Coil forming apparatus and coil forming method

Abstract

A coil forming apparatus includes: a coil winding fixture for winding a strip coil by inserting the straight portion of the strip coil into a plurality of comb-shaped grooves on its outer periphery; a coil conveying mechanism for rotatably conveying the strip coil along the outer periphery of the coil winding fixture; and a guiding member that, near both axial ends of the coil winding fixture, contacts the side ends of the strip coil while guiding the strip coil into an arc shape and inserting it into the plurality of comb-shaped grooves respectively. The guiding member has: a diameter-reducing guiding portion that gradually reduces in diameter during the latter half of the rotational conveying of the strip coil; and an extension guiding portion connected to the end of the diameter-reducing guiding portion, maintaining the diameter under curvature at the end and extending it by a predetermined length. In this coil forming apparatus, the strip coil can be easily formed into a wound state, and the winding posture on the coil winding fixture will not become disordered due to the springback of the strip coil.

Description

Technical Field

[0001] This invention relates to a coil forming apparatus and a coil forming method. Background Technology

[0002] The stator of a rotary electric machine has a wound strip coil. The strip coil is pre-formed into a roughly cylindrical wound state with a diameter smaller than the inner diameter of the stator core and is inserted into the inside of the stator core. The wound strip coil is installed by expanding the diameter inside the stator core and inserting the straight portion of the strip coil into a slot in the stator core.

[0003] Previously, it was known that a coil was fed into a cylindrical coil winding fixture at intervals while being wound onto the coil winding fixture, thereby forming a generally cylindrical winding state (for example, see Patent Document 1).

[0004] [Previous Technical Documents]

[0005] (Patent Documents)

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

[0007] [The problem the invention aims to solve]

[0008] When winding the coil and shaping it into a wound state, it is important to wind it with high precision to avoid misalignment of multiple straight sections. In the aforementioned conventional technology, a pre-alignment member is inserted between adjacent straight sections at a position directly in front of the coil winding fixture on the transport path of the strip coil, thereby making the straight sections to be wound onto the coil winding fixture neatly overlap.

[0009] However, the aforementioned prior art does not specifically disclose how the coil winding fixture winds the strip coil, nor does it address the issue of the winding posture on the coil winding fixture becoming disordered due to the springback of the strip coil. Disordered winding posture of the strip coil leads to poor quality. The decrease in yield due to poor quality results in material waste and increased power consumption due to extended equipment operating time.

[0010] The present invention was made in view of the above circumstances, and its object is to provide a coil forming apparatus and a coil forming method that can easily form a strip coil into a wound state without causing the winding posture on the coil winding fixture to become disordered due to the springback of the strip coil. Furthermore, a further object is to mitigate the adverse impact on the Earth's environment by reducing the resources or energy consumed as materials.

[0011] [Technical means to solve the problem]

[0012] (1) The coil forming apparatus of the present invention (e.g., coil forming apparatus 1 described later) forms a strip coil (e.g., strip coil 100 described later) into a wound state. The strip coil has a plurality of straight portions (e.g., straight portions 102 described later) and side ends (e.g., side ends 103 described later) disposed at both ends of the aforementioned straight portions. The coil forming apparatus includes: a coil winding fixture (e.g., coil winding fixture 2 described later), having a plurality of comb-shaped grooves (e.g., comb-shaped grooves 23 described later) on its outer periphery into which the aforementioned plurality of straight portions can be inserted respectively, and configured to wind the aforementioned strip coil; and a coil conveying mechanism (e.g., coil conveying mechanism 3 described later), configured to move along the aforementioned coil winding fixture. At least a portion of the outer periphery of the aforementioned strip coil is rotated to transport the aforementioned strip coil; and guide members (e.g., guide member 4 described later) are respectively disposed near both ends of the aforementioned coil winding fixture along the axial direction, while contacting the aforementioned side ends, guiding the aforementioned strip coil into an arc shape and inserting it into the aforementioned plurality of comb-shaped grooves respectively; and the aforementioned guide members have: a diameter reduction guide portion (e.g., diameter reduction guide portion 41r described later), formed to gradually reduce in diameter with rotation in the latter half of the rotational transport of the aforementioned strip coil; and an extension guide portion (e.g., extension guide portion 41m described later), connected to the end of the aforementioned diameter reduction guide portion (e.g., end 4b described later), maintaining the diameter under the curvature at the end and extending it by a predetermined length.

[0013] (2) In the coil forming apparatus described in (1) above, optionally, the aforementioned extended guide portion has an extended length that is capable of abutting against a pair of straight portions of the aforementioned strip coil that are connected to the same side end.

[0014] (3) The coil forming method of the present invention forms a strip coil (e.g., strip coil 100 described later) into a wound state, the strip coil having a plurality of straight portions (e.g., straight portions 102 described later) and side ends (e.g., side ends 103 described later) disposed at both ends of the plurality of straight portions, the coil forming method comprising: a coil conveying step, wherein the strip coil is rotatably conveyed along at least a portion of the outer periphery of a coil winding fixture (e.g., coil winding fixture 2 described later), the coil winding fixture having a plurality of comb-shaped grooves (e.g., comb-shaped grooves 23 described later) on its outer periphery into which the plurality of straight portions can be inserted respectively, and constituting... The device becomes capable of winding the aforementioned strip coil; and, in a guiding step, guide members (e.g., guide member 4 described later) are respectively arranged near both ends of the aforementioned coil winding fixture along the axial direction, while the aforementioned guide members are brought into contact with the aforementioned side ends, and the aforementioned strip coil is guided into an arc shape and inserted into the aforementioned plurality of comb-shaped grooves respectively; and, the aforementioned guiding step includes: a diameter reduction guiding step, guiding the aforementioned strip coil to gradually reduce its diameter along the path of the aforementioned rotary conveying in the latter half of the aforementioned rotary conveying; and an extension guiding step, after the aforementioned diameter reduction guiding step is just completed, maintaining the diameter under the curvature just completed and extending the aforementioned strip coil by a predetermined length to guide the aforementioned strip coil.

[0015] (4) In the coil forming method described in (3) above, optionally, the aforementioned extension guiding step maintains the guidance over an extension length that is able to abut against a pair of straight portions connected to the same side end of the aforementioned strip coil.

[0016] (The effect of the invention)

[0017] According to the coil forming apparatus described in (1) above, the strip coil gradually narrows in diameter during the latter half of the rotary conveying process via a diameter reduction guide. Even when it reaches the end of the diameter reduction guide, springback is suppressed by an extension guide connected to that end. Therefore, the winding posture on the coil winding fixture can be prevented from becoming disordered due to the springback of the strip coil. Furthermore, the adverse impact on the Earth's environment can be mitigated by reducing material waste caused by decreased yield due to poor quality and increased power consumption caused by extended operating time of the apparatus.

[0018] According to the coil forming apparatus described in (2) above, the extended guide portion has an extended length that can at least abut against a pair of straight portions connected to the same side end of the aforementioned strip coil, thus effectively suppressing the springback of the strip coil.

[0019] According to the coil forming method described in (3) above, the guiding step of guiding the strip coil into an arc shape and inserting it into multiple comb-shaped slots includes a diameter reduction guiding step and an extension guiding step. That is, immediately after the diameter reduction guiding step, in which the diameter of the strip coil is gradually reduced, the guide step moves to the extension guiding step, which maintains the curvature at the point of completion and extends the diameter by a predetermined length to guide the strip coil. Therefore, the springback of the strip coil is suppressed. Thus, the winding posture of the strip coil can be prevented from becoming disordered due to the springback.

[0020] According to the coil forming method described in (4) above, in the extension guiding step, the guide is maintained over an extension length that can abut against a pair of straight portions connected to the same side end of the strip coil, thus effectively suppressing the springback of the strip coil.

[0021] Furthermore, both the coil forming apparatus described in (1) and (2) above, and the coil forming methods described in (3) and (4) above, are based on the premise of using coils pre-formed as a series of strip coils as coils assembled on the stator. The current mainstream method for assembling the coils in the stator slots is to divide the coils into multiple segments for forming, insert them into the slots, and then weld the ends of the coils. This common method requires the use of high-purity copper in the coils to withstand the heat treatment at the welded areas. In contrast, the present invention does not require heat treatment, thus enabling the use of recycled copper containing impurities, thereby contributing to resource recycling. Attached Figure Description

[0022] Figure 1 This is a side view illustrating one embodiment of the coil forming apparatus of the present invention.

[0023] Figure 2 From Figure 1 Observation in direction A Figure 1 A diagram of the coil forming apparatus shown.

[0024] Figure 3 From Figure 1 Observation in direction B Figure 1 A diagram of the coil forming apparatus shown.

[0025] Figure 4 This is a perspective view illustrating one embodiment of a coil winding fixture.

[0026] Figure 5 It is a perspective view of the control section of the coil conveying mechanism.

[0027] Figure 6 It is a drawing from Figure 5 A perspective view of the section component of the coil delivery mechanism, viewed from the opposite side.

[0028] Figure 7 It is a three-dimensional diagram showing the state in which two components are connected to each other.

[0029] Figure 8 yes Figure 1 Enlarged view of part E in the image.

[0030] Figure 9 yes Figure 1 Enlarged view of section C.

[0031] Figure 10 It is a cross-sectional view illustrating the use of a guide component to guide a strip coil in an arc shape to a coil winding fixture.

[0032] Figure 11 yes Figure 1 Enlarged cross-sectional view of part D in the image.

[0033] Figure 12 It is a partial enlarged view showing the multiple windings of the strip coil onto the coil winding fixture.

[0034] Figure 13 It is a three-dimensional diagram showing the state of a strip coil being formed into a wound state on a coil winding fixture. Detailed Implementation

[0035] The embodiments of the present invention will be described below. Figure 1 As shown, the coil forming apparatus 1 of this embodiment includes: a coil winding fixture 2; a coil conveying mechanism 3 for conveying a strip coil 100, which is a so-called wave winding strip coil, along the outer periphery of the coil winding fixture 2; and a pair of guide members 4 for guiding the strip coil 100 conveyed by the coil conveying mechanism 3 onto the coil winding fixture 2.

[0036] (Strip coil)

[0037] like Figure 3 As shown, the strip coil 100 is formed from a flat conductor 101 with a roughly rectangular cross-sectional shape into a long, wavy strip. The flat conductor 101 is formed, for example, from a metal with high conductivity such as copper or aluminum.

[0038] The strip coil 100 has a plurality of straight portions 102 and a plurality of side portions 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 portions 103 are respectively disposed near the side ends of the strip coil 100 closer to the straight portions 102 than the side ends, specifically disposed at both ends in the extending direction of the straight portions 102. The side portions 103 constitute coil end portions, which alternately connect one end of adjacent straight portions 102 to each other in a mountain-shaped configuration, and protrude from the slots along the axial direction of the stator core when the strip coil 100 is installed in the slots of the stator core.

[0039] The strip coil 100 of this embodiment is formed into a long strip by bending six flat conductors 101 into waveforms 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 staggered and overlapped with respect to the spacing of the straight portions 102. The straight portions 102 of the strip coil 100 are extended in the thickness direction of the strip coil 100 by folding the flat conductors 101 back midway. Figure 3 Multiple coils overlap in the direction perpendicular to the paper surface. The strip coil 100 of this embodiment has a length of four turns wound on the coil winding fixture 2 described later.

[0040] (Coil winding fixture)

[0041] like Figure 4 As shown, the coil winding fixture 2 has: a generally cylindrical fixture body 21; a plurality of comb-shaped portions 22 that radiate outwards along the outer periphery of the fixture body 21; a plurality of comb-shaped grooves 23 disposed between adjacent comb-shaped portions 22, 22 in the circumferential direction; and a shaft hole 24 that opens 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. The coil winding fixture 2 of this embodiment 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 grooves on the stator core on which the strip coil 100 is mounted.

[0042] The distance between the comb-shaped portion 22 and comb-shaped groove 23 at one end of the fixture body 21 and the comb-shaped portion 22 and comb-shaped groove 23 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 in the comb-shaped groove 23 at one end and the comb-shaped groove 23 at the other end of the fixture body 21.

[0043] The coil winding fixture 2 is formed such that the outer diameter of the coil winding fixture 2, defined by the front end position of the comb portion 22, is less than or equal to the inner diameter of the stator core, so that it can be inserted into the inner side of the stator core. The coil winding fixture 2 is disposed at a specific location on the coil forming apparatus 1 and is configured to be able to wind around the shaft hole 24 as a center, driven by a motor (not shown). Figure 1 Rotate in the direction of d1 as indicated by the arrow in the image.

[0044] (Coil conveying mechanism)

[0045] The coil conveying mechanism 3 rotates to convey the strip coil 100 along at least a portion of the outer periphery of the coil winding fixture 2. Specifically, as... Figure 1 and Figure 2 As shown, the coil conveying mechanism 3 has: a pair of conveying tracks 31 that form a conveying path for the strip coil 100; and a conveying body 32 that holds the strip coil 100 and conveys it along the conveying tracks 31.

[0046] The conveying track 31 is formed of a metal strip and is arranged parallel to each other in the width direction of the coil forming device 1, at intervals approximately equal in length to the straight portions 102 of the strip coil 100. For example... Figure 2 As shown, the interval between a pair of conveying tracks 31 is approximately equal to the axial distance between the comb-shaped portion 22 and the comb-shaped groove 23 of the coil winding fixture 2.

[0047] The conveyor track 31 has a pair of parallel linear conveying sections 311 and 312 forming a straight conveying path, and a rotary conveying section 313 connecting the ends of the linear conveying sections 311 and 312 in an arc shape, thereby forming a transverse U-shaped conveying path. The conveyor track 31 is configured to surround the coil winding fixture 2 inside the U-shaped portion, so that the rotary conveying section 313 travels along the outer periphery of the coil winding fixture 2. Figure 2 As shown, on the surfaces of a pair of conveying tracks 31 facing each other, a guide groove 314 extending along the total length of the conveying track 31 is provided. The guide groove 314 forms the moving path of the conveyor body 32, which will be described later.

[0048] In this embodiment, the rotary conveying section 313 of the coil conveying mechanism 3 is formed within approximately half of the outer periphery of the coil winding fixture 2. The rotary conveying section 313 has a front half 313a serving as the inlet side of the strip coil 100 and a rear half 313b serving as the output side of the strip coil 100. The front half 313a is formed within approximately half of the front half of the rotary conveying section 313. The rear half 313b is formed within approximately half of the rear half of the rotary conveying section 313. However, the rotary conveying section 313 only needs to be configured to rotary convey the strip coil 100 along at least a portion of the outer periphery of the coil winding fixture 2.

[0049] The conveyor body 32 extends in a long strip along the conveyor track 31 and is configured to move along the conveyor track 31 between a pair of conveyor tracks 31. The conveyor body 32 has at least a length corresponding to the total length of the strip coil 100, and by moving along the conveyor track 31 while holding the straight portion 102 of the strip coil 100 on the upper surface, it rotates and conveys the strip coil 100 along the outer periphery of the coil winding fixture 2.

[0050] like Figure 1 and Figure 3 As shown, the conveyor 32 is composed of multiple segmented components 33 with the same structure arranged in a stacked manner along the length direction of the strip coil 100. Figure 5 , Figure 6 and Figure 7 As shown, the segment member 33 has a metal segment member body 331 with a generally rectangular plate shape, and a pair of guide protrusions 332 protruding laterally from both ends of the segment member body 331 in the width direction from the lower end. In this embodiment, the guide protrusions 332 are each composed of rotatable rollers, but they can also be simple protrusions. Furthermore, regarding the orientation of the segment member 33, Figure 5 , Figure 6 and Figure 7 In the diagram, the X direction is defined as the width direction, the Y direction as the thickness direction, and the Z direction as the height direction. Regarding the height direction, the top direction in the diagram is defined as "up," and the bottom direction is defined as "down."

[0051] The segment member body 331 has a thickness approximately equal to the gap between adjacent straight portions 102, 102 in the length direction of the strip coil 100. A pair of first gripping claws 333 are provided protruding along the height direction from the upper end face 331a of the segment member body 331. The first gripping claws 333 have a thickness approximately half the thickness of the segment member body 331. The thickness of the first gripping claws 333 is approximately equal to the gap between adjacent straight portions 102, 102 of the strip coil 100. The first gripping claws 333 are positioned on the upper end face 331a at one end biased towards the thickness direction of the segment member body 331. The pair of first gripping claws 333 are spaced apart and separately disposed at both ends of the segment member body 331 in the width direction.

[0052] On the upper end face of the first gripping claw 333, there are engagement grooves 333a that engage with the front end of the comb teeth 22 of the coil winding fixture 2. More specifically, as... Figure 4 As shown, engagement portions 22a are provided at the front end of the comb portion 22 of the coil winding fixture 2. Engagement grooves 333a have positions and shapes that can engage with engagement portions 22a of the coil winding fixture 2.

[0053] The first gripper 333 has a conical surface 333b on the opposite side of the side with the upper end surface 331a. By means of the conical surface 333b, the first gripper 333 is formed to be slightly narrower at the front end as it moves away from the joint member body 331.

[0054] Between a pair of first gripping claws 333, a rectangular recess 334 is provided along the height direction of the segment member body 331. The recess 334 extends approximately halfway along the height direction of the segment member body 331, starting from the upper end face 331a. Similar to the first gripping claws 333, the recess 334 has a depth approximately half the thickness of the segment member body 331 along the thickness direction.

[0055] A rectangular protrusion 335 is provided on one side 331b of the segment member body 331. The protrusion 335 is configured to protrude in a block shape from the side 331b opposite to the side where the first gripping claw 333 is located, in the thickness direction of the segment member body 331, in a direction perpendicular to the side 331b. The protrusion 335 is positioned above approximately half the distance along the height direction of the segment member body 331. The height of the protrusion 335 in the height direction of the segment member body 331 is approximately equal to the height of the recess 334. The thickness of the protrusion 335 in the thickness direction of the segment member body 331 is approximately equal to the depth of the recess 334.

[0056] A second gripping claw 336 is provided at the upper end of the protrusion 335. Similar to the first gripping claw 333, the second gripping claw 336 protrudes upwards more than the upper end face 331a of the segment member body 331. Also similar to the first gripping claw 333, the thickness of the second gripping claw 336 is approximately equal to the gap between adjacent straight portions 102, 102 of the strip coil 100. Since the second gripping claw 336 has the same width as the protrusion 335, therefore... Figure 7 As shown, when the two segment components 33, 33 are overlapped in a consistent orientation, a second gripping claw 336 of the other segment component 33 is disposed between a pair of first gripping claws 333, 333 of one segment component 33.

[0057] The second gripping claw 336 has a conical surface 336a on the side with the upper end surface 331a and the opposite side. With the help of the conical surface 336a, the second gripping claw 336 is formed to be slightly narrower at the front end as it moves away from the joint member body 331.

[0058] like Figure 7 As shown, the multiple segment components 33 are aligned such that the first gripping claw 333 and the second gripping claw 336 point in the same direction, and overlap such that the protrusions 335 of the segment components 33 are housed within the recesses 334 of the adjacent segment components 33. Thus, the adjacent segment components 33, 33 overlap each other closely.

[0059] Near the root of the first gripping claw 333, at a position approximately level with the upper end face 331a of the segment member body 331, a through hole 337a extending across the width of the segment member 33 is provided. Additionally, near the root of the second gripping claw 336, at a position approximately level with the upper end face 331a of the segment member body 331, a through hole 337b extending across the width of the protrusion 335 is provided. Figure 7 As shown, when two segment components 33, 33 are overlapped, a shaft component 338 is inserted through the interconnected through holes 337a and 337b. Thus, multiple segment components 33 are connected so that the lower end side, which is provided with guide protrusions 332, can rotate (rock) along the length direction of the conveyor body 32 with the shaft component 338 as the axis of rotation, thereby forming a long strip-shaped conveyor body 32.

[0060] In the conveyor body 32, between the first gripping claws 333, 333 and the second gripping claws 336, 336 of adjacent section components 33, 33, such as Figure 3 , Figure 7 , Figure 8 and Figure 9As shown, a holding groove 321 is formed to hold the straight portion 102 of the strip coil 100. The upper end face 331a of the section member body 331 faces the bottom of the holding groove 321. The holding groove 321 has a groove width capable of receiving the straight portion 102 of the strip coil 100. The groove width of the holding groove 321 is approximately equal to the circumferential width of the comb-shaped grooves 23 of the coil winding fixture 2. The spacing of the holding grooves 321 in the length direction of the conveyor body 32 is approximately equal to the spacing of the comb-shaped grooves 23 in the circumferential direction of the coil winding fixture 2. Therefore, if the engagement groove 333a engages with the engagement portion 22a, then as Figure 8 As shown, the holding groove 321 of the conveyor 32 and the comb-shaped groove 23 of the coil winding fixture 2 are connected in the radial direction of the coil winding fixture 2.

[0061] The conveyor body 32 is configured such that each guide protrusion 332 of the segment component 33 is slidably housed in the guide groove 314 of the conveyor track 31, and protrudes towards the inner side of the U-shaped conveyor track 31. Furthermore, as... Figure 8 As shown, the conveyor 32 is configured such that when it reaches directly below the coil winding fixture 2, it engages with the engagement portion 22a of the coil winding fixture 2 via the engagement groove 333a of the segment member 33. This allows it to move synchronously along the d2 direction with the rotation of the coil winding fixture 2 in the d1 direction. When the conveyor 32 moves in an arc along the rotating conveyor portion 313 of the conveyor track 31, it rotates with the shaft member 338 based on the portions holding the straight portion 102 (i.e., the first gripping claw 333 and the second gripping claw 336), with the guide protrusions 332 of adjacent segment members 33, 33 moving away from each other. Therefore, it can move smoothly.

[0062] like Figure 3 , Figure 8 and Figure 9 As shown, the conveyor body 32, slidably disposed on the conveyor track 31, holds the strip coil 100 by inserting the first gripping claw 333 and the second gripping claw 336 into the gap between adjacent straight portions 102, 102 in the longitudinal direction of the strip coil 100, and housing the straight portions 102 in the gripping groove 321. Therefore, the conveyor body 32 can convey the strip coil 100 without misaligning the straight portions 102 and maintaining a fixed interval. Figure 2 and Figure 3 As shown, the side ends 103 of the strip coil 100 are configured to extend to both sides in the moving direction of the conveyor body 32. Furthermore, in Figure 1 The illustration of the strip coil 100 held by the conveyor 32 is omitted.

[0063] (Guide component)

[0064] like Figure 1As 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 is positioned such that it clamps the coil winding fixture 2, with the inner side of the U-shaped portion facing the coil winding fixture 2 along the axial direction of the coil winding fixture 2. Figure 1 The vertical direction of the paper surface in the middle, Figure 2 Near both ends (in the left and right directions) and fixed on the conveyor track 31.

[0065] The guide member 4 guides the side end 103 of the strip coil 100 conveyed by the conveyor 32 along its inner wall surface 41 from the inlet end 4a to the outlet end 4bb. The inner wall surface 41 of the guide member 4, extending from the inlet end 4a to the outlet end 4bb, is formed by a curved surface that is smoothly and continuously curved along approximately half the outer periphery of the coil winding fixture 2. Approximately half the outer periphery of the coil winding fixture 2... Figure 10 The area shown corresponds to the rear half 313b of the rotary conveyor 313. The guide member 4 is guided smoothly in an arc shape by bringing the side end 103, which is introduced from the inlet end 4a, into contact with the inner wall surface 41 during the rotational conveying by the rotary conveyor 313, so that the entire strip coil 100 is wound around the outer periphery of the coil fixture 2.

[0066] Reference Figure 10 It is easy to understand that the curved path in the guide member 4 extending from the inlet end 4a to the outlet end 4bb has a reduced-diameter guide portion 41r corresponding to the rear half 313b of the rotary conveying section 313, and an extended guide portion 41m immediately following it. The reduced-diameter guide portion 41r is a guide portion formed such that, in the portion corresponding to the rear half 313b of the rotary conveying section 313 of the strip coil 100, the curvature increases and the diameter gradually decreases along the rotary conveying path. The front end of the rear half 313b of the rotary conveying section 313 roughly corresponds to the front end of the reduced-diameter guide portion 41r, and the end of the rear half 313b of the rotary conveying section 313 corresponds to the end 4b of the reduced-diameter guide portion 41r. The extended guide portion 41m is a guide portion that connects to the end 4b of the reduced-diameter guide portion 41r, maintains the diameter under the curvature at the end 4b, and extends by a predetermined length. Figure 10 In this context, the extended length is marked as the extended portion 313e following the end of the rear half 313b of the rotary conveyor 313. This extended length is set to be at least long enough to abut against a pair of straight portions 102 in the strip coil 100 that are connected to the same side end 103.

[0067] like Figure 10As shown, the inner wall surface 41 at the inlet end 4a of the guide member 4 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 as it approaches the end 4b of the tapered guide portion 41r from the inlet end 4a. The inner wall surface 41 at the end 4b of the tapered guide portion 41r is located radially inward from the outer periphery of the coil winding fixture 2. Therefore, as the tape 100 enters the rear half 313b from the front half 313a of the rotary conveyor 313, the inner wall surface 41 of the tape 100 contacts the side end 103 of the tape 100 and guides the tape 100 into an arc shape with a diameter smaller than the outer diameter of the coil winding fixture 2.

[0068] As the strip coil 100 moves from the front half 313a of the rotating conveyor 313 towards the rear half 313b, it is guided by the inner wall surface 41 of the reduced-diameter guide portion 41r in the guide member 4, and thus gradually pushed toward the coil winding fixture 2. As a result, the straight portion 102, held by the conveyor 32, rises from the holding groove 321 and is forcibly disengaged, gradually moving toward the interior of the comb-shaped groove 23 of the coil winding fixture 2. Since the inner wall surface 41 of the reduced-diameter guide portion 41r in the guide member 4 is located radially inward than the outer periphery of the coil winding fixture 2, the straight portion 102 is completely inserted into the comb-shaped groove 23 of the coil winding fixture 2.

[0069] The strip coil 100, immediately behind the end 4b of the tapered guide 41r, is further restricted by the extended guide 41m until it reaches the output end 4bb, to prevent springback of the tapered shape during its journey to the end 4b. Therefore, the diameter (curvature) of the strip coil 100 remains constant during its journey to the end 4b, and it leaves the guide member 4 at the output end 4bb, being wound onto the coil winding fixture 2 by the rotation of the coil winding fixture 2. Furthermore, in Figure 10 and Figure 12 The diagram of the conveyor 32 is omitted, and the strip coil 100 is shown in a simplified manner. In this case, the path length of the extended guide portion 41m is set to a length that can at least abut against a pair of straight portions 102 in the strip coil 100 connected to the same side end 103, thus effectively suppressing rebound.

[0070] Furthermore, the guide member 4 is not limited to the structure having an inner wall surface 41 that is continuous throughout the entire rotary conveyor section 313 as described in this embodiment. Although not shown, the guide member 4 may also be a structure in which multiple guide rollers are arranged along the rotary conveyor section 313. However, from the viewpoint that the strip coil 100 can be continuously guided to the comb-shaped groove 23 of the coil winding fixture 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 that contacts the side end 103 in the rear half 313b of the rotary conveyor section 313. From the viewpoint that the strip coil 100 can be smoothly guided into an arc shape throughout the rotary conveying section 313 and the straight portion 102 can be smoothly inserted into the comb-shaped groove 23 of the coil winding fixture 2, the guide member 4 preferably has an inner wall surface 41 as described in this embodiment, the inner wall surface 41 being in contact with the side end 103 of the rotary conveying section 313 as a wall surface.

[0071] like Figure 1 and Figure 2 As shown, on the inlet end 4a side of the guide member 4, there is a pair of shaping portions 42. These shaping portions 42 are used to forcibly deform the strip coil 100 introduced into the rotary conveyor 313 into an arc shape that winds around the outer periphery of the coil winding fixture 2. In the guide member 4, the range of the shaping portions 42 is within the front half 313a of the rotary conveyor 313. Specifically, the shaping portions 42 can be provided, for example, extending from the inlet end 4a of the guide member 4 to approximately 1 / 2 to approximately 3 / 4 of the front half 313a of the rotary conveyor 313.

[0072] The shaping part 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 plate 421 is arranged to clamp the coil winding fixture 2 from both axial ends and is fixed to the guide member 4. In the shaping part 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 part 42 contacts and supports the radially outer surface of the side end 103 of the strip coil 100, and the guide plate 421 contacts and supports the radially inner surface of the side end 103 of the strip coil 100.

[0073] The shaping section 42 forcibly deforms the strip coil 100 into an arc shape by clamping and conveying it while receiving the side end 103 of the strip coil 100, which is introduced to the inlet end 4a of the guide member 4, into the shaping groove 422. Thus, the strip coil 100 is formed into an arc shape during the initial introduction of the rotary conveyor section 313 before being wound into the coil winding fixture 2, thereby suppressing the force that would otherwise cause it to elastically return to a flat shape while being guided into an arc shape by the inner wall surface 41 of the guide member 4. Therefore, the strip coil 100 is guided into an arc shape by the guide member 4, thus smoothly and precisely forming a generally cylindrical winding state.

[0074] (Coil forming method)

[0075] Next, the method for forming the strip coil 100 into a generally cylindrical wound state using the coil forming apparatus 1 will be described.

[0076] First, a coil winding fixture 2 is configured to rotate via a motor (not shown) inside the U-shaped portion of the conveyor track 31 of the coil forming apparatus 1. After the coil winding fixture 2 is mounted on the coil forming apparatus 1, a pre-formed, wavy strip coil 100 is supplied to a conveyor body 32, located on the lower side of the conveyor track 31, by a coil supply device (not shown) or by an operator. The conveyor body 32 holds the strip coil 100 by inserting the first gripping claw 333 and the second gripping claw 336 of each section 33 of the conveyor body 32 into the gap between adjacent straight sections 102, 102, and by housing the straight sections 102 in the gripping grooves 321.

[0077] Subsequently, the conveyor 32 holding the strip coil 100 is pushed by a conveyor pushing device (not shown) or an operator, and moves along the linear conveyor 311 toward the coil winding fixture 2 such that the engagement groove 333a of the section component 33 engages with the engagement part 22a of the coil winding fixture 2. After the engagement groove 333a and the engagement part 22a are engaged directly below the coil winding fixture 2, if the coil winding fixture 2 is driven to rotate in the d1 direction, the conveyor 32 and the coil winding fixture 2 rotate synchronously along the d2 direction on the conveyor track 31, thereby rotating and conveying the strip coil 100 along the outer circumference of the coil winding fixture 2 (coil conveying step).

[0078] If the conveyor 32 reaches the rotary conveyor 313, the side end 103 of the strip coil 100 is first guided from the inlet end 4a of the guide member 4 into the shaping groove 422 of the shaping section 42, and is rotated and conveyed while being held between the inner wall surface 41 and the guide plate 421. As a result, the strip coil 100 is forcibly deformed and shaped in a way that it bends into an arc shape along the shaping groove 422 (shaping step).

[0079] As the coil winding fixture 2 rotates, the strip coil 100 passing through the shaping part 42 is rotated and transported 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 fixture 2, specifically along approximately half of the outer periphery of the coil winding fixture 2, while being guided in a manner that gradually curls into an arc shape.

[0080] As the curvature of the inner wall surface 41 of the guide member 4 gradually increases from the front half 313a to the rear half 313b of the rotary conveyor 313, the side end 103 of the strip coil 100 is pressed by the inner wall surface 41 in a manner that gradually narrows radially inward. As a result, the strip coil 100 is wound into a diameter smaller than the outer diameter of the coil winding fixture 2. The side end 103, pressed by the inner wall surface 41, gradually disengages from the holding groove 321 toward the comb-shaped groove 23 of the coil winding fixture 2 as the strip coil 100 approaches the output end 4bb of the guide member 4. After completely disengaging from the holding groove 321, the straight portion 102 is pressed by the inner wall surface 41 of the guide member 4 while... Figure 10 As shown, they are respectively inserted into the comb-shaped grooves 23 of the coil winding fixture 2 that are connected to the holding groove 321 (guiding step).

[0081] The guiding steps include a diameter reduction guiding step and an extension guiding step. In the diameter reduction guiding step, the strip coil 100 is guided to the latter half of its rotational transport and between the end 4b of the diameter reduction guiding section 41r and the end 4b of the diameter reduction guiding section 41r in a manner that gradually reduces in diameter with rotation. In the extension guiding step, the strip coil 100 is restricted to a diameter that maintains a fixed curvature in the extension guiding section 41m until it reaches the output end 4bb, so as to prevent the shape from springing back during the process of reaching the end 4b after diameter reduction. The path length of the extension guiding section 41m is set to be at least long enough to abut against a pair of straight portions 102 of the strip coil 100 that are connected to the same side end 103, thus effectively suppressing springback. Thereafter, with the rotation of the coil winding fixture 2, the strip coil 100 is wound onto the coil winding fixture 2 and output from the output end 4bb of the guiding member 4 (the diameter reduction guiding step and the extension guiding step in the guiding steps).

[0082] If the entire conveyor body 32 finishes moving along the conveyor track 31, the strip coil 100 is inserted into the comb-shaped groove 23 in a stacked manner via the straight portion 102, thereby... Figure 12 As shown, it is wound multiple times by winding the coil around the jig 2 four times. 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, misalignment is impossible. Therefore, the strip coil 100 can stably maintain a generally cylindrical wound state. Furthermore, the strip coil is not limited to being multiple-wound onto the coil winding fixture 2.

[0083] The coil forming apparatus 1 described above achieves the following effect: 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 ends of the coil winding fixture 2 along its axial direction, contacting the side ends 103 while guiding the strip coil 100 into an arc shape so that it is inserted into the multiple comb-shaped grooves 23. The guide member 4 includes: a diameter-reducing guide portion 41r, which is formed to gradually reduce in diameter during the latter half of the rotary transport of the strip coil 100; and an extension guide portion 41m, which is connected to the end 4b of the diameter-reducing guide portion 41r, maintaining the diameter under the curvature at the end 4b and extending it by a predetermined length. Accordingly, the strip coil 100 gradually reduces in diameter during the latter half of the rotary transport by means of the diameter-reducing guide portion 41r, and even when it reaches the end 4b of the diameter-reducing guide portion 41r, the extension guide portion 41m connected to the end 4b suppresses springback. Therefore, the winding posture on the coil winding fixture can be prevented from becoming disordered due to the springback of the strip coil. Therefore, the straight portion 102 of the strip coil 100 can be continuously inserted into the comb-shaped groove 23 of the coil winding fixture 2 and wound onto the coil winding fixture 2 in an orderly manner. Thus, the strip coil 100 can be easily formed into a wound state without the straight portion 102 becoming misaligned.

[0084] In the guide member 4 of this embodiment, the extended guide portion 41m has an extended length that allows it to abut against at least a pair of straight portions 102 connected to the same side end of the strip coil 100. Accordingly, the rebound of the strip coil 100 can be effectively suppressed.

[0085] The coil forming method described above achieves the following effect. That is, the coil forming method of this embodiment forms a strip coil 100 into a wound state, the strip coil 100 having a plurality of straight portions 102 and side ends 103 disposed at both ends of the plurality of straight portions 102. The coil forming method includes: a coil conveying step, in which a strip coil 100 is conveyed rotatably along at least a portion of the outer periphery of a coil winding fixture 2, the coil winding fixture 2 having a plurality of comb-shaped grooves 23 on its outer periphery into which a plurality of straight portions 102 are respectively inserted, and configured to wind the strip coil 100; and a guiding step, in which guiding members 4 are respectively arranged near both ends of the coil winding fixture 2 along the axial direction, and while the guiding members 4 are in contact with the side ends 103, the strip coil 100 is guided into an arc shape and inserted into the plurality of comb-shaped grooves respectively; and the guiding step includes: a diameter reduction guiding step, in which the strip coil 100 is guided to gradually reduce in diameter along the path of the rotary conveying in the latter half of the rotary conveying; and an extension guiding step, in which the diameter under the curvature at the moment the diameter reduction guiding step is completed is maintained and the strip coil 100 is extended by a predetermined length to guide the strip coil 100. Accordingly, immediately after the diameter reduction guiding step of gradually reducing the diameter of the guide strip coil 100 is completed, the process shifts to an extension guiding step that maintains the diameter at the curvature just completed and extends the diameter by a predetermined length to guide the strip coil. Therefore, the springback of the strip coil 100 is suppressed. Thus, the winding posture of the strip coil 100 can be prevented from becoming disordered due to the springback.

[0086] In this embodiment, the extended guiding step maintains guidance along an extended length that abuts against a pair of straight portions 102 connected to the same-side end 103 of the strip coil 100. This effectively suppresses the rebound of the strip coil 100.

[0087] Figure Labels

[0088] 1. Coil forming device

[0089] 2. Coil winding fixture

[0090] 23. Comb-like grooves

[0091] 3. Coil conveying mechanism

[0092] 313 Rotary Conveyor Unit

[0093] 313b (second half)

[0094] 313e Extended Area

[0095] 4. Guiding components

[0096] 4b end

[0097] 4bb output terminal

[0098] 41 inner wall

[0099] 41m extended guide section

[0100] 41r Reduced Diameter Guide Section

[0101] 100 strip coils

[0102] 102 Straight part

[0103] 103 Side End

Claims

1. A coil forming apparatus for forming a strip coil into a wound state, the strip coil having a plurality of straight portions and side ends disposed at both ends of the aforementioned straight portions, the coil forming apparatus comprising: The coil winding fixture has multiple comb-shaped grooves on its outer periphery into which the aforementioned multiple straight portions can be inserted respectively, and is configured to wind the aforementioned strip coil. The coil conveying mechanism is configured to rotatably convey the aforementioned strip coil along at least a portion of the outer periphery of the aforementioned coil winding fixture; and, The guiding components are respectively disposed near both ends of the aforementioned coil winding fixture along the axial direction, and while contacting the aforementioned side ends, they guide the aforementioned strip coil into an arc shape and insert it into the aforementioned plurality of comb-shaped grooves respectively. Furthermore, the aforementioned guiding member has: a diameter-reducing guiding portion, which is formed to gradually reduce in diameter along the path of the rotary conveying of the aforementioned strip coil in the latter half of the rotary conveying; and an extension guiding portion, which is connected to the end of the aforementioned diameter-reducing guiding portion, maintaining the diameter under the curvature at the end and extending the length by a predetermined length.

2. The coil forming apparatus according to claim 1, wherein, The aforementioned extended guide portion has an extended length capable of abutting against at least one of the aforementioned straight portions connected to the same aforementioned side end of the aforementioned strip coil.

3. A coil forming method, comprising forming a strip coil into a wound state, the strip coil having a plurality of straight portions and side ends disposed at both ends of the plurality of straight portions, the coil forming method comprising: In the coil conveying step, the aforementioned strip coil is rotated and conveyed along at least a portion of the outer periphery of a coil winding fixture, the coil winding fixture having a plurality of comb-shaped grooves on its outer periphery into which the aforementioned plurality of straight portions can be inserted respectively, and configured to wind the aforementioned strip coil; and, In the guiding step, guide members are respectively arranged near both ends of the aforementioned coil winding fixture along the axial direction. While the aforementioned guide members are in contact with the aforementioned side ends, the aforementioned strip coil is guided into an arc shape and inserted into the aforementioned plurality of comb-shaped grooves respectively. Furthermore, the aforementioned guiding steps include: The diameter reduction guiding step guides the aforementioned strip coil to gradually reduce its diameter along the path of the aforementioned rotary conveying in the latter half of the rotary conveying process. Furthermore, the guiding step is extended, and immediately after the aforementioned diameter reduction guiding step is completed, the diameter under the curvature at the point of completion is maintained and the aforementioned strip coil is extended by a predetermined length to guide the aforementioned strip coil.

4. The coil forming method according to claim 3, wherein, The aforementioned extended guiding step maintains guidance over an extended length that is capable of abutting against a pair of straight portions connected to the same aforementioned side end of the aforementioned strip coil.

Images