positional shifts, the power lines, due to their circular cross-section, rotate about their axis within the insertion holes of the power line fixing member. As a result, the difficulty in positioning the power lines when fastened to the terminals and positional shifts caused by vibration cannot be completely eliminated. In light of this, Patent Document 2 discloses a technique in which a clamp is used to flatten a predetermined portion of a power cable, resulting in a non-circular cross-section. A resin member, serving as a fixing member for the power cable, is then integrally molded with this portion. Because the resin member is integrated with the non-circular cross-section, relative rotation between the power cable and the resin member is suppressed.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2014-128095

[0006] Patent Document 2: Japanese Patent Application Laid-Open No. 2017-55486 Summary of the Invention

[0007] Problems to be solved by the invention

[0008] However, in the case of Patent Document 2, before the resin component serving as the power line fixing component is integrated, a clamp is used to form a portion with a non-circular cross-section on the power line. Although the round metal wire made of copper or the like is flexible and can be bent to a certain extent to match the shape of the installation portion when assembled to a motor or the like as described above, in reality, a power line is used that is formed in a three-dimensional shape with a predetermined bending angle, length, etc. that matches the installation portion. The power line of Patent Document 2 is also the same, and the specified portion of the power line processed into a three-dimensional shape according to the specified design specifications is flattened by a clamp through additional processing, and the resin component is integrated.

[0009] The process of flattening a portion of such a metal round wire processed to the prescribed design specifications and precision using a clamp will affect the bending angle, bending position, etc. of the metal round wire formed into a three-dimensional shape. Therefore, even if the purpose of preventing rotation based on the resin component can be achieved, there is a possibility that the dimensional accuracy and shape accuracy of the metal round wire itself will be inferior to the design specifications.

[0010] The present invention has been completed in view of the above situation, and its object is to provide a processing method for a metal round wire, a processing device for a metal round wire, and a manufacturing method for a distribution component, which can process a metal round wire having a non-circular cross-sectional portion at a predetermined position and a three-dimensional shape with predetermined dimensional accuracy and shape accuracy without performing additional processing.

[0011] Solutions to Problems

[0012] To solve the above-mentioned problems, the present invention provides a method for processing a round metal wire, wherein the round metal wire is formed of a single wire having a circular cross section, is bent into a predetermined three-dimensional shape, and is provided as a conductor at a predetermined position of an electrical device, wherein:

[0013] The processing method of the metal round wire comprises:

[0014] a straightening step of straightening the coiled raw material of the metal round wire into a straight shape;

[0015] a non-circular cross-sectional portion forming step of forming a non-circular cross-sectional portion having a non-circular cross-sectional shape in a diameter direction at at least one portion of the metal round wire material corrected into a straight shape by the correcting step; and

[0016] The bending step is to bend the metal round wire into the three-dimensional shape by holding the non-circular cross-sectional portion on a wire holding portion of a bending machine.

[0017] Preferably, in the non-circular cross-sectional portion forming step, the non-circular cross-sectional portion is processed into a shape having a flat surface that comes into surface contact with a contact surface of a wire material holding portion of the bending machine.

[0018] The metal round wire is preferably cut into a predetermined length at any time after the straightening step and before the cross-sectional non-circular portion forming step, or after the cross-sectional non-circular portion forming step.

[0019] Furthermore, the metal round wire processing device of the present invention is used to bend a single wire with a circular cross section provided as a conductor at a predetermined position of an electrical device into a predetermined three-dimensional shape, and is characterized in that:

[0020] The metal round wire processing device comprises:

[0021] a straightening machine for straightening the coiled raw material of the metal round wire into a straight shape;

[0022] a processing machine for forming a non-circular cross-section portion, which forms a non-circular cross-section portion having a non-circular cross-section shape in a diameter direction at at least one portion of the metal round wire straightened into a straight shape by the straightening device;

[0023] a bending machine for bending the metal round wire into the three-dimensional shape by holding the non-circular cross-sectional portion on a wire holding portion; and

[0024] A cutting machine cuts the metal round wire.

[0025] The machine for forming the non-circular cross-section portion preferably includes a pressing portion that forms the non-circular cross-section portion into a flat surface that comes into surface contact with a contact surface of a wire material holding portion of the bending machine.

[0026] Preferably, the processing device for metal round wire also has a control unit for a cutting machine, which controls the cutting machine in a manner that cuts the metal round wire into a specified length at any time after the correction and before the formation of the non-circular cross-section portion, or after the formation of the non-circular cross-section portion and before the bending process.

[0027] Furthermore, in the manufacturing method of the power distribution component of the present invention, the power distribution component is provided at a predetermined position of the electrical equipment and comprises: a processed product of a metal round wire material, which is composed of a single wire with a circular cross section and is bent into a predetermined three-dimensional shape; and a resin member integrally mounted on the processed product. The manufacturing method of the power distribution component is characterized in that:

[0028] The resin member is fixed to the outer periphery of the non-circular cross-sectional portion of the processed metal round wire product processed by the metal round wire processing method.

[0029] Effects of the Invention

[0030] According to the present invention, during the process of processing a round metal wire into a predetermined three-dimensional shape, a non-circular cross-sectional portion having a non-circular cross-sectional shape is formed at at least one location. During the bending process, the non-circular cross-sectional portion is held in the wire holding portion of the bending machine, thereby bending the round metal wire into the predetermined three-dimensional shape. By holding the non-circular cross-sectional portion, the relative rotation of the non-circular cross-sectional portion and the wire holding portion about the axis is suppressed compared to the case of a circular cross-sectional shape. In particular, by processing the non-circular cross-sectional portion into a shape having a flat surface that makes surface contact with the abutting surface of the wire holding portion of the bending machine, the relative rotation of the non-circular cross-sectional portion and the wire holding portion is further suppressed. As a result, the accuracy of the bending process into the three-dimensional shape is improved. In addition, since the holding position of the wire holding portion of the bending machine does not shift, the error between the processed products is also reduced. In addition, after the bending process, the processed products are usually measured for size using an optical microscope or the like. At this time, when the cross section is circular, it is difficult to focus on the tangent along the length direction, and it is difficult to align with the reference line of the optical microscope. However, by having a non-circular cross section, preferably a flat surface, the outer shape line becomes clear, so that focusing is easy, alignment becomes easy, and the dimensional measurement accuracy is also improved.

[0031] Therefore, according to the present invention, after obtaining a three-dimensionally shaped metal round wire product with high dimensional and shape accuracy, no additional processing is required to form a non-circular cross-sectional portion. This allows the product to be directly combined with a component such as a detent while maintaining high dimensional accuracy. Furthermore, power distribution components integrated with resin components by insert molding can be easily manufactured by directly utilizing the non-circular cross-sectional portion without additional processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a perspective view showing an example of a processed metal round wire product (processed product) processed using the metal round wire processing apparatus according to one embodiment of the present invention. Figure 1 (b) is Figure 1 (a) Enlarged cross-sectional view along line AA.

[0033] Figure 2 (a) shows that the anti-rotation resin member is integrally formed and mounted on the Figure 1 A perspective view of an example of a power distribution component made of a processed wire material is shown. Figure 2 (b) is Figure 2 (a) Enlarged cross-sectional view along line BB.

[0034] Figure 3 This is a diagram showing a schematic configuration of a metal round wire processing device according to one embodiment of the present invention.

[0035] Figure 4 The diagram shows the schematic configuration of each processing machine in accordance with the processing steps in a scheme for cutting a round metal wire rod after straightening and before forming a portion having a non-circular cross section.

[0036] Figure 5 The diagram shows the schematic configuration of each processing machine according to the processing steps in a scheme for cutting a metal round wire rod after forming a non-circular cross-section portion and before performing bending.

[0037] Figure 6 (a) is a diagram showing an example of a wire material holding portion of a bending machine. Figure 6 (b) is a diagram showing another example of the wire rod holding portion of the bending machine.

[0038] Figure 7 It shows Figure 4 Flowchart of an example of a process for processing a metal round wire in the scheme of FIG.

[0039] Figure 8 It shows Figure 5 Flowchart of an example of a process for processing a metal round wire in the scheme of FIG.

[0040] Figure 9 This is a flowchart showing an example of the process of the method for manufacturing the power distribution component according to one embodiment of the present invention. DETAILED DESCRIPTION

[0041] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Figure 1 (a) shows a metal round wire processing device 1 (see Figure 3 ) is a processed product (hereinafter referred to as "wire processed product") 100A of a metal round wire 100 processed by a process. The wire processed product 100A is used as a power line of a motor, etc. as shown in Patent Documents 1 and 2, for example, and is formed into a three-dimensional shape having connection portions 101, 101 connected to terminals, etc. at both ends, a plurality of bent portions 102, 102, and straight portions 103, 103 between the plurality of bent portions 102, 102. Furthermore, in the present embodiment, at any part of the wire processed product 100A, a non-circular cross-sectional shape of the metal round wire 100 in the diameter direction (direction orthogonal to the length direction (axial direction) of the metal round wire 100) is formed within the range of the straight portion 103 near the middle of the entire length. In the present embodiment, as Figure 1 As shown in (b), the cross-sectional non-circular portion 105 is formed into a rectangular shape having four flat surfaces 105a to 105d on the outer peripheral surface. It should be noted that the shape of the cross-sectional non-circular portion 105 will be further described later.

[0042] The wire rod processed product 100A is placed in a mold and integrated with the resin member 200 by insert molding (see Figure 2 (a)). At this time, if Figure 2 As shown in (b), the resin member 200 is integrated with the non-circular cross-sectional portion 105 in a manner that leaves no gaps. Because the non-circular cross-sectional portion 105 has four flat surfaces 105a to 105d, relative rotation does not occur between the resin member 200, which covers the non-circular cross-sectional portion 105 without gaps. As a result, the wire rod processing product 100A of the metal round wire 100 will not rotate in the axial direction and shift when fastened to a terminal of a motor, etc. or due to external vibration. It should be noted that, as shown in Patent Documents 1 and 2, for example, when used in a three-phase motor, a structure can naturally be adopted in which the wire rod processing products 100A of three metal round wires 100 are insert-molded together and covered with a common resin member 200 to prevent mutual positional shifting.

[0043] Next, a method and apparatus for processing the metal round wire 100 used as described above will be described. Figure 3 1 is a diagram schematically showing the general structure of a metal round wire processing device 1. Figure 4 as well as Figure 5 As shown in these figures, the metal round wire processing device 1 of this embodiment includes a straightening machine 10 , a machine 20 for forming a non-circular cross-section portion, a bending machine 30 , and a cutting machine 40 .

[0044] like Figure 4 as well as Figure 5 As shown, the correction processing machine 10 is configured to have a plurality of correction rollers 11 arranged opposite to each other. The metal round wire 100 to be processed is composed of a single wire made of a metal such as copper with a surface covered with enamel and a circular cross section, and is provided as a coil-shaped raw material wound into a coil. Since it is wound into a coil, it is provided in order to correct its winding marks. Here, for Figure 1 In the wire rod processed product 100A shown, each end portion becomes a connection portion 101, 101, and the enamel film is removed at these connection portions 101, 101. After the straightening process, the enamel film is removed by, for example, cutting the surface or using chemicals.

[0045] The cross-sectional non-circular portion forming machine 20 forms a predetermined portion of the metal round wire 100 processed into a straight shape by the correction machine 10 so that the cross-sectional shape in the diameter direction of the metal round wire 100 is non-circular. Although the specific structure of the cross-sectional non-circular portion forming machine 20 is not limited, for example, Figure 4 as well as Figure 5 As shown, the cross-sectional non-circular portion forming machine 20 is composed of a press machine having a pressing portion 21 that clamps a metal round wire 100 from both sides along the diameter direction. The opposing surface 21a of the pressing portion 21 that faces the metal round wire 100 has a shape that is substantially identical to the contact surface 31a of the wire holding portion 31 of the bending machine 30 that contacts and separates from the metal round wire 100 (see FIG. Figure 6 Specifically, for example, the wire holding portion 31 has at least two contact surfaces 31 a that contact the metal round wire 100 , and at least one of the two contact surfaces 31 a is a flat surface. Therefore, the pressing surface 21 a of at least one pressing portion 21 is also a flat surface.

[0046] In this embodiment, the opposing surfaces 21a, 21a of the pressing parts 21, 21 on both sides of the non-circular cross-section forming machine 20, which are 180 degrees opposite to each other, are both flat surfaces. Therefore, when these pressing parts 21, 21 are brought closer to each other, a pair of opposing flat surfaces 105a, 105c are formed, which become the non-circular cross-section portion 105. Then, the metal round wire 100 is rotated about the 90-degree axis and the pressing parts 21, 21 are brought closer to each other again, thereby forming another pair of opposing flat surfaces 105b, 105d, thereby forming the non-circular cross-section portion 105 having a substantially rectangular cross-section in the diameter direction.

[0047] However, the cross-sectional shape of the non-circular cross-sectional portion 105 does not need to be circular. For example, it may be a structure in which a flat surface is formed only on one side, or a structure in which flat surfaces are formed only on two opposing sides. It may also be formed with three, or five or more flat surfaces. However, the closer it is to a circle, the easier it is to cause relative rotation with the wire holding portion 31 of the bending machine 230, or Figure 2 In order to prevent the relative rotation of the two in the case of being integrally formed with the resin component 200, it is preferred to form eight or fewer flat surfaces. In addition, it can also be a special-shaped cross-section with arbitrary concave or convex parts such as four sides or triangles in the cross-section. In short, these surfaces can be shaped as long as they have at least one flat surface that can make surface contact with the abutment surface 31a of the wire holding portion 31 of the bending machine 30. If there is at least one flat surface, surface contact will occur with the abutment surface 31a of the wire holding portion 31 of the bending machine 30, thereby preventing the metal round wire 100 from rotating around the axis during bending.

[0048] The bending machine 30 can be used, for example, Figure 6 As shown in (a) of FIG. 1 , a bending machine having a wire holding portion (chuck) 31 provided at the front end of a three-dimensionally movable robot arm 32 or a bending machine having Figure 6 Bending machines, such as those shown in (b) of FIG. , include a wire holding portion 31 comprising a pair of opposing plates (equivalent to the portion of a press die that holds the workpiece) that can contact and separate from each other. These wire holding portions 31 have at least one surface (in this embodiment, both opposing surfaces) that holds the round metal wire 100 as a flat surface. Therefore, when a round metal wire 100 having flat surfaces 105a to 105d formed thereon by the cross-sectional non-circular portion forming machine 20 is placed in these wire holding portions 31, the round metal wire 100 will not rotate about its axis, even though the portion other than the non-circular cross-sectional portion 105 has a circular cross-sectional shape.

[0049] exist Figure 6 In the case of (a), the bending machine 30 includes a wire holding portion (chuck) 31 and a processing portion (not shown) that contacts the metal round wire 100. By moving one or both of them three-dimensionally, the metal round wire 100 is bent in a predetermined direction at a predetermined angle, etc., and processed into a predetermined three-dimensional shape according to design specifications. Figure 6 In the case of (b), for example, the metal round wire 100 is held between a pair of contact surfaces 31a, 31a of the wire holding portion 31 composed of two plates, and the processing tool 33 (see Figure 4 as well as Figure 5 In the "bending process" ("bending process"), the portion protruding from the wire holding portion 31 is approached and contacted from any direction, thereby forming the wire into a predetermined shape. Furthermore, by changing the orientation of the round metal wire 100 or using a tool that can approach from different directions as the processing tool, a three-dimensional shape is imparted. It should be noted that the specific structure of the bending machine 30 is not limited at all as long as it can bend the round metal wire 100.

[0050] The cutting machine 40 cuts the metal round wire 100 into a predetermined length according to the design specifications. As long as the metal round wire 100 can be cut, the structure of the cutting machine 40 is not limited at all. In this embodiment, there is a cutting machine control unit 50 (see FIG. 1 ) that automatically operates the cutting machine 40. Figure 3). The cutting machine control unit 50 controls the cutting machine 40 so that the cutting operation is performed at a predetermined length according to the pre-set design specifications. The cutting machine control unit 50 can only control the cutting length, but in this embodiment, it can also automatically control the timing of the operation of the cutting machine 40. Specifically, after the correction is performed by the correction machine 10 and before it is transferred to the cross-section non-circular portion forming machine 20 ( Figure 4 ), or after the non-circular cross-section portion 105 is formed and before it is transferred to the bending machine 30 ( Figure 5 The cutting machine 40 is operated at any timing in the scheme of FIG. 1 ) to cut the metal round wire 100 into a predetermined length.

[0051] The timing of cutting by the cutting machine 40 can be arbitrarily set according to the type of three-dimensional shape to be given to the metal round wire 100, the dimensional accuracy to be sought, etc. Figure 4 As shown, when cutting after straightening, the non-circular cross-sectional portion 105 is formed at either the end or the middle portion, making positioning easier and making subsequent bending easier. Furthermore, when cutting after bending, there is a risk of deformation due to the impact of cutting. However, this concern is eliminated if cutting is performed beforehand.

[0052] like Figure 5 As shown, when cutting is performed after forming the non-circular cross-sectional portion 105 and before bending, bending is easier. However, since the non-circular cross-sectional portion 105 is formed in a long strip, positioning the portion where the non-circular cross-sectional portion 105 will be formed is more difficult than when cutting is performed before the bending process. On the other hand, when forming the non-circular cross-sectional portion 105, there is a possibility that deformation in the diameter direction may slightly affect the longitudinal dimensions. Furthermore, there is also the possibility that deformation may occur during cutting after bending, as described above. Therefore, in cases where stricter dimensional accuracy is required, it is also possible to form the non-circular cross-sectional portion 105 in a long strip until the end, and then cut it before bending.

[0053] Next, based on Figure 4 as well as Figure 7 An example of a method for processing a metal round wire 100 will be described. As described above, the processing method of this embodiment transfers the raw material provided in a coil shape to the straightening processing machine 10 of the metal round wire processing device 1 and straightens it into a straight shape ( Figure 7 Then, according to the specifications of the wire rod processed product 100A, the enamel coating is peeled off at predetermined intervals to form connection ends 101, 101 to be connected to terminals or the like at the installation location.

[0054] Next, for example, the metal round wire 100 ( Figure 7 Since the cutting is performed at this point, there is an advantage that the subsequent processing becomes easier as described above. Next, the metal round wire 100 cut to a predetermined length is transferred to the processing machine 20 for forming the non-circular cross-section portion, thereby forming the non-circular cross-section portion 105 ( Figure 7 S3). The non-circular cross-sectional portion 105 is formed at least in one location. The non-circular cross-sectional portion 105 is provided to prevent movement in the rotational direction when the wire is held by the wire holding portion 31 of the bending machine 30. However, if the locations held by the wire holding portion 31 are different or if multiple bending machines 30 are used, the non-circular cross-sectional portion 105 can be formed at multiple locations depending on the situation.

[0055] Next, the wire holding portion 31 of the bending machine 30 holds the non-circular cross-section portion 105 and gives it a three-dimensional shape according to the design specifications ( Figure 7 At this time, when a plurality of bending machines 30 are used, for example, in the first bending machine 30, the non-circular cross-section portion 105 at a predetermined position can be held by the wire holding portion 31 and bent, and then, in the next bending machine 30, the non-circular cross-section portion 105 formed at a position different from the previous position can be held by the wire holding portion 31 and bent.

[0056] Thus, the wire rod processed product 100A is completed. It should be noted that the timing of the cutting process is not limited to before the formation of the non-circular cross-section portion after correction, as described above, it can also be Figure 5 As shown, this is performed after the non-circular cross-section portion is formed. Figure 8 This is a flowchart showing an example of the processing steps in this case. After the correction step ( Figure 8 S5), forming a non-circular cross-section portion ( Figure 8 S6), and then cut off ( Figure 8 S7), and implement the bending process ( Figure 8 S8 of FIG. 1 ), thereby obtaining the wire rod processed product 100A.

[0057] According to this embodiment, a non-circular cross-sectional portion 105 is formed on the metal round wire 100 before the bending process. Therefore, the wire holding portion 31 can hold the non-circular cross-sectional portion 105 while the bending process is performed, and can prevent movement in the rotational direction around the axis during the bending process, thereby improving the bending accuracy. In addition, because the holding position of the wire holding portion 31 is stable, the variation in processing accuracy between products is also reduced. In addition, the metal round wire 100 is moved between the various processing machines via feed rollers (not shown), but after the non-circular cross-sectional portion 105 is formed, the slippage relative to the feed rollers is suppressed, thereby also suppressing the deterioration of processing accuracy caused mainly by variations in feed amount.

[0058] Furthermore, when measuring the dimensions of the processed wire rod product 100A using an optical microscope, the contour lines of the non-circular cross-section portion 105, particularly the flattened surface, are easily observed. Specifically, in the case of a circular cross-section, focusing on the tangent line of the circular cross-section is sometimes difficult when observing with an optical microscope, which can affect dimensional measurement accuracy. However, according to this embodiment, focusing on the contour lines of a flat surface, etc., is easier, thereby improving dimensional measurement accuracy.

[0059] Next, since the wire rod processed product 100A of this embodiment is used as a power distribution component, for example, when it is integrated with a resin member 200 that functions as a rotation stopper to prevent rotation toward the mounting portion, as shown in FIG. Figure 9 As shown, the resin member 200 and the cross-section non-circular portion 105 are integrated by insert molding (S10), thereby obtaining the power distribution component 300 (see Figure 2 In the resulting power distribution component 300, the resin member 200 and the non-circular cross-sectional portion 105 are integrally formed, and thus do not rotate relative to each other. According to the present invention, there is no need to form the non-circular cross-sectional portion through additional processing after the wire rod is completed, as is conventionally done. This prevents the effects of additional processing on dimensional accuracy and deformation that can occur.

[0060] As described above, the processed wire product 100A of the metal round wire 100 and the power distribution component 300 obtained by the present invention are round wires that are less expensive than square wires and are particularly suitable for applications requiring high dimensional accuracy and shape accuracy.

[0061] Description of Reference Numerals

[0062] 1 Processing equipment for metal round wire

[0063] 10 Correction processing machines

[0064] 11 Correction roller

[0065] 20 Processing machine for forming non-circular cross-section parts

[0066] 21 Pressing part

[0067] 21a Opposing surface

[0068] 30 Bending Machine

[0069] 31 Wire holding part

[0070] 31a contact surface

[0071] 40 Cutting machine

[0072] 50 Cutting machine control unit

[0073] 100 Metal round wire

[0074] 100A wire rod processing products (finished products made of metal round wire rods)

[0075] 105 Non-circular cross-section

[0076] 105a, 105b, 105c, 105d flat surfaces

[0077] 200 resin components

[0078] 300 Power distribution components.

Claims

1. A method for manufacturing a power distribution component, wherein the power distribution component is installed at a predetermined position of an electrical device, characterized in that: The method for manufacturing the power distribution component includes the steps of processing a metal round wire material, which is used as a conductor of the power distribution component and is composed of a single wire with a circular cross section. The manufacturing method of the power distribution component comprises: a straightening step of straightening the coiled raw material of the metal round wire into a straight shape; a non-circular cross-sectional portion forming step of forming a non-circular cross-sectional portion having a non-circular cross-sectional shape in a diameter direction at at least one portion of the metal round wire material corrected into a straight shape by the correcting step; a bending step of holding the non-circular cross-sectional portion in a wire holding portion of a bending machine to bend the metal round wire into a predetermined three-dimensional shape; and a step of integrally attaching a resin member to the outer periphery of the non-circular cross-section portion of the processed metal round wire rod.

2. The method for manufacturing a power distribution component according to claim 1, wherein: In the non-circular cross-sectional portion forming step, the non-circular cross-sectional portion is processed into a shape having a flat surface that comes into surface contact with a contact surface of a wire material holding portion of the bending machine.

3. The method for manufacturing a power distribution component according to claim 1 or 2, wherein: The metal round wire is cut into a predetermined length at any time after the straightening step and before the cross-sectional non-circular portion forming step, or after the cross-sectional non-circular portion forming step.

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