Coil forming device and coil forming method

Abstract

A coil forming device is provided that can easily and precisely form a strip-shaped coil into a wound state. The coil forming device comprises: a coil winding jig having a plurality of comb-shaped grooves on its outer circumference into which a plurality of straight portions can be inserted, and configured to wind a strip-shaped coil; a coil conveying mechanism configured to rotatably convey the strip-shaped coil along at least a portion of the outer circumference of the coil winding jig; and guide members disposed near both axial ends of the coil winding jig, guiding the strip-shaped coil into an arc shape along the outer circumference of the coil winding jig while contacting the side ends, and inserting the plurality of straight portions into the plurality of comb-shaped grooves in the latter half of the rotational conveyance of the strip-shaped coil; and a shaping member comprising a shaping member that, in the first half of the rotational conveyance of the strip-shaped coil, clamps the side ends of the strip-shaped coil and deforms the strip-shaped coil into an arc shape along the outer circumference of the coil winding jig to shape the strip-shaped coil.

Description

Technical Field

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

[0002] The stator of a rotating electrical machine has a wound strip coil. The strip coil is preformed into a roughly cylindrical shape with a diameter smaller than the inner diameter of the stator core and then inserted into the stator core. The wound strip coil is installed by expanding the diameter of the stator core and inserting the straight portion of the strip coil into the stator core slot.

[0003] Conventionally, it is known to feed a strip-shaped coil pitch by pitch to a cylindrical core member and to wind the strip-shaped coil around the core member to form a substantially cylindrical wound state (for example, refer to Patent Document 1).

[0004] [Prior technical literature]

[0005] (Patent Document)

[0006] Patent Document 1: Japanese Patent No. 4953032 Summary of the Invention

[0007] [Problems to be solved by the invention]

[0008] The above-mentioned prior art does not specifically disclose how to wind the strip-shaped coil around the core member.

[0009] However, since the strip-shaped coil is formed by bending a metal conductor, it has elasticity inherent to the conductor itself, making it difficult to smoothly and accurately form the strip-shaped coil into a wound state.

[0010] An object of the present invention is to provide a coil forming device and a coil forming method capable of forming a strip-shaped coil into a wound state with high precision and smoothly.

[0011] [Technical means to solve the problem]

[0012] (1) A coil forming device of the present invention (e.g., coil forming device 1 described below) forms a strip-shaped coil (e.g., strip-shaped coil 100 described below) into a wound state, wherein the strip-shaped coil (e.g., strip-shaped coil 100 described below) has a plurality of straight portions (e.g., straight portion 102 described below) and side end portions (e.g., side end portions 103 described below) arranged at both ends of the plurality of straight portions, the coil forming device comprising: a coil winding jig (e.g., coil winding jig 2 described below) having a plurality of comb-shaped grooves (e.g., comb-shaped grooves 23 described below) on its outer periphery into which the plurality of straight portions can be inserted, respectively, and configured to wind the strip-shaped coil; a coil conveying mechanism (e.g., coil conveying mechanism 3 described below) configured to rotatably convey the strip-shaped coil along at least a portion of the outer periphery of the coil winding jig; and The guiding components (for example, the guiding components 4 described below) are respectively arranged near the axial ends of the aforementioned coil winding jig, and while contacting the aforementioned side end portions, guide the aforementioned strip-shaped coil into an arc shape along the outer circumference of the aforementioned coil winding jig, and, in the rear half of the rotational conveyance of the aforementioned strip-shaped coil (for example, the rear half 313b of the rotational conveying portion 313 described below), the aforementioned multiple straight portions are respectively inserted into the aforementioned multiple comb-shaped grooves; the aforementioned guiding components have a shaping portion (for example, the shaping portion 42 described below), and the shaping portion deforms the aforementioned strip-shaped coil into an arc shape along the outer circumference of the aforementioned coil winding jig and shapes it in the front half of the rotational conveyance of the aforementioned strip-shaped coil (for example, the front half 313a of the rotational conveying portion 313 described below).

[0013] (2) In the coil forming device described in (1) above, the guide member may guide the strip-shaped coil into an arc shape having a diameter smaller than the outer diameter of the coil winding jig in the latter half of the rotational conveyance of the strip-shaped coil, and insert the plurality of straight portions into the plurality of comb-shaped grooves, respectively.

[0014] (3) In the coil forming device described in (2) above, the guide member may include an inner wall surface (for example, inner wall surface 41 described below) that contacts the side end portion in the latter half of the rotational transport of the strip-shaped coil.

[0015] (4) In the coil forming device described in (2) above, the guide member may include an inner wall surface that contacts the side end portion throughout the entire rotational conveyance process of the strip-shaped coil.

[0016] (5) The coil forming method of the present invention forms a strip-shaped coil (for example, the strip-shaped coil 100 described below) into a wound state, wherein the strip-shaped coil has a plurality of straight portions (for example, the straight portion 102 described below) and side end portions (for example, the side end portions 103 described below) arranged at both ends of the plurality of straight portions, and the coil forming method includes: a coil conveying step of rotating and conveying the strip-shaped coil along at least a portion of the outer circumference of a coil winding jig (for example, the coil winding jig 2 described below), wherein the coil winding jig has a plurality of comb-shaped grooves (for example, the comb-shaped grooves 23 described below) on the outer circumference into which the plurality of straight portions can be inserted, respectively, and is configured to be able to wind the strip-shaped coil; and a guiding step of arranging guiding grooves near the axial ends of the coil winding jig. The component (for example, the guide component 4 described below) guides the strip-shaped coil into an arc shape along the outer circumference of the coil winding jig while bringing the guide component into contact with the side end portion, and in the rear half of the rotational conveyance of the strip-shaped coil (for example, the rear half 313b of the rotational conveying portion 313 described below), the plurality of straight portions are respectively inserted into the plurality of comb-shaped grooves; the guiding step includes a shaping step, wherein in the front half of the rotational conveyance of the strip-shaped coil (for example, the front half 313a of the rotational conveying portion 313 described below), the strip-shaped coil is deformed into an arc shape along the outer circumference of the coil winding jig for shaping while the side end portion of the strip-shaped coil is clamped by the guide component.

[0017] (6) In the coil forming method described in (5) above, it may also be that in the guiding step, the guiding member is used to guide the strip-shaped coil into an arc shape having a diameter smaller than the outer diameter of the coil winding jig in the latter half of the rotational conveyance of the strip-shaped coil, thereby allowing the plurality of straight portions to be respectively inserted into the plurality of comb-shaped grooves.

[0018] (7) In the coil forming method described in (6) above, in the guiding step, the side end portion may be guided by the inner wall surface of the guiding member (for example, the inner wall surface 41 described below) in at least the latter half of the rotational transport of the strip-shaped coil.

[0019] (8) In the coil forming method described in (6) above, in the guiding step, the side end portion may be guided by the inner wall surface of the guiding member (for example, the inner wall surface 41 described below) during the entire rotational conveyance process of the strip-shaped coil.

[0020] (Effects of the Invention)

[0021] According to the coil forming device described in (1), the strip-shaped coil can be formed into an arc shape in the first half of the rotational conveyance before being wound on the coil winding jig, so the strip-shaped coil can be formed into a wound state with high precision and ease.

[0022] According to the coil forming device described in (2) above, the straight portion of the strip-shaped coil can be continuously inserted into the comb-shaped groove of the coil winding jig while the side end portion of the strip-shaped coil is guided by the guide member, and then wound on the coil winding jig. Therefore, the strip-shaped coil can be easily formed into a wound state without causing positional displacement of the straight portion.

[0023] According to the coil forming device described in (3) above, in the latter half of the rotational conveyance, the side end portion of the strip-shaped coil is guided to the comb-shaped groove of the coil winding jig by the wall surface, thereby enabling the straight portion of the strip-shaped coil to be smoothly guided to the comb-shaped groove of the coil winding jig.

[0024] According to the coil forming device described in (4) above, the side end portion of the strip-shaped coil is guided by the wall surface during the entire rotational conveying process, so that the strip-shaped coil can be smoothly guided along the outer periphery of the coil winding jig, and the straight portion of the strip-shaped coil can be smoothly guided to the comb-shaped groove of the coil winding jig.

[0025] According to the coil forming method described in (5) above, since the strip-shaped coil is formed into an arc shape in the first half of the rotational conveyance, the strip-shaped coil can be easily formed into a wound state with high accuracy.

[0026] According to the coil forming method described in (6), the straight portion of the strip-shaped coil can be continuously inserted into the comb-shaped groove of the coil winding jig while the side end portion of the strip-shaped coil is guided by the guide member, and wound on the coil winding jig. Therefore, the strip-shaped coil can be easily formed into a wound state without causing positional displacement of the straight portion.

[0027] According to the coil forming method described in (7) above, the side end portion of the strip-shaped coil can be guided to the comb-shaped groove of the coil winding jig by using the wall surface in the latter half of the rotational conveyance, thereby enabling the straight portion of the strip-shaped coil to be smoothly guided to the comb-shaped groove of the coil winding jig.

[0028] According to the coil forming method described in (8) above, the side end of the strip coil can be guided by the wall surface during the entire rotation and conveying process, so that the strip coil can be smoothly guided along the outer periphery of the coil winding jig, and the straight portion of the strip coil can be smoothly guided to the comb-shaped groove of the coil winding jig. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a side view showing one embodiment of the coil forming device of the present invention.

[0030] Figure 2 It is from Figure 1 Observation in the A direction Figure 1 The figure is obtained by using the coil forming device shown.

[0031] Figure 3 It is from Figure 1 Observation in the B direction Figure 1 The figure is obtained by using the coil forming device shown.

[0032] Figure 4 This is a perspective view showing one embodiment of a coil winding jig.

[0033] Figure 5 It is a perspective view showing a node component of the gripping portion of the coil feeding mechanism.

[0034] Figure 6 It is from Figure 5 A three-dimensional view of the node component of the holding portion of the coil conveying mechanism portion observed from the opposite side.

[0035] Figure 7 It is a perspective view showing a state where two node components are connected to each other.

[0036] Figure 8 yes Figure 1 Magnified view of part E in FIG.

[0037] Figure 9 yes Figure 1 Magnified view of section C in FIG.

[0038] Figure 10 This is a cross-sectional view showing how a strip-shaped coil is guided to a coil winding jig by a guide member and formed into an arc shape.

[0039] Figure 11 yes Figure 1 An enlarged cross-sectional view of portion D in FIG.

[0040] Figure 12 This is a partially enlarged view showing a state where a strip-shaped coil is multi-wound on a coil winding jig.

[0041] Figure 13 This is a perspective view showing a state in which a strip-shaped coil is formed into a wound state on a coil winding jig. DETAILED DESCRIPTION

[0042] Next, the embodiments of the present invention will be described. Figure 1As shown, the coil forming device 1 of this embodiment includes: a coil winding jig 2; a coil conveying mechanism 3 that conveys a strip-shaped coil 100 along the outer periphery of the coil winding jig 2; and a pair of guide components 4 that guide the strip-shaped coil 100 conveyed by the coil conveying mechanism 3 so as to be wound on the coil winding jig 2.

[0043] (Strip Coil)

[0044] like Figure 3 As shown, the strip-shaped coil 100 is formed into a long corrugated strip shape by a flat conductor 101 having a substantially rectangular cross-section. The flat conductor 101 is formed of a highly conductive metal such as copper or aluminum.

[0045] The strip-shaped 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 the stator core (not shown), and each extends approximately linearly in the same direction and is arranged in parallel at regular intervals. The side ends 103 are arranged at positions closer to the side ends of the strip-shaped coil 100 than the straight portions 102, specifically, at both ends in the direction in which the straight portions 102 extend. The side ends 103 alternately connect one end and the other end of adjacent straight portions 102 in a mountain shape, and constitute coil ends. When the strip-shaped coil 100 is installed in the slot of the stator core, the coil ends protrude from the slot in the axial direction of the stator core.

[0046] The strip-shaped coil 100 of this embodiment is formed into a long strip shape by bending six flat conductors 101 into a wave shape by bending a plurality of straight portions 102 and a plurality of side ends 103. The straight portions 102 are arranged parallel to each other at a fixed interval, and the side ends 103 are overlapped at an interval corresponding to the pitch of the straight portions 102. The straight portions 102 of the strip-shaped coil 100 are formed by bending the flat conductor 101 midway, so that the straight portions 102 are parallel to each other in the thickness direction ( Figure 3 The strip-shaped coil 100 of this embodiment has a length sufficient to be wound four times around the coil winding jig 2 described below.

[0047] (Coil Winding Jig)

[0048] like Figure 4As shown, the coil winding jig 2 includes: a generally cylindrical jig body 21; a plurality of comb-teeth portions 22 radially projecting from the outer periphery of the jig body 21; a plurality of comb-teeth-like slots 23 disposed between circumferentially adjacent comb-teeth portions 22; and an axial hole 24 opening in the center of the jig body 21. The comb-teeth portions 22 and comb-teeth-like slots 23 are disposed at both axial ends of the jig body 21. The comb-teeth portions 22 and comb-teeth-like slots 23 at one end of the jig body 21 are aligned with the comb-teeth portions 22 and comb-teeth-like slots 23 at the other end. The coil winding jig 2 of this embodiment has 72 comb-teeth-like slots 23 at each of the axial ends of the jig body 21. The number of these comb-teeth-like slots 23 matches the number of slots in the stator core to which the strip-shaped coil 100 is mounted.

[0049] The distance between the comb-teeth 22 and comb-teeth-shaped grooves 23 at one end of the jig body 21 and the comb-teeth 22 and comb-teeth-shaped grooves 23 at the other end is approximately equal to the length of the straight portion 102 of the strip-shaped coil 100 in the extending direction. Therefore, the straight portion 102 of the strip-shaped coil 100 can be accommodated within the comb-teeth-shaped grooves 23 at one end and the comb-teeth-shaped grooves 23 at the other end of the jig body 21.

[0050] The coil winding jig 2 is formed such that the outer diameter of the coil winding jig 2, which is defined by the tip of the comb teeth 22, is smaller than the inner diameter of the stator core, so that the coil winding jig 2 can be inserted into the inner side of the stator core. The coil winding jig 2 is arranged at a specific position of the coil forming device 1 and is set to be able to move forward and backward with the shaft hole 24 as the center under the drive of a motor (not shown). Figure 1 The d1 direction is shown by the arrow.

[0051] (Coil conveying mechanism)

[0052] The coil conveying mechanism 3 rotates and conveys the strip-shaped coil 100 along at least a portion of the outer circumference of the coil winding jig 2. Specifically, Figure 1 and Figure 2 As shown, the coil transport mechanism 3 includes a pair of transport rails 31 constituting a transport path for the strip-shaped coil 100 , and a transport body 32 that holds the strip-shaped coil 100 and transports it along the transport rails 31 .

[0053] The conveying rails 31 are formed of a metal strip plate and are arranged parallel to each other at intervals substantially 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. Figure 2 As shown, the distance between the pair of conveying rails 31 is substantially equal to the axial distance between the comb-tooth portion 22 and the comb-tooth-shaped grooves 23 of the coil winding jig 2 .

[0054] The conveying track 31 has a pair of upper and lower parallel straight conveying parts 311 and 312 forming a straight conveying path, and a rotating conveying part 313 connecting the ends of the straight conveying parts 311 and 312 to each other in an arc shape, thereby forming a horizontal U-shaped conveying path. The conveying track 31 is configured to place the coil winding jig 2 inside the U-shaped part and surround it so that the rotating conveying part 313 is along the outer periphery of the coil winding jig 2. Figure 2 As shown, on the mutually facing surfaces of the pair of conveying rails 31, there is provided a guide groove 314 extending over the entire length of the conveying rails 31. The guide groove 314 forms a moving path for the conveying body 32 described below.

[0055] In this embodiment, the rotating conveyor section 313 of the coil conveying mechanism 3 is formed within approximately 1 / 2 of the outer circumference of the coil winding jig 2. The rotating conveyor section 313 includes a front half 313a, which serves as the introduction side for the strip-shaped coil 100, and a rear half 313b, which serves as the discharge side for the strip-shaped coil 100. The front half 313a is formed over approximately 1 / 2 of the front half of the rotating conveyor section 313. The rear half 313b is formed over approximately 1 / 2 of the rear half of the rotating conveyor section 313. However, the rotating conveyor section 313 only needs to be configured to rotate and convey the strip-shaped coil 100 along at least a portion of the outer circumference of the coil winding jig 2.

[0056] The conveyor 32 extends in an elongated shape along the conveyor rails 31 and is configured to be movable along the conveyor rails 31 between the pair of conveyor rails 31. The conveyor 32 has a length at least corresponding to the total length of the strip-shaped coil 100, and by moving along the conveyor rails 31 while holding the straight portion 102 of the strip-shaped coil 100 on the upper surface, the strip-shaped coil 100 is rotated and conveyed along the outer circumference of the coil winding jig 2.

[0057] like Figure 1 and Figure 3 As shown, the transport body 32 is composed of a plurality of node components 33 of the same structure arranged in a stacked manner along the longitudinal direction of the strip-shaped coil 100. Figure 5 、 Figure 6 and Figure 7 As shown, the node component 33 comprises: a node component body 331 made of metal with a roughly rectangular plate shape, and a pair of guide protrusions 332 protruding toward the side from both ends of the width direction of the lower end of the node component body 331. The guide protrusions 332 of this embodiment are respectively composed of rotatable rollers, but can also be simple protrusions. In addition, regarding the direction of the node component 33, Figure 5 、 Figure 6 and Figure 7The X direction in the figure 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. Regarding the height direction, the upper direction in the figure is defined as "up", and the lower direction is defined as "down".

[0058] The node component body 331 has a thickness that is approximately equal to the gap between the adjacent straight portions 102, 102 in the longitudinal direction of the strip-shaped coil 100. On the upper end surface 331a of the node component body 331, a pair of first gripping claws 333 are provided to protrude in the height direction. The first gripping claws 333 have a thickness that is approximately 1 / 2 of the thickness of the node component body 331. The thickness of the first gripping claws 333 is approximately equal to the gap between the adjacent straight portions 102, 102 of the strip-shaped coil 100. The first gripping claws 333 are arranged at a position on one end side of the node component body 331 in the thickness direction in the upper end surface 331a. The pair of first gripping claws 333 are spaced apart from each other at specific intervals and are arranged at both end sides in the width direction of the node component body 331.

[0059] The upper end surface of the first gripping claw 333 is provided with an engagement groove 333a that engages with the front end of the comb-tooth portion 22 of the coil winding jig 2. Figure 4 As shown, the front ends of the comb teeth 22 of the coil winding jig 2 are provided with engaging portions 22a. The engaging grooves 333a have positions and shapes that can engage with the engaging portions 22a of the coil winding jig 2.

[0060] The first gripping claws 333 have tapered surfaces 333b on the opposite side of the side where the upper end surface 331a is arranged. Due to the tapered surfaces 333b, the first gripping claws 333 are formed so as to have a slightly narrower tip as they move away from the joint member body 331.

[0061] A rectangular recess 334 is provided between the pair of first gripping claws 333, extending along the height direction of the section member body 331. The recess 334 extends from the upper end surface 331a to approximately 1 / 2 of the height direction of the section member body 331. Similar to the first gripping claws 333, the depth of the recess 334 along the thickness direction of the section member body 331 is approximately 1 / 2 of the thickness of the section member body 331.

[0062] A rectangular protrusion 335 is provided on a side surface 331b of the node component body 331. The protrusion 335 is provided in a block-like shape so as to protrude in a direction perpendicular to the side surface 331b from the side surface 331b on the opposite side to the side where the first gripping claw 333 is provided in the thickness direction of the node component body 331. The protrusion 335 is arranged above a position approximately 1 / 2 in the height direction of the node component body 331. The height of the protrusion 335 along the height direction of the node component body 331 is approximately equal to the height of the recess 334. The thickness of the protrusion 335 along the thickness direction of the node component body 331 is approximately equal to the depth of the recess 334.

[0063] A second gripping claw 336 is provided at the upper end of the convex portion 335. Similar to the first gripping claw 333, the second gripping claw 336 protrudes upwards from the upper end surface 331a of the node component body 331. Similar to 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 strip-shaped coil 100. Since the second gripping claw 336 has the same width as the convex portion 335, as shown in FIG. Figure 7 As shown, when the two node members 33 , 33 are overlapped with each other in the same direction, the second gripping claws 336 of the other node member 33 are arranged between the pair of first gripping claws 333 , 333 of one node member 33 .

[0064] The second gripping claw 336 has a tapered surface 336a on the side where the upper end surface 331a is arranged and on the side opposite thereto.

[0065] like Figure 7 As shown, the plurality of node members 33 are aligned in such a manner that the first gripping claws 333 and the second gripping claws 336 point in the same direction, and overlap in such a manner that the convex portions 335 of the node members 33 are accommodated in the concave portions 334 of the adjacent node members 33. Thus, the adjacent node members 33, 33 overlap closely with each other.

[0066] A through hole 337a extending across the width of the node 33 is provided near the base of the first gripping claw 333 and at a position substantially at the same height as the upper end surface 331a of the node body 331. Furthermore, a through hole 337b extending across the width of the convex portion 335 is provided near the base of the second gripping claw 336 and at a position substantially at the same height as the upper end surface 331a of the node body 331. Figure 7As shown, when two node members 33, 33 are overlapped, a shaft member 338 is inserted through the connected through holes 337a and 337b. Thus, the multiple node members 33 are connected so that the lower end side provided with the guide protrusion 332 can be rotated (rocked) in the longitudinal direction of the conveyor 32 with the shaft member 338 as the rotation axis, thereby forming a long conveyor 32.

[0067] In the conveying body 32, between the first gripping claws 333, 333 and the second gripping claws 336, 336 of the adjacent node parts 33, 33, as shown in FIG. Figure 3 、 Figure 7 、 Figure 8 and Figure 9 As shown, a holding groove 321 is formed for holding the straight portion 102 of the strip-shaped coil 100. The upper end surface 331a of the node component body 331 faces the bottom of the holding groove 321. The holding groove 321 has a groove width that can accommodate the straight portion 102 of the strip-shaped coil 100. The groove width of the holding groove 321 is roughly equal to the groove width of the comb-shaped groove 23 along the circumference of the coil winding jig 2. The arrangement pitch of the holding groove 321 along the length direction of the conveying body 32 is roughly equal to the arrangement pitch of the comb-shaped groove 23 along the circumference of the coil winding jig 2. Therefore, if the meshing groove 333a is engaged with the meshing portion 22a, as shown Figure 8 As shown, the holding grooves 321 of the conveying body 32 and the comb-shaped grooves 23 of the coil winding jig 2 communicate with each other in the radial direction of the coil winding jig 2 .

[0068] The conveying body 32 is configured such that each guide protrusion 332 of the node component 33 is slidably received in the guide groove 314 of the conveying track 31 and protrudes toward the inner side of the U-shaped conveying track 31. Figure 8 As shown, the conveyor body 32 is configured so that when it reaches directly below the coil winding jig 2, the engagement groove 333a of the node member 33 engages with the engagement portion 22a of the coil winding jig 2, thereby being able to utilize the rotation of the coil winding jig 2 in the d1 direction to move in the d2 direction synchronously with the rotation of the coil winding jig 2. When the conveyor body 32 moves in an arc shape along the rotating conveying portion 313 of the conveying rail 31, the shaft member 338 is used to rotate in a manner isolating the guide protrusions 332 sides of adjacent node members 33 and 33, respectively, with the first gripping claw 333 and the second gripping claw 336 as the reference for gripping the straight portion 102, thereby enabling smooth movement.

[0069] like Figure 3 、 Figure 8 and Figure 9As shown, the conveyor body 32 slidably arranged on the conveyor rail 31 holds the strip-shaped coil 100 by inserting the first holding claw 333 and the second holding claw 336 into the gap between the adjacent straight portions 102, 102 in the longitudinal direction of the strip-shaped coil 100 and accommodating the straight portion 102 in the holding groove 321. Therefore, the conveyor body 32 can convey the strip-shaped coil 100 while maintaining the straight portion 102 at a fixed interval without positional displacement. Figure 2 and Figure 3 As shown in FIG. 1 , the side end portions 103 of the strip-shaped coil 100 are configured to extend toward both sides of the moving direction of the conveyor 32. Figure 1 In FIG, the strip-shaped coil 100 held by the transport body 32 is omitted from illustration.

[0070] (Guide component)

[0071] like Figure 1 As shown, the guide member 4 is formed into a substantially U-shape in the horizontal direction by a metal strip plate so as to respectively follow the rotating conveying portion 313 of the conveying rail 31. The guide member 4 is respectively formed so as to sandwich the coil winding jig 2 and to extend in the axial direction ( Figure 1 In the direction perpendicular to the paper, Figure 2 Near both ends of the U-shaped portion (in the left and right directions), the inner side of the U-shaped portion is configured in the direction of the coil winding jig 2 and is fixed to the conveying rail 31.

[0072] The guide member 4 includes an inlet end 4a for introducing the side end 103 of the strip-shaped coil 100 conveyed by the conveyor 32; a discharge end 4b for discharging the side end 103 of the strip-shaped coil 100; and an inner wall surface 41 for guiding the side end 103 from the inlet end 4a to the discharge end 4b. The inner wall surface 41 is formed as a curved surface that smoothly and continuously curves along approximately half of the circumference of the coil winding jig 2 from the inlet end 4a to the discharge end 4b. The guide member 4 smoothly guides the entire strip-shaped coil 100 in an arc shape along the circumference of the coil winding jig 2 by bringing the side end 103 introduced from the inlet end 4a into contact with the inner wall surface 41 during rotational conveyance by the rotating conveyor 313.

[0073] The curvature of the arc-shaped inner wall surface 41 of the guide member 4 is formed to gradually increase from the inlet end 4a toward the outlet end 4b. Figure 10As shown, the inner wall surface 41 at the inlet end 4a is positioned slightly radially outward from the outer circumference of the coil winding jig 2. However, the inner wall surface 41 gradually and smoothly decreases 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 positioned radially inward from the outer circumference of the coil winding jig 2. Therefore, the inner wall surface 41 of the guide member 4 guides the strip-shaped coil 100 as it moves from the front half 313a of the rotating conveyor 313 toward the rear half 313b, while contacting the side end 103 of the strip-shaped coil 100 and guiding it to gradually curl into an arc shape with a diameter smaller than the outer diameter of the coil winding jig 2.

[0074] The strip-shaped coil 100 is guided to the inner wall surface 41 of the guide component 4 as it moves from the front half 313a of the rotating conveying portion 313 toward the rear half 313b, and is gradually pushed toward the coil winding jig 2. As a result, the straight portion 102 held by the conveying body 32 rises from the holding groove 321 and is forcibly separated, and gradually moves toward the inside of the comb-shaped groove 23 of the coil winding jig 2. Since the discharge end 4b of the guide component 4 is arranged radially inwardly of the outer periphery of the coil winding jig 2, the straight portion 102 is completely inserted into the comb-shaped groove 23 of the coil winding jig 2. Thereafter, the strip-shaped coil 100 is wound on the coil winding jig 2 by utilizing the rotation of the coil winding jig 2. In addition, at Figure 10 and Figure 12 In the figure, the transport body 32 is omitted and the strip-shaped coil 100 is simplified.

[0075] Furthermore, the guide member 4 is not limited to a structure having an inner wall surface 41 extending continuously across the entire rotating conveyor section 313 as in the present embodiment. Although not shown, the guide member 4 may also have a structure having multiple guide rollers arranged along the rotating conveyor section 313. However, to ensure that the strip-shaped coil 100 can be continuously guided into the comb-shaped groove 23 of the coil winding jig 2 and that the straight portion 102 can be smoothly inserted into the comb-shaped groove 23, the guide member 4 preferably has an inner wall surface 41 in contact with the side end portion 103 at the rear half 313b of the rotating conveyor section 313. To ensure that the strip-shaped coil 100 can be smoothly guided into an arc shape along the entire rotating conveyor section 313 and that the straight portion 102 can be smoothly inserted into the comb-shaped groove 23 of the coil winding jig 2, the guide member 4 preferably has an inner wall surface 41 in contact with the side end portion 103 along the entire rotating conveyor section 313, as in the present embodiment.

[0076] like Figure 1 and Figure 2As shown, the guide member 4 has a pair of shaping portions 42 on the inlet end 4a side. These shaping portions 42 are used to forcibly deform and shape the strip-shaped coil 100 introduced into the rotating conveyor 313 into an arc shape that follows the outer circumference of the coil winding jig 2. The shaping portions 42 are provided within the front half 313a of the rotating conveyor 313. Specifically, the shaping portions 42 can be provided, for example, from the inlet end 4a of the guide member 4 to approximately one-half to three-quarters of the front half 313a of the rotating conveyor 313.

[0077] The shaping portion 42 is composed of the inner wall surface 41 of the guide member 4 and the guide plate 421. The guide plate 421 is formed to be smoothly curved into an arc shape according to the curvature of the inner wall surface 41 of the guide member 4. Similar to the guide member 4, the guide plates 421 are arranged so as to sandwich the coil winding jig 2 from both axial ends and are fixed to the guide member 4. In the shaping portion 42, a shaping groove 422 for clamping the side end 103 is formed between the inner wall surface 41 and the guide plate 421. The inner wall surface 41 of the shaping portion 42 contacts and supports the radially outer surface of the side end 103 of the strip-shaped coil 100, and the guide plate 421 contacts and supports the radially inner surface of the side end 103 of the strip-shaped coil 100.

[0078] The shaping section 42 forcibly deforms the strip-shaped coil 100, introduced into the introduction end 4a of the guide member 4, into a shaping groove 422 and clamps it while conveying it, thereby forcibly bending it into an arcuate shape. This allows the strip-shaped coil 100 to be formed into an arcuate shape during the initial introduction process by the rotating conveyor section 313 before being wound onto the coil winding jig 2. This suppresses the force that would otherwise cause the strip-shaped coil 100 to elastically return to a flattened state while being guided into the arcuate shape by the inner wall surface 41 of the guide member 4. Consequently, the strip-shaped coil 100 is guided into an arcuate shape by the guide member 4, allowing it to be smoothly and accurately formed into a substantially cylindrical wound state.

[0079] (Coil Forming Method)

[0080] Next, a method for forming the strip-shaped coil 100 into a substantially cylindrical wound state using the coil forming apparatus 1 will be described.

[0081] First, a coil winding jig 2 is positioned inside the U-shaped portion of the conveyor track 31 of the coil forming apparatus 1, rotatably driven by a motor (not shown). After the coil winding jig 2 is positioned on the coil forming apparatus 1, a coil supply device (not shown) or an operator supplies the strip-shaped coil 100, preformed into a long, wavy strip, to the conveyor 32, which is positioned on the linear conveyor section 311 below the conveyor track 31. The conveyor 32 grips the strip-shaped coil 100 by inserting the first gripping claws 333 and the second gripping claws 336 of each section 33 of the conveyor 32 into the gaps between adjacent straight sections 102, 102, and placing each straight section 102 within the gripping groove 321.

[0082] Thereafter, the conveyor body 32 holding the strip-shaped coil 100 is pushed by a conveyor body pushing device (not shown) or an operator, so that the engaging groove 333a of the node member 33 engages with the engaging portion 22a of the coil winding jig 2, and the conveyor body 32 moves toward the coil winding jig 2 on the linear conveyor portion 311. After the engaging groove 333a and the engaging portion 22a engage directly below the coil winding jig 2, if the coil winding jig 2 is rotated in the direction d1, the conveyor body 32 moves on the conveyor track 31 in the direction d2 in synchronization with the rotation of the coil winding jig 2, thereby rotating and conveying the strip-shaped coil 100 along the outer circumference of the coil winding jig 2 (coil conveying step).

[0083] When the conveyor 32 reaches the rotating conveyor section 313, the side end 103 of the strip-shaped coil 100 is first introduced from the introduction end 4a of the guide member 4 into the shaping groove 422 of the shaping section 42. There, it is rotated and conveyed while being held between the inner wall surface 41 and the guide plate 421. As a result, the strip-shaped coil 100 is forcibly deformed and shaped into an arc shape along the shaping groove 422 (shaping step).

[0084] The strip-shaped coil 100 that has passed through the shaping section 42 is guided so as to be gradually curved into an arc shape while being conveyed along the inner wall surface 41 of the guide member 4 and along at least a portion of the outer circumference of the coil winding jig 2, specifically, along approximately 1 / 2 of the outer circumference of the coil winding jig 2, as the coil winding jig 2 rotates.

[0085] Since the curvature of the inner wall surface 41 of the guide component 4 gradually increases from the front half 313a toward the rear half 313b of the rotating conveying portion 313, the side end portion 103 of the strip-shaped coil 100 is pushed by the inner wall surface 41 and gradually shrinks in diameter toward the radial inside. As a result, the strip-shaped coil 100 is wound into a diameter smaller than the outer diameter of the coil winding jig 2. The side end portion 103 pushed by the inner wall surface 41 causes the straight portion 102 to gradually detach from the holding groove 321 toward the comb-shaped groove 23 of the coil winding jig 2 as the strip-shaped coil 100 moves toward the discharge end 4b of the guide component 4. The straight portion 102 that has completely detached from the holding groove 321 is pushed by the inner wall surface 41 of the guide component 4, as shown in FIG. Figure 10 As shown, the strip-shaped coil 100 is inserted into the comb-shaped groove 23 of the coil winding jig 2 connected to the holding groove 321 (guiding step). Thereafter, as the coil winding jig 2 rotates, the strip-shaped coil 100 is wound on the coil winding jig 2 and discharged from the discharge end 4b of the guide member 4.

[0086] When the entire conveyor 32 finishes moving along the conveyor track 31, the strip-shaped coils 100 are inserted into the comb-shaped grooves 23 in a stacked manner through the straight portions 102. Figure 12 As shown in FIG. 1 , the coil is wound on the coil winding jig 2 in a manner of winding 4 turns and multiple winding is performed. Figure 13 As shown, the strip-shaped coil 100 is easily formed into a generally cylindrical wound state. Since the straight portion 102 of the wound strip-shaped coil 100 is accommodated within the comb-shaped grooves 23, it does not shift position. Therefore, the strip-shaped coil 100 can stably maintain its generally cylindrical wound state. Furthermore, the strip-shaped coil is not limited to being wound multiple times on the coil winding jig 2.

[0087] The coil forming device 1 described above provides the following effects: Specifically, the coil forming device 1 of this embodiment forms a strip-shaped coil 100 having a plurality of straight portions 102 and side end portions 103 disposed at both ends of the plurality of straight portions 102 into a wound state. The coil forming device 1 includes: a coil winding jig 2 having a plurality of comb-shaped grooves 23 on its outer periphery into which a plurality of straight portions 102 can be inserted, and configured to wind a strip-shaped coil 100; a coil conveying mechanism 3 configured to rotatably convey the strip-shaped coil 100 along at least a portion of the outer periphery of the coil winding jig 2; and a guide member 4, each disposed near both axial ends of the coil winding jig 2, guiding the strip-shaped coil 100 into an arc shape along the outer periphery of the coil winding jig 2 while contacting the side end portion 103, and inserting the plurality of straight portions 102 into the plurality of comb-shaped grooves 23 in the rear half 313b of the rotating conveying portion 313 that rotates and conveys the strip-shaped coil 100. The guide member includes a shaping portion 42 that deforms the strip-shaped coil 100 into an arc shape along the outer circumference of the coil winding jig 2 while the front half 313a of the rotating conveyor 313, which rotates and conveys the strip-shaped coil 100, holds the side end 103 of the strip-shaped coil 100. This shaping portion 42 is configured to shape the strip-shaped coil 100 into an arc shape along the outer circumference of the coil winding jig 2. Thus, the strip-shaped coil 100 can be shaped into an arc shape by the front half 313a of the rotating conveyor 313 before being wound on the coil winding jig 2. This allows the strip-shaped coil 100 to be easily and accurately formed into a wound state.

[0088] The guide member 4 of this embodiment guides the strip-shaped coil 100 into an arcuate shape with a diameter smaller than the outer diameter of the coil winding jig 2 at the rear half 313b of the rotating conveying portion 313, which rotates and conveys the strip-shaped coil 100. This allows the plurality of straight portions 102 to be inserted into the plurality of comb-tooth-shaped grooves 23. This allows the straight portions 102 of the strip-shaped coil 100 to be continuously inserted into the comb-tooth-shaped grooves 23 of the coil winding jig 2 while the guide member 4 guides the side ends 103 of the strip-shaped coil 100, allowing them to be wound around the coil winding jig 2. Consequently, the strip-shaped coil 100 can be easily formed into a wound state without causing positional displacement of the straight portions 102.

[0089] The guide member 4 of this embodiment includes an inner wall surface 41 that contacts the side end portion 103 of at least the rear half 313b of the rotating conveying portion 313 that rotates and conveys the strip-shaped coil 100. This allows the side end portion 103 of the strip-shaped coil 100 to be guided to the comb-shaped groove 23 of the coil winding jig 2 using the wall surface in the rear half 313b of the rotating conveying portion 313. This allows the straight portion 102 of the strip-shaped coil 100 to be smoothly guided to the comb-shaped groove 23 of the coil winding jig 2.

[0090] The guide member 4 of this embodiment includes an inner wall surface 41 that contacts the side end portion 103 along the entire rotating conveying portion 313 that rotates and conveys the strip-shaped coil 100. Thus, the side end portion 103 of the strip-shaped coil 100 is guided by the wall surface throughout the entire rotating conveying portion 313. This allows the strip-shaped coil 100 to be smoothly guided along the outer circumference of the coil winding jig 2 and allows the straight portion 102 of the strip-shaped coil 100 to be smoothly inserted into the comb-shaped groove 23 of the coil winding jig 2.

[0091] The coil forming method described above provides the following effects: Specifically, the coil forming method of this embodiment forms the strip-shaped coil 100 having a plurality of straight portions 102 and side end portions 103 disposed at both ends of the plurality of straight portions 102 into a wound state. The coil forming method includes: a coil conveying step of rotating and conveying a strip-shaped coil 100 along at least a portion of the outer circumference of a coil winding jig 2, wherein the coil winding jig 2 has a plurality of comb-shaped grooves 23 on the outer circumference into which a plurality of straight portions 102 can be respectively inserted, and is configured to be able to wind the strip-shaped coil 100; and a guiding step of arranging guide members 4 near both axial ends of the coil winding jig 2, guiding the strip-shaped coil 100 into an arc shape along the outer circumference of the coil winding jig 2 while bringing the guide members 4 into contact with the side end portions 103, and inserting the plurality of straight portions 102 into the plurality of comb-shaped grooves 23 in the rear half 313b of the rotating conveying portion 313 that rotates and conveys the strip-shaped coil 100. The guiding step includes a shaping step in which the front half 313a of the rotating conveying unit 313, which rotates and conveys the strip-shaped coil 100, deforms the strip-shaped coil 100 into an arc shape along the outer circumference of the coil winding jig 2 while the side end 103 of the strip-shaped coil 100 is held by the guide member 4. Thus, since the strip-shaped coil 100 can be shaped into an arc shape by the front half 313a of the rotating conveying unit 313 before being wound on the coil winding jig 2, the strip-shaped coil 100 can be easily and accurately formed into the wound state.

[0092] In the guiding step of this embodiment, the guide member 4 guides the strip-shaped coil 100 into an arc shape with a diameter smaller than the outer diameter of the coil winding jig 2 at the rear half 313b of the rotating conveying portion 313, which rotates and conveys the strip-shaped coil 100. This allows the plurality of straight portions 102 to be inserted into the plurality of comb-tooth-shaped grooves 23. This allows the straight portions 102 of the strip-shaped coil 100 to be continuously inserted into the comb-tooth-shaped grooves 23 of the coil winding jig 2 while the guide member 4 guides the side ends 103 of the strip-shaped coil 100, and to be wound around the coil winding jig 2. Consequently, the strip-shaped coil 100 can be easily formed into a wound state without causing positional displacement of the straight portions 102.

[0093] In the guiding step of this embodiment, the inner wall surface 41 of the guide member 4 guides the side end 103 during at least the second half 313b of the rotational transport of the strip-shaped coil 100. This allows the straight portion 102 of the strip-shaped coil 100 to be smoothly guided to the comb-shaped groove 23 of the coil winding jig 2.

[0094] In the guiding step of this embodiment, the inner wall surface 41 of the guide member 4 guides the side end portion 103 throughout the entire rotational conveyance process of the strip-shaped coil 100. This allows the strip-shaped coil 100 to be smoothly guided along the outer circumference of the coil winding jig 2, and the straight portion 102 of the strip-shaped coil 100 to be smoothly guided into the comb-shaped groove 23 of the coil winding jig 2.

[0095] Reference numerals

[0096] 1 Coil forming device

[0097] 2 Coil winding jig

[0098] 23 comb-shaped grooves

[0099] 3 Coil conveying mechanism

[0100] 313 Rotating conveyor unit

[0101] 313a first half

[0102] 313b Second half

[0103] 4 Guide components

[0104] 41 inner wall

[0105] 42 Forming Department

[0106] 100 Strip Coil

[0107] 102 Straight part

[0108] 103 side end

Claims

1. A coil forming device for forming a strip-shaped coil into a wound state, the strip-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 device comprising: A coil winding jig having a plurality of comb-shaped grooves on its outer periphery into which the plurality of straight portions can be inserted, and configured to wind the strip-shaped coil; a coil conveying mechanism configured to rotatably convey the strip-shaped coil along at least a portion of the outer circumference of the coil winding jig; and A substantially U-shaped guide member is disposed near each axial end of the coil winding jig, and while contacting the side end portions, guides the strip-shaped coil into an arc shape along the outer circumference of the coil winding jig, and in the latter half of the rotational transport of the strip-shaped coil, causes the plurality of straight portions to be respectively inserted into the plurality of comb-tooth-shaped grooves; The guide member has a shaping portion, and the shaping portion is provided in the front half of the rotational conveyance of the strip-shaped coil. The shaping portion includes: an inner wall surface of the guide member; a guide plate formed into an arc shape along the inner wall surface; and a shaping groove formed between the inner wall surface and the guide plate, wherein the shaping groove sandwiches the side end portion of the strip-shaped coil, thereby deforming the strip-shaped coil into an arc shape along the outer circumference of the coil winding jig for shaping.

2. The coil forming device according to claim 1, wherein The guide member guides the strip-shaped coil into an arc shape having a diameter smaller than an outer diameter of the coil winding jig in the latter half of the rotational conveyance of the strip-shaped coil, and inserts the plurality of straight portions into the plurality of comb-shaped grooves, respectively.

3. The coil forming device according to claim 2, wherein The guide member includes an inner wall surface that contacts the side end portion in the latter half of the rotational conveyance of the strip-shaped coil.

4. The coil forming device according to claim 2, wherein The guide member includes an inner wall surface that contacts the side end portion throughout the entire rotational conveyance process of the strip-shaped coil.

5. A coil forming method for forming a strip-shaped coil into a wound state, the strip-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 rotating and conveying the strip-shaped coil along at least a portion of an outer circumference of a coil winding jig, wherein the coil winding jig has a plurality of comb-shaped grooves on its outer circumference into which the plurality of straight portions can be inserted, and is configured to wind the strip-shaped coil; and a guiding step of disposing substantially U-shaped guide members near both axial ends of the coil winding jig, guiding the strip-shaped coil into an arc shape along the outer circumference of the coil winding jig while the guide members contact the side ends, and inserting the plurality of straight portions into the plurality of comb-shaped grooves in the latter half of the rotational conveyance of the strip-shaped coil; The guiding step includes a shaping step, wherein in the first half of the rotational conveyance of the strip-shaped coil, the strip-shaped coil is deformed into an arc shape along the outer circumference of the coil winding jig while the side end portion of the strip-shaped coil is clamped by a shaping groove, wherein the shaping groove is formed between the inner wall surface of the guiding member and a guide plate formed into an arc shape along the inner wall surface.

6. The coil forming method according to claim 5, wherein: In the guiding step, the guide member guides the strip-shaped coil into an arc shape having a diameter smaller than an outer diameter of the coil winding jig in the latter half of the rotational conveyance of the strip-shaped coil, thereby inserting the plurality of straight portions into the plurality of comb-shaped grooves.

7. The coil forming method according to claim 6, wherein: In the guiding step, the side end portion is guided by the inner wall surface of the guide member during at least the latter half of the rotational transport of the strip-shaped coil.

8. The coil forming method according to claim 6, wherein: In the guiding step, the side end portion is guided by the inner wall surface of the guide member throughout the entire rotational conveyance process of the strip-shaped coil.

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