Coil forming apparatus and coil forming method

Abstract

Provided is a coil forming device capable of easily forming a band-shaped coil into a wound state without positional displacement of straight portions. A coil forming device includes: a coil winding jig having a plurality of comb-tooth-shaped grooves into which a plurality of straight portions can be respectively inserted on an outer periphery, and configured to wind a band-shaped coil; a coil conveying mechanism portion configured to convey the band-shaped coil while rotating along at least a portion of the outer periphery of the coil winding jig; and guide members respectively disposed near both axial ends of the coil winding jig, guiding the band-shaped coil into a circular arc shape while contacting side end portions, and guiding the band-shaped coil into a circular arc shape having a smaller diameter than the outer diameter of the coil winding jig in a latter half of the rotation conveying of the band-shaped coil, and causing the plurality of straight portions to be respectively inserted into the plurality of comb-tooth-shaped grooves.

Description

TECHNICAL FIELD

[0001] The present application relates to a coil forming apparatus and a coil forming method. BACKGROUND

[0002] A stator of a rotating electric machine has a band-shaped coil in a wound state. The band-shaped coil is formed in advance in a wound state of a substantially cylindrical shape with a smaller diameter than an inner diameter of a stator core, and is inserted into an inner side of the stator core. The band-shaped coil in the wound state is installed by expanding the band-shaped coil in a straight state at the inner side of the stator core and inserting the straight portion of the band-shaped coil into a slot of the stator core.

[0003] Conventionally, it is known that a band-shaped coil is fed one pitch at a time to a cylindrical core member while being wound on the core member, and is formed in a wound state of a substantially cylindrical shape (for example, see Patent Literature 1).

[0004] [Prior Art Documents]

[0005] (Patent Literature)

[0006] Patent Literature 1: Japanese Patent No. 4953032 SUMMARY

[0007] [Problems to be Solved by the Invention]

[0008] When the coil is wound to be formed in a wound state, it is important to wind with high accuracy so that the plurality of straight portions do not shift in position. The above-described conventional technique is to insert a preliminary alignment member between adjacent straight portions at a position directly in front of the core member on a conveyance path of the band-shaped coil, and align the overlapping portions of the straight portions to be wound on the core member.

[0009] However, in the above-described conventional technique, how the core member winds the band-shaped coil is not specifically disclosed, and there is a problem that it is not possible to prevent the straight portions of the band-shaped coil wound on the core member from shifting in position.

[0010] An object of the present application is to provide a coil forming apparatus and a coil forming method that can easily form a band-shaped coil in a wound state without the straight portions shifting in position.

[0011] [Technical Means to Solve the Problems]

[0012] (1) A coil forming apparatus (e.g., coil forming apparatus 1 described below) that forms a band-shaped coil (e.g., band-shaped coil 100 described below) into a wound state, the band-shaped coil (e.g., band-shaped coil 100 described below) having a plurality of straight portions (e.g., straight portions 102 described below) and side end portions (e.g., side end portions 103 described below) disposed at both ends of the plurality of straight portions, the coil forming apparatus including: a coil winding jig (e.g., coil winding jig 2 described below) having a plurality of comb-tooth-shaped grooves (e.g., comb-tooth-shaped grooves 23 described below) into which the plurality of straight portions can be respectively inserted on an outer periphery, and configured to wind the band-shaped coil; a coil conveying mechanism portion (e.g., coil conveying mechanism portion 3 described below) configured to rotationally convey the band-shaped coil along at least a portion of the outer periphery of the coil winding jig; and guide members (e.g., guide members 4 described below) respectively disposed near both axial ends of the coil winding jig, guiding the band-shaped coil into an arc shape while being in contact with the side end portions; and the guide members guide the band-shaped coil into an arc shape having a smaller diameter than an outer diameter of the coil winding jig in a latter half of the rotationally conveying the band-shaped coil (e.g., latter half 313b of rotationally conveying portion 313 described below), and cause the plurality of straight portions to be respectively inserted into the plurality of comb-tooth-shaped grooves of the coil winding jig.

[0013] (2) In the coil forming apparatus described in (1) above, the guide members can have inner wall surfaces (e.g., inner wall surfaces 41 described below) that are in contact with the side end portions by wall surfaces in a latter half of the rotationally conveying the band-shaped coil.

[0014] (3) In the coil forming apparatus described in (1) above, the guide members can have inner wall surfaces (e.g., inner wall surfaces 41 described below) that are in contact with the side end portions by wall surfaces throughout the rotationally conveying the band-shaped coil (e.g., rotationally conveying portion 313 described below).

[0015] (4) The coil forming method of the present application forms a band-shaped coil (e.g., band-shaped coil 100 described below) into a wound state, the band-shaped coil having a plurality of straight portions (e.g., straight portions 102 described below) and side end portions (e.g., side end portions 103 described below) disposed at both ends of the plurality of straight portions, the coil forming method including: a coil conveying step of rotatingly conveying the band-shaped coil along at least a portion of the outer periphery of a coil winding jig (e.g., coil winding jig 2 described below) having a plurality of comb-tooth-shaped grooves (e.g., comb-tooth-shaped grooves 23 described below) into which the plurality of straight portions can be respectively inserted and configured to wind the band-shaped coil; and a guiding step of disposing guide members (e.g., guide members 4 described below) near both axial ends of the coil winding jig, respectively, and guiding the band-shaped coil into an arc shape having a smaller diameter than the outer diameter of the coil winding jig while bringing the guide members into contact with the side end portions, and causing the plurality of straight portions to be respectively inserted into the plurality of comb-tooth-shaped grooves in the latter half of the rotationally conveying the band-shaped coil (e.g., latter half 313b of rotationally conveying portion 313 described below).

[0016] (5) In the coil forming method described in (4) above, in the guiding step, the side end portions can be guided by the inner wall surfaces (e.g., inner wall surfaces 41 described below) of the guide members in at least the latter half of the rotationally conveying the band-shaped coil.

[0017] (6) In the coil forming method described in (4) above, in the guiding step, the side end portions can be guided by the inner wall surfaces (e.g., inner wall surfaces 41 described below) of the guide members throughout the rotationally conveying the band-shaped coil (e.g., rotationally conveying portion 313 described below).

[0018] (EFFECTS OF THE INVENTION)

[0019] The coil forming apparatus described in (1) above can guide the side end portions of the band-shaped coil using the guide members while continuously inserting the straight portions of the band-shaped coil into the comb-tooth-shaped grooves of the coil winding jig and winding the band-shaped coil on the coil winding jig. Therefore, the band-shaped coil can be easily formed into a wound state without positional displacement of the straight portions.

[0020] The coil forming apparatus described in (2) above guides the side end portions of the band-shaped coil using the wall surfaces in the latter half of the rotationally conveying, and therefore, the straight portions of the band-shaped coil can be smoothly guided into the comb-tooth-shaped grooves of the coil winding jig.

[0021] The coil forming device according to the above (3) can guide the side end portion of the band-shaped coil using the wall surface during the entire rotation conveying, and thus can smoothly guide the band-shaped coil along the outer periphery of the coil winding jig and smoothly guide the straight portion of the band-shaped coil to the comb-toothed groove of the coil winding jig.

[0022] The coil forming method according to the above (4) can continuously insert the straight portion of the band-shaped coil to the comb-toothed groove of the coil winding jig while guiding the side end portion of the band-shaped coil using the guide member, and wind the band-shaped coil on the coil winding jig. Thus, the band-shaped coil can be easily formed in the wound state without positional deviation of the straight portion.

[0023] The coil forming method according to the above (5) can guide the side end portion of the band-shaped coil to the comb-toothed groove of the coil winding jig using the wall surface during the latter half of the rotation conveying, and thus can smoothly guide the straight portion of the band-shaped coil to the comb-toothed groove of the coil winding jig.

[0024] The coil forming method according to the above (6) can guide the side end portion of the band-shaped coil using the wall surface during the entire rotation conveying, and thus can smoothly guide the band-shaped coil along the outer periphery of the coil winding jig and smoothly guide the straight portion of the band-shaped coil to the comb-toothed groove of the coil winding jig. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 is a side view showing an embodiment of a coil forming device of the present application.

[0026] Figure 2 is a view obtained by viewing the coil forming device shown in Figure 1 from the A direction. Figure 1

[0027] Figure 3 is a view obtained by viewing the coil forming device shown in Figure 1 from the B direction. Figure 1

[0028] Figure 4 is a perspective view showing an embodiment of a coil winding jig.

[0029] Figure 5 is a perspective view showing a link member of a gripping portion of a coil conveying mechanism portion.

[0030] Figure 6 is a perspective view obtained by viewing the link member of the gripping portion of the coil conveying mechanism portion from the opposite side of Figure 5

[0031] Figure 7 ​​​is a perspective view showing a state in which two joint members are joined to each other.

[0032] Figure 8 is Figure 1 is an enlarged view of E part in

[0033] Figure 9 is Figure 1 is an enlarged view of C part in

[0034] Figure 10 is a sectional view showing a case where a band-shaped coil is guided to a coil winding jig in a circular arc shape by a guide member.

[0035] Figure 11 is Figure 1 is an enlarged sectional view of D part in

[0036] Figure 12 is a partial enlarged view showing a case where a band-shaped coil is wound on a coil winding jig in multiple.

[0037] Figure 13 is a perspective view showing a state where a band-shaped coil is shaped into a wound state on a coil winding jig. DETAILED DESCRIPTION

[0038] Hereinafter, an embodiment of the present application will be described. As shown in Figure 1 the coil shaping device 1 of the present embodiment includes a coil winding jig 2, a coil conveying mechanism part 3 that conveys a band-shaped coil 100 along the outer periphery of the coil winding jig 2, and a pair of guide members 4 that guide the band-shaped coil 100 conveyed by the coil conveying mechanism part 3 in a manner to be wound on the coil winding jig 2.

[0039] (Band-shaped coil)

[0040] As shown in Figure 3 the band-shaped coil 100 is shaped into a long strip wave type band from a flat wire 101 having a sectional shape of a substantially rectangular shape. The flat wire 101 is formed of, for example, a highly conductive metal such as copper, aluminum, or the like.

[0041] The strip coil 100 has a plurality of straight portions 102 and a plurality of side ends 103. The straight portions 102 are inserted into slots provided on the inner circumference of a stator core (not shown), and extend generally in a straight line in the same direction, arranged in parallel at fixed intervals. The side ends 103 are respectively disposed closer to the side ends of the strip coil 100 than the straight portions 102, specifically disposed at both ends in the extending direction of the straight portions 102. The side ends 103 alternately connect one end of adjacent straight portions 102 to each other and the other end to each other in a mountain-shaped shape, forming coil ends that protrude axially from the slots toward the stator core when the strip coil 100 is installed in the slots of the stator core.

[0042] The strip coil 100 of this embodiment is formed by bending six flat conductors 101 into a waveform by bending multiple straight portions 102 and multiple side ends 103 respectively. The straight portions 102 are arranged parallel to each other at fixed intervals, and the side ends 103 are overlapped with staggered pitches of the straight portions 102, thus forming a long strip. The straight portions 102 of the strip coil 100 are formed by folding the flat conductors 101 back midway, and in the thickness direction of the strip coil 100 (… Figure 3 Multiple coils overlap in the direction perpendicular to the paper. The strip coil 100 of this embodiment has a length of 4 turns wound on the coil winding fixture 2 described below.

[0043] (Coil winding fixture)

[0044] like Figure 4 As shown, the coil winding fixture 2 includes: a generally cylindrical fixture body 21; a plurality of comb-shaped portions 22 protruding radially outward from the outer periphery of the fixture body 21; a plurality of comb-shaped grooves 23 disposed between adjacent comb-shaped portions 22 in the circumferential direction; and a shaft hole 24 opening at the center of the fixture body 21. The comb-shaped portions 22 and comb-shaped grooves 23 are respectively disposed at both ends of the fixture body 21 in the axial direction. The comb-shaped portions 22 and comb-shaped grooves 23 at one end of the fixture body 21 are phase-aligned with the comb-shaped portions 22 and comb-shaped grooves 23 at the other end. In this embodiment, the coil winding fixture 2 has 72 comb-shaped grooves 23 at each end of the fixture body 21 in the axial direction. The number of these comb-shaped grooves 23 is consistent with the number of slots on which the stator core of the strip coil 100 is mounted.

[0045] The distance between the comb-shaped teeth 22 and comb-shaped grooves 23 at one end of the fixture body 21 and at the other end is approximately equal to the length of the straight portion 102 of the strip coil 100 in the extending direction. Therefore, the straight portion 102 of the strip coil 100 can be accommodated throughout the comb-shaped grooves 23 at both ends of the fixture body 21.

[0046] The coil winding jig 2 is formed so that the outer diameter thereof defined by the front end position of the comb tooth portion 22 is below the inner diameter of the stator core, so as to be able to be inserted to the inner side of the stator core. The coil winding jig 2 is disposed at a specific position of the coil forming device 1, and is provided so as to be able to rotate around the shaft hole 24 under the drive of a motor not shown, in the d1 direction indicated by the arrow in FIG. 1. Figure 1

[0047] (coil conveying mechanism portion)

[0048] The coil conveying mechanism portion 3 conveys the strip-shaped coil 100 while rotating it along at least a portion of the outer periphery of the coil winding jig 2. Specifically, as shown in FIGS. 2 and 3, the coil conveying mechanism portion 3 has a pair of conveying rails 31 that constitute a conveying path for the strip-shaped coil 100, and a conveying body 32 that holds the strip-shaped coil 100 and conveys it along the conveying rails 31. Figure 1 Figure 2

[0049] The conveying rails 31 are formed of a metal strip-shaped plate material, and are disposed in parallel with each other at intervals approximately equal to the length of the straight portion 102 of the strip-shaped coil 100 in the width direction of the coil forming device 1. As shown in FIG. 2, the interval of the pair of conveying rails 31 is approximately equal to the axial interval distance of the comb tooth portion 22 and the comb tooth-like groove 23 of the coil winding jig 2. Figure 2

[0050] The conveying rails 31 each have a pair of straight conveying portions 311, 312 that form a straight conveying path in parallel, and a rotating conveying portion 313 that connects the end portions of the straight conveying portions 311, 312 in a circular arc shape, so as to form a conveying path in the shape of a lateral U. The conveying rails 31 are disposed so as to surround the coil winding jig 2 disposed inside the U portion, so that the rotating conveying portion 313 follows the outer periphery of the coil winding jig 2. As shown in FIG. 2, a guide groove 314 that extends over the entire length of the conveying rail 31 is provided on the surface of each of the pair of conveying rails 31 that faces the other. Figure 2

[0051] ​​​​​In the present embodiment, the rotation conveying section 313 of the coil conveying mechanism section 3 is formed in a range of approximately 1 / 2 of the outer periphery of the coil winding jig 2. The rotation conveying section 313 has a front half section 313a as an introduction side of the band-shaped coil 100 and a rear half section 313b as a discharge side of the band-shaped coil 100. The front half section 313a is formed in a range of approximately 1 / 2 of the front half of the rotation conveying section 313. The rear half section 313b is formed in a range of approximately 1 / 2 of the rear half of the rotation conveying section 313. However, the rotation conveying section 313 can be configured to convey the band-shaped coil 100 along at least a portion of the outer periphery of the coil winding jig 2.

[0052] The conveying body 32 extends in a long strip shape along the conveying rail 31 and is configured to move along the conveying rail 31 between the pair of conveying rails 31. The conveying body 32 has a length corresponding to at least the total length of the band-shaped coil 100 and conveys the band-shaped coil 100 along the outer periphery of the coil winding jig 2 by moving along the conveying rail 31 while holding the straight section 102 of the band-shaped coil 100 on the upper surface.

[0053] As shown in Figs. 1, 2, and 3, the conveying body 32 is composed of a plurality of link members 33 of the same configuration arranged in a stacked manner along the length direction of the band-shaped coil 100. As shown in Figs. 4, 5, and 6, the link member 33 has a link member body 331 made of metal and having a substantially rectangular plate shape and a pair of guide protrusions 332 protruding laterally from both width direction end portions of the lower end of the link member body 331, respectively. Figure 1 Figure 3 As shown in Figs. 4, 5, and 6, the link member 33 has a link member body 331 made of metal and having a substantially rectangular plate shape and a pair of guide protrusions 332 protruding laterally from both width direction end portions of the lower end of the link member body 331, respectively. Figure 5 Figure 6 Figure 7 As shown in Figs. 4, 5, and 6, the link member 33 has a link member body 331 made of metal and having a substantially rectangular plate shape and a pair of guide protrusions 332 protruding laterally from both width direction end portions of the lower end of the link member body 331, respectively. Figure 5 Figure 6 Figure 7 In the present embodiment, the X direction in Figs. 4, 5, and 6 is defined as the width direction, the Y direction is defined as the thickness direction, and the Z direction is defined as the height direction. In the height direction, the upward direction in the figures is defined as "up" and the downward direction is defined as "down".

[0054] ​​​​​The joint member body 331 has a thickness that is substantially equal to the gap between the straight portions 102, 102 adjacent in the length direction of the band coil 100. A pair of first gripping claws 333 are provided protruding in the height direction from an upper end surface 331a of the joint member body 331. The first gripping claws 333 have a thickness that is substantially 1 / 2 of the thickness of the joint member body 331. The thickness of the first gripping claws 333 is substantially equal to the gap between the adjacent straight portions 102, 102 of the band coil 100. The first gripping claws 333 are disposed at positions on the one end side in the thickness direction of the joint member body 331 in the upper end surface 331a. The pair of first gripping claws 333 are disposed separately from each other at both ends in the width direction of the joint member body 331 at a predetermined interval.

[0055] On the upper end surface of the first gripping claws 333, engagement grooves 333a that engage with the front ends of the comb teeth 22 of the coil winding jig 2 are respectively provided. In detail, as shown in Figure 4 engagement portions 22a are respectively provided at the front ends of the comb teeth 22 of the coil winding jig 2. The engagement grooves 333a have a position and a shape that can engage with the engagement portions 22a of the coil winding jig 2.

[0056] The first gripping claws 333 respectively have tapered surfaces 333b on the side opposite to the side on which the upper end surface 331a is disposed. By the tapered surfaces 333b, the first gripping claws 333 are formed so as to be slightly narrower at the front end as they move away from the joint member body 331.

[0057] Between the pair of first gripping claws 333, a rectangular recess 334 is provided in the height direction of the joint member body 331. The recess 334 is provided from the upper end surface 331a to a position that is substantially 1 / 2 in the height direction of the joint member body 331. Like the first gripping claws 333, the depth of the recess 334 in the thickness direction of the joint member body 331 has a depth that is substantially 1 / 2 of the thickness of the joint member body 331.

[0058] On one side surface 331b of the joint member body 331, a rectangular protrusion 335 is provided. The protrusion 335 is provided so as to protrude in a block shape in a direction perpendicular to the side surface 331b from the side surface 331b on the side opposite to the side on which the first gripping claws 333 are provided in the thickness direction of the joint member body 331. The protrusion 335 is disposed further upward than a position that is substantially 1 / 2 in the height direction of the joint member body 331. The height of the protrusion 335 in the height direction of the joint member body 331 is substantially equal to the height of the recess 334. The thickness of the protrusion 335 in the thickness direction of the joint member body 331 is substantially equal to the depth of the recess 334.

[0059] At the upper end of the convex portion 335, a second gripping claw 336 is provided. Like the first gripping claw 333, the second gripping claw 336 protrudes more upward than the upper end surface 331a of the link member main body 331. Like the first gripping claw 333, the thickness of the second gripping claw 336 is substantially equal to the gap between the adjacent straight portions 102, 102 of the band coil 100. Since the second gripping claw 336 has the same width as the convex portion 335, as shown in Figure 7 When the two link members 33, 33 are overlapped with the same orientation, the second gripping claw 336 of the other link member 33 is disposed between the pair of first gripping claws 333, 333 of one link member 33.

[0060] The second gripping claw 336 has a tapered surface 336a on each of the side and the opposite side of the upper end surface 331a. By the tapered surface 336a, the second gripping claw 336 is formed to be slightly narrower toward the front end as it moves away from the link member main body 331.

[0061] As shown in Figure 7 , the plurality of link members 33 are aligned with the first gripping claws 333 and the second gripping claws 336 pointing in the same direction, and are overlapped with the convex portion 335 of the link member 33 being received in the concave portion 334 of the adjacent link member 33. Thus, the adjacent link members 33, 33 are closely overlapped with each other.

[0062] At the position near the root of the first gripping claw 333 and substantially at the same level as the upper end surface 331a of the link member main body 331, a through hole 337a is provided that extends in the width direction of the link member 33. Also, at the position near the root of the second gripping claw 336 and substantially at the same level as the upper end surface 331a of the link member main body 331, a through hole 337b is provided that extends in the width direction of the convex portion 335. As shown in Figure 7 When the two link members 33, 33 are overlapped, the shaft member 338 is inserted through the connected through holes 337a and 337b. Thus, the plurality of link members 33 are connected so that the lower end side provided with the guide protrusion 332 can rotate (swing) in the length direction of the conveying body 32 with the shaft member 338 as the rotation axis, thereby forming the long conveying body 32.

[0063] In the conveying body 32, between the first gripping claws 333, 333 and the second gripping claws 336, 336 of the adjacent link members 33, 33, as shown in Figure 3 , Figure 7 , Figure 8 and Figure 9As shown, a gripping groove 321 that grips the straight portion 102 of the band-shaped coil 100 is formed. The upper end surface 331a of the link member body 331 faces the bottom of the gripping groove 321. The gripping groove 321 has a groove width that can accommodate the straight portion 102 of the band-shaped coil 100. The groove width of the gripping groove 321 is substantially equal to the groove width in the circumferential direction of the comb-toothed groove 23 of the coil winding jig 2. The arrangement pitch of the gripping groove 321 in the length direction of the conveying body 32 is substantially equal to the arrangement pitch in the circumferential direction of the comb-toothed groove 23 of the coil winding jig 2. Therefore, if the engagement groove 333a engages with the engagement portion 22a, as shown in Figure 8 As shown, the gripping groove 321 of the conveying body 32 and the comb-toothed groove 23 of the coil winding jig 2 communicate in the radial direction of the coil winding jig 2.

[0064] The conveying body 32 is configured such that each guide protrusion 332 of the link member 33 is slidably accommodated in the guide groove 314 of the conveying rail 31 and protrudes toward the inside of the U-shaped conveying rail 31. Further, as shown in Figure 8 As shown, the conveying body 32 is configured such that, when it reaches directly below the coil winding jig 2, it can move in the d2 direction in synchronization with the rotation of the coil winding jig 2 by the rotation of the coil winding jig 2 in the d1 direction by the engagement of the engagement groove 333a of the link member 33 with the engagement portion 22a of the coil winding jig 2. When the conveying body 32 moves in a circular arc shape along the rotating conveying portion 313 of the conveying rail 31, the shaft member 338 is used to rotate the first gripping claw 333 and the second gripping claw 336, which grip the straight portion 102, with respect to the guide protrusions 332 of the adjacent link members 33, 33, and thus the conveying body 32 can move smoothly.

[0065] As shown in Figure 3 , Figure 8 and Figure 9 The conveying body 32 that is slidably arranged on the conveying rail 31 grips the band-shaped coil 100 by inserting the first gripping claw 333 and the second gripping claw 336 into the gap between the straight portions 102, 102 adjacent in the length direction of the band-shaped coil 100, respectively, and accommodating the straight portions 102 in the gripping grooves 321. Therefore, the conveying body 32 can convey the band-shaped coil 100 while maintaining the straight portions 102 at a fixed interval without positional deviation. As shown in Figure 2 and Figure 3 The side end portions 103 of the band-shaped coil 100 are configured to protrude to both sides of the moving direction of the conveying body 32, respectively. In addition, in Figure 1 , the band-shaped coil 100 gripped by the conveying body 32 is omitted.

[0066] (Guiding member)

[0067] AsFigure 1 As shown, the guide member 4 is made of a metal strip plate, formed in a roughly U-shape laterally along the rotating conveyor section 313 of the conveyor track 31. The guide member 4 clamps the coil winding fixture 2 and is positioned along the axial direction of the coil winding fixture 2. Figure 1 The direction perpendicular to the paper surface Figure 2 Near both ends of the U-shaped part (in the left and right directions), the inner side of the U-shaped part is arranged in the direction of the coil winding fixture 2 and is fixed on the conveyor track 31.

[0068] The guiding member 4 has: an inlet end 4a for introducing the side end 103 of the strip coil 100 conveyed by the conveyor 32; an outlet end 4b for discharging the side end 103 of the strip coil 100; and an inner wall surface 41 for guiding the side end 103 from the inlet end 4a to the outlet end 4b. The inner wall surface 41 is formed by a curved surface that smoothly and continuously curves along approximately half of the outer periphery of the coil winding fixture 2 from the inlet end 4a to the outlet end 4b. The guiding member 4 smoothly guides the entire strip coil 100 into an arc shape along the outer periphery of the coil winding fixture 2 by contacting the side end 103 introduced from the inlet end 4a with the inner wall surface 41 during the rotational conveying by the rotary conveyor 313.

[0069] The curvature of the arc-shaped inner wall surface 41 of the guide component 4 is formed to gradually increase from the inlet end 4a toward the outlet end 4b. Specifically, as... Figure 10 As shown, the inner wall surface 41 at the inlet end 4a is located slightly radially outward from the outer periphery of the coil winding fixture 2. However, the inner wall surface 41 gradually and smoothly narrows in diameter as it moves from the inlet end 4a toward the outlet end 4b. The inner wall surface 41 at the outlet end 4b is located radially inward from the outer periphery of the coil winding fixture 2. Therefore, the inner wall surface 41 of the guide member 4 is guided in such a way that as the strip coil 100 moves from the front half 313a of the rotary conveyor 313 toward the rear half 313b, it contacts the side end 103 of the strip coil 100 while gradually curling into an arc shape with a diameter smaller than the outer diameter of the coil winding fixture 2.

[0070] The band-shaped coil 100 is gradually pushed toward the coil winding jig 2 by being guided to the inner wall surface 41 of the guide member 4 as it moves from the front half portion 313a of the rotating conveyance portion 313 toward the rear half portion 313b. As a result, the straight portion 102 held by the conveyance body 32 is lifted from the holding groove 321 and forcibly detached, and gradually moves toward the inside of the comb-toothed groove 23 of the coil winding jig 2. Since the discharge end 4b of the guide member 4 is disposed at a position more radially inward than the outer periphery of the coil winding jig 2, the straight portion 102 is completely inserted into the comb-toothed groove 23 of the coil winding jig 2. Thereafter, the band-shaped coil 100 is wound on the coil winding jig 2 by the rotation of the coil winding jig 2. In addition, in Figure 10 and Figure 12 the band-shaped coil 100 is omitted, and the band-shaped coil 100 is simplified.

[0071] In addition, the guide member 4 is not limited to the configuration having the inner wall surface 41 that is continuous over the entire rotating conveyance portion 313 as in the present embodiment. Although not shown, for example, the guide member 4 can be configured with a plurality of guide rollers disposed along the rotating conveyance portion 313. However, from the viewpoint of being able to continuously guide the band-shaped coil 100 to the comb-toothed groove 23 of the coil winding jig 2 and being able to smoothly insert the straight portion 102 into the comb-toothed groove 23, the guide member 4 preferably has the inner wall surface 41 that contacts the side end portion 103 at the rear half portion 313b of the rotating conveyance portion 313. From the viewpoint of being able to smoothly guide the band-shaped coil 100 in an arc shape along the entire rotating conveyance portion 313 and being able to smoothly insert the straight portion 102 into the comb-toothed groove 23 of the coil winding jig 2, the guide member 4 preferably has the inner wall surface 41 that contacts the side end portion 103 at the entire rotating conveyance portion 313 as in the present embodiment.

[0072] As shown in Figure 1 and Figure 2 on the introduction end 4a side of the guide member 4, a pair of shaping portions 42 for forcibly deforming and shaping the band-shaped coil 100 introduced to the rotating conveyance portion 313 in a manner of being bent in an arc shape along the outer periphery of the coil winding jig 2 is provided. In the guide member 4, the range in which the shaping portions 42 are provided is within the range of the front half portion 313a of the rotating conveyance portion 313. Specifically, the shaping portions 42 can be provided, for example, in a range from the introduction end 4a of the guide member 4 to about 1 / 2 to about 3 / 4 of the front half portion 313a of the rotating conveyance portion 313.

[0073] The shaped portion 42 is formed of the inner wall surface 41 of the guide member 4 and a guide plate 421. The guide plate 421 is formed so as to smoothly curve in an arc shape in accordance with the curvature of the inner wall surface 41 of the guide member 4. Like the guide member 4, the guide plate 421 is arranged so as to sandwich the coil winding jig 2 from both axial end sides, and is fixed to the guide member 4. In the shaped portion 42, a shaped groove 422 that sandwiches the side end portion 103 is formed between the inner wall surface 41 and the guide plate 421. The inner wall surface 41 of the shaped portion 42 contacts and supports the radially outer side of the side end portion 103 of the ribbon coil 100, and the guide plate 421 contacts and supports the radially inner side of the side end portion 103 of the ribbon coil 100.

[0074] The shaped portion 42, by sandwiching the side end portion 103 of the ribbon coil 100 introduced into the introduction end 4a of the guide member 4 into the shaped groove 422 and performing the sandwiching while performing the conveyance, forcibly deforms the ribbon coil 100 in a curved arc shape. Thus, the ribbon coil 100 is shaped in an arc shape at the initial stage of the introduction into the rotation conveyance portion 313 before being wound on the coil winding jig 2, and thus it is possible to suppress the exertion of the force to elastically return to a flat shape during the guiding of the ribbon coil 100 into an arc shape by the inner wall surface 41 of the guide member 4. Therefore, the ribbon coil 100 is guided into an arc shape by the guide member 4, and is smoothly and highly accurately shaped into a winding state in a substantially cylindrical shape.

[0075] (Coil shaping method)

[0076] Next, a method of shaping the ribbon coil 100 into a winding state in a substantially cylindrical shape by the coil shaping device 1 will be described.

[0077] First, the coil winding jig 2 is arranged so as to be rotatable by the drive of a motor not shown on the inner side of the U-shaped portion of the conveyance track 31 of the coil shaping device 1. After the coil winding jig 2 is arranged on the coil shaping device 1, the ribbon coil 100 shaped in advance in a long wave-shaped ribbon is supplied to the conveyance body 32 arranged on the straight conveyance portion 311 on the lower side of the conveyance track 31 by a coil supply device not shown or a worker. The ribbon coil 100 is gripped by the conveyance body 32 by inserting the first gripping claw 333 and the second gripping claw 336 of each section member 33 of the conveyance body 32 into the gap between the adjacent straight portions 102, 102, and by housing the straight portions 102 in the gripping grooves 321, respectively.

[0078] After that, the transport body 32 holding the band coil 100 is pushed by a not-shown transport body pushing device or an operator to move toward the coil winding jig 2 on the straight transport section 311 in a manner that the engaging groove 333a of the joint member 33 engages with the engaging section 22a of the coil winding jig 2. After the engaging groove 333a and the engaging section 22a engage right below the coil winding jig 2, if the coil winding jig 2 is rotationally driven in the dl direction, the transport body 32 moves along the d2 direction on the transport rail 31 in synchronization with the rotation of the coil winding jig 2, thereby rotating the transport band coil 100 in a manner along the outer periphery of the coil winding jig 2 (coil transport step).

[0079] If the transport body 32 reaches the rotational transport section 313, the side end portion 103 of the band coil 100 is first introduced from the lead-in end 4a of the guide member 4 to the profiling groove 422 of the profiling section 42, and is rotationally transported while being sandwiched between the inner wall surface 41 and the guide plate 421. Thus, the band coil 100 is forcibly deformed and profiled in a manner of being curved in an arc shape along the profiling groove 422 (profiling step).

[0080] The band coil 100 that has passed through the profiling section 42 is rotationally transported while being guided along the inner wall surface 41 of the guide member 4 and along at least a portion of the outer periphery of the coil winding jig 2, specifically, along substantially 1 / 2 of the range of the outer periphery of the coil winding jig 2, in a manner of being gradually curved in an arc shape, accompanying the rotation of the coil winding jig 2.

[0081] Since the curvature of the inner wall surface 41 of the guide member 4 gradually becomes larger as it goes from the front half portion 313a toward the rear half portion 313b of the rotational transport section 313, the side end portion 103 of the band coil 100 is pushed by the inner wall surface 41 to gradually shrink in diameter toward the radially inner side. Thus, the band coil 100 is curved to have a smaller diameter than the outer diameter of the coil winding jig 2. The side end portion 103 pushed by the inner wall surface 41 gradually separates the straight portion 102 from the holding groove 321 toward the comb-shaped groove 23 of the coil winding jig 2 as the band coil 100 goes toward the discharge end 4b of the guide member 4. The straight portion 102 that has completely separated from the holding groove 321 is inserted into the comb-shaped groove 23 of the coil winding jig 2 as shown in FIG. 6, while being pushed by the inner wall surface 41 of the guide member 4 (guiding step). After that, the band coil 100 is wound on the coil winding jig 2 while being discharged from the discharge end 4b of the guide member 4, accompanying the rotation of the coil winding jig 2. Figure 10

[0082] If the entire transport body 32 ends the movement along the transport rail 31, the band coil 100 is inserted into the comb-shaped groove 23 in a layered manner by the straight portion 102, as shown in FIG. 6. Figure 12 ​As shown, it is wound multiple times on the coil winding fixture 2 in a manner of winding 4 turns. Thus, as Figure 13 As shown, the strip coil 100 can be easily formed into a generally cylindrical wound state. Since the straight portion 102 of the wound strip coil 100 is housed within the comb-shaped groove 23, it does not experience positional shift. Therefore, the strip coil 100 can stably maintain a generally cylindrical wound state. Furthermore, the strip coil is not limited to being wound multiple times on the coil winding fixture 2.

[0083] The coil forming apparatus 1 described above achieves the following effect. Specifically, the coil forming apparatus 1 of this embodiment forms a strip coil 100 into a wound state, the strip coil 100 having multiple straight portions 102 and side ends 103 disposed at both ends of the straight portions 102. The coil forming apparatus 1 includes: a coil winding fixture 2 having multiple comb-shaped grooves 23 on its outer periphery into which the multiple straight portions 102 can be inserted, and configured to wind the strip coil 100; a coil conveying mechanism 3 configured to rotatably convey the strip coil 100 along at least a portion of the outer periphery of the coil winding fixture 2; and guide members 4 disposed near both axial ends of the coil winding fixture 2, contacting the side ends 103 while guiding the strip coil 100 into an arc shape. The guide member 4 guides the strip coil 100 into an arc shape with a diameter smaller than the outer diameter of the coil winding fixture 2 in the rear half 313b of the rotary conveying section 313 of the rotary conveying strip coil 100, and inserts multiple straight portions 102 into multiple comb-shaped grooves 23 of the coil winding fixture 2. Thus, while guiding the side ends 103 of the strip coil 100 using the guide member 4, the straight portions 102 of the strip coil 100 can be continuously inserted into the comb-shaped grooves 23 of the coil winding fixture 2 and wound onto the coil winding fixture 2. Therefore, the strip coil 100 can be easily shaped into a wound state without the straight portions 102 shifting position.

[0084] In the guide member 4 of this embodiment, there is an inner wall surface 41 in which at least the rear half 313b of the rotary conveying section 313 of the rotary conveying strip coil 100 contacts the side end 103. Thus, in the rear half 313b of the rotary conveying section 313, the side end 103 of the strip coil 100 is guided by the wall surface, so the straight portion 102 of the strip coil 100 can be smoothly guided to the comb-shaped groove 23 of the coil winding fixture 2.

[0085] The guide member 4 of the present embodiment has an inner wall surface 41 that contacts the side end portion 103 with a wall surface in the entire rotation conveying portion 313 of the rotationally conveyed belt-like coil 100. Thus, the side end portion 103 of the belt-like coil 100 is guided with the wall surface throughout the entire rotation conveying portion 313, so the belt-like coil 100 can be smoothly guided along the outer periphery of the coil winding jig 2, and the straight portion 102 of the belt-like coil 100 can be smoothly inserted into the comb-toothed groove 23 of the coil winding jig 2.

[0086] According to the coil forming method described above, the following effects are achieved. That is, the coil forming method of the present embodiment forms the belt-like coil 100, which has a plurality of straight portions 102 and side end portions 103 arranged at both ends of the plurality of straight portions 102, into a wound state. The coil forming method includes a coil conveying step of rotationally conveying the belt-like coil 100 along at least a portion of the outer periphery of the coil winding jig 2, the coil winding jig 2 having a plurality of comb-toothed grooves 23 into which the plurality of straight portions 102 can be respectively inserted and configured to wind the belt-like coil 100, and a guiding step of arranging the guide member 4 near both ends in the axial direction of the coil winding jig 2, respectively, and guiding the belt-like coil 100 into an arc shape having a smaller diameter than the outer diameter of the coil winding jig 2 while contacting the guide member 4 with the side end portion 103, and causing the plurality of straight portions 102 to be respectively inserted into the plurality of comb-toothed grooves 23 in the latter half 313b of the rotation conveying portion 313 in which the belt-like coil 100 is rotationally conveyed. Thus, the straight portion 102 of the belt-like coil 100 can be continuously inserted into the comb-toothed groove 23 of the coil winding jig 2 while the side end portion 103 of the belt-like coil 100 is guided with the guide member 4, and wound on the coil winding jig 2. Therefore, the belt-like coil 100 can be easily formed into a wound state without positional deviation of the straight portion 102.

[0087] In the guiding step of the present embodiment, the side end portion 103 is guided with the inner wall surface 41 of the guide member 4 in at least the latter half 313b of the rotation conveying portion 313 in which the belt-like coil 100 is rotationally conveyed. Thus, the straight portion 102 of the belt-like coil 100 can be smoothly guided into the comb-toothed groove 23 of the coil winding jig 2.

[0088] In the guiding step of the present embodiment, the side end portion 103 is guided with the inner wall surface 41 of the guide member 4 in the entire rotation conveying portion 313 in which the belt-like coil 100 is rotationally conveyed. Thus, the belt-like coil 100 can be smoothly guided along the outer periphery of the coil winding jig 2, and the straight portion 102 of the belt-like coil 100 can be smoothly guided into the comb-toothed groove 23 of the coil winding jig 2.

[0089] REFERENCE NUMERALS

[0090] 1 Coil forming device

[0091] 2 Coil winding jig

[0092] 23 Comb-tooth-shaped groove

[0093] 3 Coil conveying mechanism section

[0094] 313 Rotating conveying section

[0095] 313b Rear half

[0096] 4 Guide member

[0097] 41 Inner wall surface

[0098] 100 Band-shaped coil

[0099] 102 Straight portion

[0100] 103 Side end portion

Claims

1. A coil forming apparatus that forms a band-shaped coil into a wound state, the band-shaped coil having a plurality of straight portions and side end portions disposed at both ends of the plurality of straight portions, the coil forming apparatus comprising: a coil winding jig having a plurality of comb-tooth-shaped grooves into which the plurality of straight portions are respectively inserted on an outer periphery, and configured to wind the band-shaped coil; a coil conveying mechanism portion configured to convey the band-shaped coil in a U shape along at least a portion of the outer periphery of the coil winding jig; and guide members respectively disposed near both axial ends of the coil winding jig, guiding the band-shaped coil into an arc shape while being in contact with the side end portions, and wherein the guide members guide the band-shaped coil into an arc shape having a smaller diameter than an outer diameter of the coil winding jig in a latter half of the conveyance of the band-shaped coil, and the plurality of straight portions are respectively inserted into the plurality of comb-tooth-shaped grooves of the coil winding jig. The guide members have inner wall surfaces that are in contact with the side end portions in the latter half of the conveyance of the band-shaped coil. The guide members have inner wall surfaces that are in contact with the side end portions throughout the conveyance of the band-shaped coil. The coil conveying mechanism portion has a conveying rail that forms a conveying path along which the band-shaped coil is conveyed in a rotating manner along the coil winding jig, and a conveying body configured to move along the conveying rail while holding the plurality of straight portions of the band-shaped coil. The conveying body is composed of a plurality of link members that overlap in a conveying direction of the band-shaped coil and hold the plurality of straight portions respectively, 2. The coil forming apparatus of claim 1, wherein, The plurality of link members are respectively connected to be rotatable with respect to positions at which the plurality of straight portions are held as the band-shaped coil is conveyed.

3. The coil forming apparatus of claim 1, wherein, The conveying body is composed of a plurality of link members that overlap in a conveying direction of the band-shaped coil and hold the plurality of straight portions respectively, 4. The coil forming apparatus of claim 1, wherein, The conveying rail has a guide groove that forms a movement path of the conveying body, 5. The coil forming apparatus of claim 4, wherein, The plurality of link members have guide protrusions that engage with the guide groove at end portions on opposite sides of the positions at which the plurality of straight portions are held.

7. A coil forming method that forms a band-shaped coil into a wound state, the band-shaped coil having a plurality of straight portions and side end portions disposed at both ends of the plurality of straight portions, the coil forming method comprising: a coil conveying step of conveying the band-shaped coil in a U shape along at least a portion of an outer periphery of a coil winding jig having a plurality of comb-tooth-shaped grooves into which the plurality of straight portions are respectively inserted on the outer periphery, and configured to wind the band-shaped coil; and a guide step of disposing guide members near both axial ends of the coil winding jig, guiding the band-shaped coil into an arc shape having a smaller diameter than an outer diameter of the coil winding jig while the guide members are in contact with the side end portions, and in a latter half of the conveyance of the band-shaped coil, inserting the plurality of straight portions into the plurality of comb-tooth-shaped grooves respectively.

6. The coil forming apparatus of claim 4, wherein, ​ ​ ​ ​ ​ ​ 8. The coil forming method of claim 7, wherein, In the aforementioned guiding step, the side end portion is guided by the inner wall surface of the guide member at least in the latter half of the rotational conveyance of the band-shaped coil.

9. The coil forming method of claim 7, wherein, In the aforementioned guiding step, the side end portion is guided by the inner wall surface of the guide member throughout the rotational conveyance of the band-shaped coil.

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