Conductor forming apparatus

Abstract

To solve the above problems, a conductor forming apparatus (200) has a holding mechanism (210) that arranges and holds a plurality of straight line sections (14) in parallel with respect to a straight line section group composed of the plurality of straight line sections (14), wherein the holding mechanism (210) includes: a fixed block (214) provided with a plurality of grooves (214a) at equal intervals, the grooves (214a) having a fixed side abutting portion (214e) that freely abuts against one end portion in a width direction of the straight line section (14); a plurality of movable blocks (215) freely movably disposed in the grooves (214a) of the fixed block (214) and provided with a movable side abutting portion (215h) that freely abuts against the other end portion in the width direction of the straight line section (14); and a driving means (216) that freely drives each of the movable blocks (215) in an independent state.

Description

Technical Field

[0001] This invention relates to a conductor forming apparatus. Background Technology

[0002] Generally, a wave-wound coil is known as a coil used in the stator of rotating electrical machines such as motors or generators, which can reduce the environmental burden by reducing CO2 emissions. The wave-wound coil has: multiple straight slotted sections arranged in slots of the stator core; and multiple rotating sections on the axially outer side of the stator core, connecting adjacent slotted sections into a mountain-shaped or arched shape. Thus, the wave-wound coil is formed into a wave shape along the circumference of the stator core.

[0003] As a type of wave-wound coil, a long, sheet-like wave-wound coil with a length equivalent to multiple turns of the stator core is known. The sheet-like wave-wound coil is wound into a spiral shape, and by inserting the respective slot configurations into the slots of the stator core, a multi-layer (multi-turn) coil is formed. The sheet-like wave-wound coil can be formed into a strip shape without soldering, thus achieving a lighter weight compared to segmented coils that require soldering.

[0004] Conventionally, one known method for forming such sheet-shaped wave-wound coils involves using a holding mechanism that holds and folds back the straight section group composed of multiple conductors arranged in parallel to form the rotating portion of the winding coil (see, for example, Patent Document 1). The holding mechanism described in Patent Document 1 holds the straight section by arranging multiple straight sections forming the straight section group in parallel and clamping the straight section with adjacent blocks.

[0005] [Previous Technical Documents]

[0006] (Patent Documents)

[0007] Patent Document 1: Japanese Patent Application Publication No. 2021-58076 Summary of the Invention

[0008] [The problem the invention aims to solve]

[0009] However, in the aforementioned conventional gripping mechanisms, in order to firmly grip multiple straight sections forming a group of straight sections inserted side-by-side into the same slot, the width of the slot needs to be smaller than the width of each straight section. When the width of the straight sections is large due to variations in their widths, adjacent blocks separate to accommodate them. This increases the distance between adjacent blocks, creating gaps. Consequently, the spacing between adjacent straight sections may deviate. Therefore, it may be impossible to form the conductor with high precision.

[0010] Therefore, the object of the present invention is to provide a conductor forming apparatus that can form conductors with high precision while achieving lightweight design.

[0011] [Technical means to solve the problem]

[0012] (1) The conductor forming apparatus of the present invention (e.g., the conductor forming apparatus 200 described later) has a holding mechanism (e.g., the holding device 210 described later), which holds a group of straight sections (e.g., straight sections 14 described later) of a plurality of conductors (e.g., coil wire 10 described later) arranged in parallel and holding the plurality of straight sections constituting the aforementioned straight section group. The holding mechanism includes: a fixing block (e.g., fixing block 214 described later) and a plurality of slots (e.g., slots 214a described later) provided at equal intervals. The groove has a fixed-side abutment portion (e.g., fixed-side abutment portion 214e described later) that freely abuts against one end of the aforementioned straight portion in the width direction; a plurality of movable blocks (e.g., movable blocks 215 described later) are movably disposed in the aforementioned groove of the aforementioned fixed block and are provided with movable-side abutment portions (e.g., movable-side abutment portions 215h described later) that freely abut against the other end of the aforementioned straight portion in the width direction; and a driving means (e.g., driving mechanism 216 described later) that freely drives each movable block in an independent state.

[0013] According to (1) above, while maintaining the spacing of each slot of the fixed block, a movable block is arranged in each slot, so that the multiple straight parts of the multiple conductors forming the straight part group abut against the movable side abutting part of the movable block and the fixed side abutting part of the fixed block, and press and hold them, thereby firmly fixing the conductor between the movable block and the fixed block. As a result, the conductor can be formed with high precision, thereby enabling the formation of high-quality conductors.

[0014] (2) The conductor forming apparatus according to (1) includes a force-applying part (e.g., the pressing adjustment spring 216a described later), which applies force to each movable block in the opposite direction to the direction in which the movable block is clamped and pressed between the movable block and the fixed block, and the driving means drives the movable block by overcoming the force applied by the force-applying part.

[0015] According to (2) above, by overcoming the force applied to each movable block by the force applied to the force-applying part, the driving means can be driven so that even if there is a deviation in the width of the multiple straight parts, the straight parts can be firmly clamped between the movable block and the fixed block. As a result, the conductor can be formed with high precision, thereby enabling the formation of high-quality conductors.

[0016] (The effect of the invention)

[0017] According to the present invention, a conductor forming apparatus can be provided that can form conductors with high precision while achieving lightweight design. Attached Figure Description

[0018] Figure 1 It is a schematic front view of the oscilloscope winding coil.

[0019] Figure 2 It is a schematic top view of the stator.

[0020] Figure 3 It is a diagram illustrating the process of forming a coil wire (conductor).

[0021] Figure 4 It is along Figure 3 A cross-sectional view along line AA in the diagram.

[0022] Figure 5 It is a magnified front view showing a portion of the coil wire (conductor).

[0023] Figure 6 Viewed from the Z direction Figure 5 A diagram of the coil wire (conductor) shown.

[0024] Figure 7 It is a magnified drawing Figure 5 The front view of a portion of a conductor group consisting of multiple coil wires (conductors) arranged side by side.

[0025] Figure 8 Viewed from the Z direction Figure 7 The diagram shows the conductor group.

[0026] Figure 9 It is a top view that schematically illustrates the outline of a conductor forming device.

[0027] Figure 10 It is a side view schematically illustrating the outline of a conductor forming apparatus.

[0028] Figure 11 It is a three-dimensional diagram showing the holding device.

[0029] Figure 12 It is a perspective view showing the state in which the holding device does not clamp the multiple straight parts.

[0030] Figure 13 It is a three-dimensional diagram showing the state in which the holding device clamps multiple straight parts.

[0031] Figure 14 It is drawn along Figure 11 The diagram shows the movable block of the gripping device in a position where it is not pressed down on the multiple straight sections, as shown in the BB line cross-sectional view.

[0032] Figure 15 It is drawn along Figure 11 The diagram shows the movable block of the gripping device in a position where multiple straight sections are pressed, as shown in the BB line cross-sectional view.

[0033] Figure 16 This diagram shows the assembly state of the fixed and movable blocks as viewed from an obliquely upward side.

[0034] Figure 17 This diagram shows the assembly state of the fixed and movable blocks as viewed from a slightly lower angle.

[0035] Figure 18 This is a top view of a conductor forming apparatus showing the process of conveying the conductor assembly to the forming position of the inclined section.

[0036] Figure 19 This is a side view of a conductor forming apparatus showing the process of conveying the conductor assembly to the forming position of the inclined section.

[0037] Figure 20 This is a top view of a conductor forming apparatus showing the formation of oblique sections in a conductor assembly.

[0038] Figure 21 It is a top view illustrating the movement of the clamping part when forming the oblique section in the conductor assembly.

[0039] Figure 22 It is a top view showing the oblique section of the shaped conductor.

[0040] Figure 23 This is a top view of a conductor forming apparatus that shows the conductor assembly after the forming inclined section is transported to the turning-back position.

[0041] Figure 24 This is a top view of a conductor forming apparatus showing the formation of the next oblique section in a conductor group after the oblique section has been formed.

[0042] Figure 25 This is a side view illustrating the movement of the clamping part when the inclined section formed in the conductor group is folded back.

[0043] Figure 26 This is a top view of a conductor forming apparatus showing the situation after the inclined section formed in the conductor group is turned back.

[0044] Figure 27 This is a top view showing the conductor assembly after the diagonal section has been folded back.

[0045] Figure 28 It is a diagram illustrating the movement of the clamping part after the inclined section is folded back.

[0046] Figure 29 It is a side view showing the action of pressing the folded section using a pressing component after the diagonal section is folded back.

[0047] Figure 30 This is a top view of a conductor forming apparatus showing the formation of the next oblique section in the conductor group after the reversal.

[0048] Figure 31 This is a top view of a conductor assembly showing the reverse folding of the oblique section corresponding to the layer change section.

[0049] Figure 32 It is a top view of a sheet-like wave winding coil composed of conductor groups whose layered sections are folded in the opposite direction.

[0050] Figure 33 It is a diagram illustrating the holding device in a deformable manner. Detailed Implementation

[0051] The following is a detailed description of a method for manufacturing a wave winding coil using a conductor forming apparatus, with reference to the accompanying drawings. First, using... Figure 1 and Figure 2 The wave winding coil and stator will be described. The wave winding coil 1 shown in this embodiment is formed into a long strip shape along the Y direction in the figure using multiple coil wires 10 arranged in parallel as described below. This Y direction corresponds to... Figure 2 The circumferential direction of the stator core 20 shown.

[0052] The stator 2 consists of a stator core 20 and a wave winding coil 1 mounted on the stator core 20. The stator core 20 has a plurality of teeth 22 that radiate outward from a central shaft hole 21. Slots 23 are formed between adjacent teeth 22. In this embodiment, a stator core 20 with 72 slots 23 is shown.

[0053] The wave winding coil 1 has multiple slot configuration portions 11 and multiple rotating portions 12. The slot configuration portions 11 are located within slots 23 of the stator core 20. The slot configuration portions 11 are located along the axial direction of the stator core 20. Figure 1 It extends linearly in the Z direction. The rotating part 12 is located on the outer side of the stator core 20 along the axial direction, where adjacent slot configuration parts 11, 11 of the coil wires 10 are connected to each other in a mountain-shaped or arch-shaped manner. One end of the wave winding coil 1 is a terminal part 13 for electrical connection with the drive circuit. Furthermore, the slot configuration part 11 and the rotating part 12 of the wave winding coil 1 are composed of multiple coil wires 10. Figure 1 In this diagram, multiple coil wires 10 constituting the slot configuration section 11, the rotating section 12, and the terminal section 13 are gathered together and schematically shown as a "surface," instead of showing the multiple coil wires 10 constituting the slot configuration section 11, the rotating section 12, and the terminal section 13 as "wires" respectively.

[0054] In this embodiment, the wave winding coil 1 has a length of four turns of the stator core 20, and is constructed as a whole with eight layers (eight turns) of coil, ranging from 1T to 8T, on the stator core 20. Therefore, the wave winding coil 1 constitutes two layers (two turns) of coil per turn of the stator core 20, and layer change occurs every time it winds around the stator core 20. Figure 1 The symbol Ta shown is a layer variation that is respectively arranged between layer 7 (7T) and layer 6 (6T), layer 5 (5T) and layer 4 (4T), and layer 3 (3T) and layer 2 (2T).

[0055] The wave winding coil 1 is wound into a spiral shape, turning four times around the stator core 20. The wave winding coil 1 is mounted on the stator core 20 by placing the slot arrangement part 11 within the slot 23 of the stator core 20. This constitutes the stator 2. Furthermore, each slot 23 is provided with an insulator to achieve insulation between the wave winding coil 1 and the stator core 20, but... Figure 2 The insulator is omitted.

[0056] Next, use Figures 3-6 An embodiment of the coil wire 10 constituting the wave winding coil 1 will be described. The coil wire 10 is a conductor made of copper wire or the like. After the coil wire 10 is cut to a predetermined length, such as... Figure 3 As shown, the coil wire 10 is bent into shape approximately at its center along its extension direction by a pull-out tool 300 that moves in the direction indicated by the hollow arrow. Figure 4 As shown, the coil wire 10 of this embodiment is constructed by arranging three single wires 10a, each made of flat wire, in the Y direction. The Y direction corresponds to the circumferential direction of the stator core 20. The coil wire 10 is formed by bending the three single wires 10a into a single unit in the arrangement direction of the three single wires 10a using a pulling tool 300 while the three single wires 10a are arranged in the Y direction.

[0057] The coil wire 10, bent into shape by the pull-out tool 300, is then formed by a forming die (not shown), such as... Figure 5 and Figure 6 As shown, the coil wire 10 is formed in a roughly U-shape, which has a mountain-shaped rotating portion 12 and two straight portions 14, 14 extending parallel to each other in the same direction from both ends of the first rotating portion 12A. Hereinafter, the rotating portion 12 initially formed on the coil wire 10 will sometimes be referred to as the first rotating portion 12A. The spacing between the two straight portions 14, 14 of the coil wire 10 in this embodiment corresponds to the spacing between two slots 23, 23 in the stator core 20 that are six slots apart.

[0058] like Figure 5 and Figure 6As shown, the first rotating portion 12A of the coil wire 10 has a first oblique portion 12a, a second oblique portion 12b, and a vertex portion 12c. The first oblique portion 12a and the second oblique portion 12b are integrally connected to the straight portions 14, 14, and extend obliquely in a direction of mutual approach from the connection portion with the straight portions 14, 14, while being integrally connected to the vertex portion 12c.

[0059] like Figure 6 As shown, when the linewidth of the coil wire 10 (the radial width of the stator core 20) is set to W, the first oblique portion 12a extends obliquely toward the vertex portion 12c with reference to the connected straight portion 14, without shifting in the X direction. On the other hand, the second oblique portion 12b, after shifting W in the X1 direction relative to the first oblique portion 12a, extends obliquely toward the straight portion 14, and at the connection point with the straight portion 14, shifts W in the X2 direction, which is the opposite direction to the above. As a result, the positions of the two straight portions 14, 14 in the X direction remain unchanged. That is, the two straight portions 14, 14 are arranged in the same plane along the Y direction. Furthermore, the X direction shown in the X1 and X2 directions corresponds to the radial direction of the stator core 20.

[0060] The coil wire 10, shaped into a roughly U-shape, is formed during the formation of the wave winding coil 1, as follows: Figure 7 and Figure 8 As shown, multiple coil wires are arranged side by side. A conductor group 100 is formed by arranging multiple coil wires 10 side by side. In this embodiment, six three-phase coil wires 10 are used. The six coil wires 10 are arranged side by side in the Y direction with a predetermined spacing, thereby forming the conductor group 100. Twelve straight sections 14 are arranged parallel to each other at equal intervals corresponding to the slot spacing of the stator core 20. The first oblique section 12a and the second oblique section 12b of each first turning section 12A are offset by the linewidth W of the coil wire 10 in the opposite direction along the X direction. Therefore, if adjacent coil wires 10 overlap each other in such a way that the first oblique section 12a and the second oblique section 12b of adjacent first turning sections 12A intersect, all twelve straight sections 14 are arranged in the same plane along the Y direction.

[0061] Next, the method for forming the wave winding coil 1 from the conductor group 100 will be described, wherein the conductor group 100 is composed of six coil wires 10 arranged in parallel. First, referring to... Figure 9 and Figure 10 The specific structure of the conductor forming device 200 used in forming the wave winding coil 1 will be described.

[0062] The conductor forming apparatus 200 includes a platform 201 for placing conductor assembly 100, a first clamping part 202, a second clamping part 203, a third clamping part 204 for holding conductor assembly 100 to form inclined sections and fold back, and a holding mechanism 205 for holding conductor assembly 100 for conveying.

[0063] On the upper surface 201a of the mounting stage 201, the conductor assembly 100, which is conveyed by a conveying device (not shown), is placed horizontally with the rotating part 12 (first rotating part 12A) facing the first clamping part 202.

[0064] The first clamping part 202, the second clamping part 203, and the third clamping part 204 are arranged along the transport path of the conductor assembly 100 to be formed, and are configured to be able to move in the vertical direction of the conductor forming apparatus 200. Figure 9 The direction perpendicular to the paper, Figure 10 The first clamping part 202, the second clamping part 203, and the third clamping part 204 are configured such that, when not clamping the conductor assembly 100, they are positioned lower than the upper surface 201a of the platform 201 to avoid obstructing the transport of the conductor assembly 100; when the conductor assembly 100 is transported above the first clamping part 202, the second clamping part 203, and the third clamping part 204, they rise to hold the conductor assembly 100.

[0065] The first clamping part 202 is positioned closest to the mounting platform 201. The first clamping part 202 has a pair of clamping components 202A and 202B, which together hold the straight portion 14 of the coil wire 10 constituting the conductor assembly 100. The clamping components 202A and 202B each have… Figure 7 The conductor assembly 100 shown is arranged in parallel with a certain gap in the D1 direction, which is the transport direction of the conductor assembly 100, with a width greater than or equal to the width in the Y direction, facing the transport path of the conductor assembly 100. With this certain gap, a space 202C is formed between the clamping members 202A and 202B, which can accommodate one of the gripping members 205A or 205B of the gripping mechanism 205 described later.

[0066] The second clamping part 203 is disposed on the side away from the mounting platform 201 relative to the first clamping part 202. Like the first clamping part 202, the second clamping part 203 has a pair of clamping components 203A and 203B, which together hold the straight portion 14 of the coil wire 10 constituting the conductor assembly 100. The clamping components 203A and 203B also have a width greater than or equal to the width of the conductor assembly 100, and are arranged parallel to each other with a certain gap in the D1 direction, which is the transport direction of the conductor assembly 100, facing the transport path of the conductor assembly 100. Through this certain gap, a space 203C is formed between the clamping components 203A and 203B, capable of accommodating one of the holding components 205A or 205B of the holding mechanism 205 described later.

[0067] The third clamping part 204 is located further away from the mounting platform 201 than the second clamping part 203. Like the first clamping part 202 and the second clamping part 203, the third clamping part 204 has a pair of clamping components 204A and 204B, which together hold the straight portion 14 of the coil wire 10 constituting the conductor assembly 100. The clamping components 204A and 204B also have a width greater than or equal to the width of the conductor assembly 100, and are arranged parallel to each other with a certain gap in the D1 direction, which is the transport direction of the conductor assembly 100, facing the transport path of the conductor assembly 100. Through this certain gap, a space 204C is formed between the clamping components 204A and 204B, capable of accommodating one of the holding components 205A or 205B of the holding mechanism 205 described later.

[0068] Pressing members 203D and 204D, respectively, capable of vertical movement, are provided on the second clamping section 203 and the third clamping section 204. The pressing members 203D and 204D are plate-shaped members that press the conductor assembly 100 with their surfaces. The pressing member 203D of the second clamping section 203 is arranged parallel to and close to the side away from the mounting stage 201 relative to the clamping member 203B. The pressing member 204D of the third clamping section 204 is arranged parallel to and close to the side near the mounting stage 201 relative to the clamping member 204A. Figure 10 The diagram shows the pressing components 203D and 204D in their downward-moved positions. At this point, the upper surfaces of the pressing components 203D and 204D are positioned lower than the upper surfaces of the clamping components 203A, 203B, 204A, and 204B, to avoid obstructing the gripping actions of the clamping components 203A, 203B, 204A, and 204B, and the conveying action of the conductor assembly 100.

[0069] like Figure 9 and Figure 10As shown, the clamping member 202B of the first clamping unit 202, located away from the mounting platform 201, is separated from the clamping member 203A of the second clamping unit 203, located closer to the mounting platform 201, by a distance L1. Furthermore, the clamping member 203B of the second clamping unit 203, located away from the mounting platform 201, is separated from the clamping member 204A of the third clamping unit 204, located closer to the mounting platform 201, by a distance L2. Distance L2 is shorter than distance L1.

[0070] The third clamping part 204, relative to the first clamping part 202 and the second clamping part 203, is positioned in the width direction of the conductor forming apparatus 200. Figure 9 One direction (in the D2-D3 direction) Figure 9 The third clamping part 204 is offset in the D2 direction relative to the second clamping part 203. The D2-D3 direction is the direction orthogonal to the D1 direction relative to the transport direction of the conductor group 100. The offset of the third clamping part 204 relative to the second clamping part 203 in the D2 direction is equivalent to half the width of the conductor group 100, that is, the spacing of the six straight sections 14 of the coil wire 10.

[0071] The second clamping part 203 and the third clamping part 204 are configured to move as a single unit in the width direction of the conductor forming apparatus 200 via a moving mechanism (not shown). However, the first clamping part 202 remains stationary. Therefore, when the conductor assembly 100 is held by at least the first clamping part 202 and the second clamping part 203, and the second clamping part 203 moves relative to the first clamping part 202 in the width direction of the conductor forming apparatus 200, the straight portion 14 of the conductor assembly 100 disposed between the first clamping part 202 and the second clamping part 203 is bent at an angle, thereby forming Figure 20 The inclined section 15 is shown. Therefore, the first clamping section 202 and at least the second clamping section 203 constitute the inclined section forming mechanism 206 in the conductor forming apparatus 200.

[0072] The third clamping part 204 is configured such that a foldback line R (see reference) extends in the width direction between it and the second clamping part 203. Figure 9 Using a boundary line (not shown), a rotary movement mechanism is employed, such as... Figure 25 As shown, it can rotate and move by overlapping the second clamping part 203. Through the rotational movement of the third clamping part 204, clamping parts 203A and 204B, clamping parts 203B and 204A, space parts 203C and 204C overlap, and pressing parts 203D and 204D overlap. Thus, the conductor assembly 100 held by the second clamping part 203 and the third clamping part 204, along the thickness direction (with the foldback line R as the boundary),... Figure 8The conductor forming apparatus folds back in the X1-X2 direction. Therefore, the second clamping part 203 and the third clamping part 204 constitute the folding mechanism 207 in the conductor forming apparatus 200.

[0073] like Figure 10 As shown, the holding mechanism 205 is configured to be positioned higher than the upper surface 201a of the mounting platform 201, and can be raised and lowered relative to the conductor group 100 positioned below using a lifting mechanism (not shown). The holding mechanism 205 holds the conductor group 100, which is composed of multiple coil wires 10 having straight sections 14 arranged in parallel, relative to the conductor group 100. The holding mechanism 205 has a pair of holding members 205A and 205B, each having a width greater than or equal to the width of the conductor group 100. The pair of holding members 205A and 205B have the same structure. The holding members 205A and 205B are arranged at a certain distance along the D1 direction, and the holding member 205B is offset relative to the holding member 205A in the D2 direction.

[0074] In this embodiment, the gripping mechanism 205 is provided independently of the second clamping part 203 and the third clamping part 204 constituting the retraction mechanism 207. Therefore, the retraction position in the retraction mechanism 207 can be kept constant, thus ensuring good positional accuracy of the retraction position.

[0075] The gripping mechanism 205 is movable relative to the first clamping part 202, the second clamping part 203, and the third clamping part 204 along the D1 direction. In this embodiment, the gripping mechanism 205 is configured to be movable along the D1 direction. As a result, the gripping mechanism 205 conveys the gripped conductor assembly 100 along a conveying path along the D1 direction and changes its relative position to the first clamping part 202, the second clamping part 203, and the third clamping part 204.

[0076] The spacing between a pair of gripping parts 205A and 205B along the D1 direction is greater than... Figure 9 In the initial state shown, the spacing between the space portion 202C of the first clamping part 202 and the space portion 203C of the second clamping part 203 is slightly narrower, and equal to the spacing between the space portion 203C of the second clamping part 203 and the space portion 204C of the third clamping part 204. The offset of the holding member 205B relative to the holding member 205A in the D2 direction is equal to the offset of the third clamping part 204 relative to the second clamping part 203 in the D2 direction.

[0077] The specific structures of each clamping component 202A, 202B, 203A, 203B, 204A, 204B and the holding components 205A, 205B for holding the conductor assembly 100 can also be the same in each clamping component 202A, 202B, 203A, 203B, 204A, 204B and the holding components 205A, 205B.

[0078] like Figure 11 As shown, the structure for holding the conductor group 100 can, for example, be configured to be able to hold the conductor group 100 in the width direction ( Figure 7 The gripping device 210 is composed of a gripping mechanism that opens and closes in the Y direction. The gripping device 210 described below is an example of the gripping mechanism 205, the first clamping part 202, the second clamping part 203, and the third clamping part 204. It grips the multiple straight sections 14 that constitute the straight section group of multiple coil wires 10 using a pair of fixed blocks 214 and multiple movable blocks 215. As an example of the gripping device 210, the structure for gripping the coil wire 10 will be described when the number of individual wires 10a of the coil wire 10 is, for example, two. The number of individual wires 10a of the coil wire 10 can also be, for example, three or more.

[0079] like Figure 12 and Figure 13 As shown, the holding device 210 holds the multiple straight sections 14 that constitute the multiple coil wires 10 by moving multiple movable blocks 215 within the grooves 214a of a pair of fixed blocks 214.

[0080] like Figure 11 , Figure 14 and Figure 15 As shown, the holding device 210 includes a base portion 211, a first end fixing portion 212, a second end fixing portion 213, a pair of fixing blocks 214, a plurality of movable blocks 215, and a drive mechanism 216 as a driving means.

[0081] The base portion 211 constitutes the base of the holding device 210, and is formed as a long strip plate extending in the D2-D3 direction along the width direction of the plurality of straight portions 14 constituting the plurality of coil wires 10. The first end fixing portion 212 is fixed to the upper surface of the end of the base portion 211 on the D2 direction side. The second end fixing portion 213 is fixed to the upper surface of the end of the base portion 211 on the D3 direction side.

[0082] like Figure 16 and Figure 17As shown, a pair of fixing blocks 214 are formed extending in the D2-D3 direction from the base portion 211, and are disposed between the first end fixing portion 212 and the second end fixing portion 213. The pair of fixing blocks 214 are disposed at a certain distance apart in the extension direction of the straight portion 14, i.e., the D1 direction. Figure 16 and Figure 17 As shown, multiple grooves 214a are formed on the fixing block 214.

[0083] like Figure 16 and Figure 17 As shown, a plurality of grooves 214a are formed by recesses from the upper part of each of a pair of fixing blocks 214. The plurality of grooves 214a are formed through the straight portion 14 in the fixing block 214 in the extension direction, i.e., in the D1 direction. The plurality of grooves 214a are arranged at equal intervals in the D2-D3 direction on the upper part of the fixing block 214.

[0084] The groove 214a has a side groove portion 214b formed in the D2 direction and a side groove portion 214c formed in the D3 direction. The side groove portion 214c is recessed deeper than the side groove portion 214b. The side groove portion 214b and the side groove portion 214c have a step difference 214d and are continuously formed in the long side direction of the fixing block 214.

[0085] like Figure 12 As shown, a straight section 14 constituting a group of straight sections 10 is arranged in a single groove 214b. At one end of the single groove 214b in the D2 direction, there is a fixed-side abutment portion 214e formed by a vertical surface facing the D3 direction. The fixed-side abutment portion 214e is arranged perpendicular to the width direction of the straight section 14. Figure 11 One end of the device (in the D2-D3 direction) is freely connected.

[0086] like Figure 16 and Figure 17 As shown, a plurality of movable blocks 215 are freely movably disposed within the slots 214a of the fixed blocks 214. The movable blocks 215 are respectively mounted on the other side of the slots 214c of the plurality of slots 214a of the pair of fixed blocks 214. Each movable block 215 has a lower structural portion 215a disposed between the pair of fixed blocks 214, and a rod-shaped holding portion 215g disposed at the upper end of the lower structural portion 215a and extending along the extension direction of the straight portion 14, i.e., the D1 direction.

[0087] The lower structural part 215a is formed in a block shape. For example... Figure 16 and Figure 17 As shown, a stepped through hole 215b extending in the D2-D3 direction and a pair of spring receiving recesses 215f are formed in the lower structural part 215a.

[0088] like Figures 14-17 As shown, the stepped through hole 215b is formed through the center of the lower structural portion 215a in the D2-D3 direction, and the small-diameter hole portion 215c formed on the D2 side and the large-diameter hole portion 215d formed on the D3 side are continuously formed via a step 215e.

[0089] like Figure 17 As shown, a pair of spring receiving recesses 215f are arranged diagonally, separated by a stepped through-hole 215b in the lower structural portion 215a. The spring receiving recesses 215f are formed in a cylindrical shape from the D2 direction side to the D3 direction side of the lower structural portion 215a. A return spring 216b (see reference) is housed in the spring receiving recesses 215f. Figure 14 and Figure 15 ).

[0090] like Figures 14-17 As shown, the rod-shaped gripping portion 215g is formed in an L-shaped cross-section and extends in a rod shape along the D1 direction. The rod-shaped gripping portion 215g is mounted on the pair of fixing blocks 214 by positioning its two ends in the groove 214c on the other side of the groove 214a of the pair of fixing blocks 214. The rod-shaped gripping portion 215g has a movable side abutting portion 215h formed by a vertical surface facing the D2 side. The movable side abutting portion 215h is positioned in the width direction of the straight portion 14 (…). Figure 11 The other end of the (D2-D3 direction) is freely connected.

[0091] The movable side abutment portion 215h of each movable block 215 is arranged opposite to the D3 side of the fixed side abutment portion 214e of the fixed block 214. For example... Figure 12 and Figure 13 As shown, a straight section arrangement groove G is formed between the movable side abutment portion 215h of each movable block 215 and the fixed side abutment portion 214e of the fixed block 214. The straight section arrangement groove G arranges multiple straight sections 14 that constitute a group of straight sections of multiple coil wires 10. The straight sections 14 arranged in the straight section arrangement groove G are pressed and clamped by moving towards one side of the movable block 215, abutting against the movable side abutment portion 215h of each movable block 215 and the fixed side abutment portion 214e of the fixed block 214.

[0092] The drive mechanism 216 can freely drive each movable block 215 in an independent state. For example... Figure 14 and Figure 15 As shown, the drive mechanism 216 includes a drive component 217, multiple movable segments 218, multiple pressing adjustment springs 216a as force-applying parts, and multiple return springs 216b.

[0093] The movable segment 218 is disposed through the stepped through hole 215b of the lower structural portion 215a of the movable block 215 in the D2-D3 direction. The movable segment 218 has a large-diameter portion 218a disposed on the D3 side and a small-diameter portion 218b disposed on the D2 side. The large-diameter portion 218a and the small-diameter portion 218b are continuously formed in the D2-D3 direction.

[0094] The pressing adjustment spring 216a is disposed between the step 215e of the stepped through hole 215b of the movable block 215 and the large diameter portion 218a of the movable segment 218. The pressing adjustment spring 216a is, for example, a disc spring. The pressing adjustment spring 216a applies force to each movable block 215 in the opposite direction to the direction in which the straight portion 14 is clamped between each movable block 215 and the fixed block 214 and pressed.

[0095] The drive member 217 is disposed through the second end fixing portion 213 in the D2-D3 direction and is driven in the D2-D3 direction by a pressure cylinder (not shown). The drive member 217 transmits the driving force from the pressure cylinder (not shown) to a plurality of movable segments 218. The drive member 217 presses the movable segments 218 by overcoming the force (spring force) of the pressing adjustment springs 216a, and drives each movable block 215 by overcoming the force of each pressing adjustment spring 216a.

[0096] like Figure 14 and Figure 15 As shown, the return spring 216b is disposed in the spring receiving recess 215f of the movable block 215 (see reference). Figure 17 The return spring 216b applies force to separate adjacent movable blocks 215. Therefore, when the drive member 217 moves from a state pressing the movable blocks 218 towards the D2 side to the D3 side, the return spring 216b moves back to the side where each movable block 215 is separated. Thus, after releasing the grip of the straight section 14, the return spring 216b moves the multiple movable blocks 218 in a manner that ensures equal spacing between them.

[0097] like Figure 14 As shown, when the drive component 217 does not press the movable segment 218 toward the D2 side, as Figure 12 As shown, the width between the movable side abutment portion 215h of each movable block 215 and the fixed side abutment portion 214e of the fixed block 214 is wider than the width of the straight portion 14 of the coil wire 10. Therefore, each straight portion 14 of the coil wire 10 can be received in the straight portion arrangement groove G between the movable side abutment portion 215h of each movable block 215 and the fixed side abutment portion 214e of the fixed block 214, or each straight portion 14 of the coil wire 10 can be removed from the straight portion arrangement groove G between the movable side abutment portion 215h of each movable block 215 and the fixed side abutment portion 214e of the fixed block 214.

[0098] On the other hand, such as Figure 15 As shown, when the drive member 217 is driven to press the movable segment 218 toward the D2 side, as Figure 13 As shown, the width between the movable side abutment portion 215h of each movable block 215 and the fixed side abutment portion 214e of the fixed block 214 is slightly narrower than the width of the straight portion 14 of the coil wire 10. Therefore, when the drive member 217 is not pressing the movable segment 218 toward the D2 side, the straight portion 14 of the coil wire 10 is arranged in the straight portion arrangement slot G. In this state, the drive member 217 is driven, thereby pressing the movable segment 218 toward the D2 side and moving it.

[0099] In this case, since a pressing adjustment spring 216a is arranged between each movable block 215 and each movable segment 218, each movable block 215 can absorb the width deviation of the straight portion 14 of the coil wire 10 and press the straight portion 14 of the coil wire 10 toward the fixed side abutment portion 214e of the fixed block 214. Thus, even if there is a width deviation of the multiple straight portions 14, the holding device 210 can absorb the width deviation of the multiple straight portions 14 of the multiple coil wires 10 and can hold the straight portion 14 of the coil wire 10 in the straight portion arrangement slot G.

[0100] Furthermore, by configuring movable blocks 215 in each slot 214a while maintaining the spacing of the slots 214a of the fixed block 214, the multiple straight portions 14 constituting the multiple coil wire 10 abut against the movable side abutting portion 215h of the movable block 215 and the fixed side abutting portion 214e of the fixed block 214, thereby pressing and holding them together. Figure 13 As shown, in adjacent straight section arrangement slots G, the distance La between the movable side abutment portion 215h formed on the D3 side end of the straight section arrangement slot G arranged on the D2 side and the movable side abutment portion 215h formed on the D2 side end of the straight section arrangement slot G arranged on the D3 side can be maintained within a predetermined range. Therefore, while maintaining the spacing of the multiple straight sections 14, the multiple straight sections 14 can be abutted and pressed against the movable block 215 and the fixed block 214 respectively. As a result, the coil wire 10 can be firmly fixed between the movable block 215 and the fixed block 214.

[0101] The holding device 210 configured as described above can absorb the width deviation of the multiple straight portions 14 constituting the multiple coil wires 10, maintain the spacing of the multiple straight portions 14, and simultaneously cause the multiple straight portions 14 to abut against and press against the movable block 215 and the fixed block 214 respectively. As a result, the coil wires 10 can be formed with high precision, thereby enabling the formation of high-quality coil wires 10.

[0102] Next, the specific forming operation when the conductor forming device 200 forms the conductor assembly 100 will be described.

[0103] First, such as Figure 9 and Figure 10 As shown, a conductor group 100 consisting of 6 coil wires 10 is placed on the upper surface 201a of the mounting table 201 with the rotating part 12 (first rotating part 12A) facing the first clamp part 202.

[0104] When the holding mechanism 205 moves toward the conductor assembly 100 on the mounting platform 201, and the holding member 205A, positioned near the mounting platform 201, is positioned above the conductor assembly 100, the holding mechanism 205 descends, and the holding member 205A grips the straight portion 14 near the rotating portion 12 (first rotating portion 12A) of the conductor assembly 100. At this time, another holding member 205B is positioned between the mounting platform 201 and the first clamping portion 202, and does not grip the conductor assembly 100. While gripping the conductor assembly 100, the holding mechanism 205 moves linearly in the D1 direction along the extension direction of the straight portion 14, as shown below. Figure 18 As shown, the conductor assembly 100 is conveyed above the first clamping part 202 and the second clamping part 203 that constitute the inclined section forming mechanism 206.

[0105] Figure 18 The symbol 208 is a guide member consisting of multiple pins disposed between the mounting platform 201 and the first clamping part 202. After the rotating part 12 (first rotating part 12A) of the conductor assembly 100 passes above the first clamping part 202, the guide member 208 rises from below the conductor assembly 100 and inserts between adjacent straight parts 14, 14. This prevents interference between the straight parts 14 of the conductor assembly 100 during transport and guides the smooth transport of the conductor assembly 100.

[0106] like Figure 18 and Figure 19 As shown, the gripping member 205A holding the conductor assembly 100, after moving above the space 203C of the second clamping part 203, is lifted as a whole by the first clamping part 202, the second clamping part 203, and the third clamping part 204, and is thus housed within the space 203C. When the first clamping part 202 and the second clamping part 203 rise, the clamping members 202A, 202B, 203A, and 203B are in an open state. Therefore, due to the rise of the first clamping part 202 and the second clamping part 203, the straight sections 14 of the conductor assembly 100 are respectively housed within the space 203C. Figures 11-13 , Figure 16 and Figure 17The straight section 14 is housed in the groove 214a shown in the figure. After the straight section 14 is housed in the groove 214a, the clamping components 202A, 202B, 203A, and 203B are closed, thereby holding the conductor assembly 100.

[0107] like Figure 18 and Figure 19 As shown, the gripped portions 140, 140 of the straight portion 14 held by the first clamp portion 202 and the second clamp portion 203 are the portions corresponding to the slot arrangement portion 11 of the wave winding coil 1. Therefore, the interval between a pair of clamp members 202A, 202B along the extending direction of the straight portion 14 (including the length in the D1 direction of the first clamp portion 202 of the space portion 202C) and the interval between a pair of clamp members 203A, 203B (including the length in the D1 direction of the second clamp portion 203 of the space portion 203C) are approximately equal to the length of the slot arrangement portion 11 of the wave winding coil 1.

[0108] like Figure 18 and Figure 19 As shown, in the straight section 14 of the conductor assembly 100, the portion 141 disposed between the first clamping portion 202 and the second clamping portion 203 is the portion of the conductor assembly 100 in which the inclined portion 15 is formed, and it corresponds to the rotating portion 12 of the wave winding coil 1. The length of this portion 141, i.e., Figure 9 and Figure 10 The distance L1 between the first clamp portion 202 and the second clamp portion 203 shown is approximately equal to the length when one of the rotating portions 12 of the wave winding coil 1 is extended into a straight line.

[0109] After the first clamping part 202 and the second clamping part 203 hold the conductor assembly 100, the holding mechanism 205 releases its grip on the conductor assembly 100 and rises, retracting to above the conductor assembly 100. Thereafter, as... Figure 20 As shown, in preparation for the next gripping action, the gripping member 205A moves above the space portion 202C of the first clamp portion 202.

[0110] Next, the conductor forming apparatus 200, from the state in which the conductor assembly 100 is held by the first clamping part 202 and the second clamping part 203, moves the second clamping part 203 and the third clamping part 204 as... Figure 20 As shown, it moves in the D2 direction relative to the first clamping part 202. That is, the first rotating part 12A of the coil wire 10 in the conductor assembly 100 and the holding part 140 held by the second clamping part 203 are moved within the extending surface of the coil wire 10 of the conductor assembly 100. Figure 20Within the paper, it is offset in a direction (D2 direction) intersecting the extending direction of the straight section 14. As a result, the portion 141 formed by the 12 straight sections 14 disposed between the first clamping section 202 and the second clamping section 203 is tilted in the offset direction (D2 direction), and a first oblique section 15 (oblique section 15A) is formed on each coil wire 10 constituting the conductor group 100.

[0111] like Figure 5 As shown, the inclination angle of the slanted portion 15 relative to the straight portion 14 is approximately equal to the inclination angle of the first slanted portion 12a or the second slanted portion 12b of the rotating portion 12 formed on the coil wire 10. By forming the slanted portion 15 in the conductor assembly 100, the rotating portion 12 (first rotating portion 12A) side of the conductor assembly 100 held by the second clamping portion 203 is offset in the D2 direction relative to the straight portion 14 held by the first clamping portion 202 by an offset equivalent to half the width of the conductor assembly 100, i.e., the spacing of the six straight portions 14 of the coil wire 10.

[0112] In this embodiment, the conductor forming apparatus 200, when forming the inclined section 15, does not move the second clamp section 203 side linearly in the D2 direction, but rather... Figure 21 As shown, the configuration is such that the second clamping part 203 moves in an arc shape with the boundary point (the bending point P) of each inclined section 15 and each straight section 14 continuous with that inclined section 15 and held by the first clamping part 202 as the center, and with the length of the inclined section 15 as the radius. At this time, the second clamping part 203 moves in an arc shape while maintaining parallelism with respect to the first clamping part 202. Thus, as... Figure 22 As shown, the oblique portion 15 (part 141) is stretched in opposite directions to form a shape, so the oblique portion 15 after forming has good straightness and the forming accuracy of the oblique portion 15 is improved.

[0113] When the second clamping part 203 is offset in the D2 direction to form the inclined part 15, as Figure 20 As shown, the distance between the space portion 202C of the first clamping portion 202 and the space portion 203C of the second clamping portion 203 is slightly reduced, matching the distance between the pair of gripping members 205A and 205B. Therefore, after the initial oblique portion 15 (oblique portion 15A) is formed in the conductor assembly 100, the gripping mechanism 205... Figure 20 When the position shown is lowered toward the conductor assembly 100, the holding members 205A and 205B are respectively housed in the space portions 202C and 203C, thereby holding the conductor assembly 100.

[0114] At this time, because the pair of gripping parts 205A and 205B grip the conductor assembly 100 at the two points of the straight portions 14 and 14 respectively arranged on both sides of the clamping inclined portion 15, the conductor assembly 100 is not easily loosened. Subsequently, when the gripping mechanism 205 grips the conductor assembly 100, the first clamping portion 202 and the second clamping portion 203 release their grip on the conductor assembly 100 and descend, and move in the D3 direction to return to the initial position.

[0115] Subsequently, the holding mechanism 205 holding the conductor assembly 100 moves in the D1 direction, and as... Figure 23 As shown, the conductor assembly 100 is conveyed until the holding member 205A is positioned above the space portion 203C of the second clamping part 203, and the holding member 205B is positioned above the space portion 204C of the third clamping part 204. The third clamping part 204 is offset by half the width of the conductor assembly 100 in the D2 direction relative to the first clamping part 202 and the second clamping part 203. The holding member 205B of the holding mechanism 205 is also offset relative to the holding member 205A in the same way. Therefore, when the first clamping part 202, the second clamping part 203 and the third clamping part 204 rise, the holding members 205A and 205B, which hold the conductor assembly 100 after the initial inclined section 15 (inclined section 15A) is formed, are respectively housed in the space portion 203C of the second clamping part 203 and the space portion 204C of the third clamping part 204.

[0116] After the first clamping part 202, the second clamping part 203, and the third clamping part 204 rise, they respectively grip the straight portion 14 of the conductor assembly 100, and the gripping mechanism 205 releases its grip on the conductor assembly 100. At this time, the inclined portion 15 formed in the conductor assembly 100 is positioned between the clamping member 203B of the second clamping part 203 and the clamping member 204A of the third clamping part 204. That is, the distance L2 between the clamping member 203B and the clamping member 204A is approximately equal to the distance between the adjacent straight portions 14, 14 separated by the inclined portion 15. In addition, a portion 141 for the inclined portion 15 to be formed next is newly arranged between the first clamping part 202 and the second clamping part 203. After the gripping mechanism 205 retracts to above the conductor assembly 100, as Figure 24 As shown, in preparation for the next gripping, it moves above the space portion 202C of the first clamping portion 202 and the space portion 203C of the second clamping portion 203.

[0117] Subsequently, with Figure 20 The situation is the same as shown in the figure. By moving the second clamping part 203 and the third clamping part 204 in the D2 direction, as shown in the figure, Figure 24As shown, a second inclined section 15 (inclined section 15B) is formed between the first clamping section 202 and the second clamping section 203 (inclined section forming process).

[0118] Next, at the center of the initial oblique section 15A located between the second clamp section 203 and the third clamp section 204, that is, at the foldback line R located between the second clamp section 203 and the third clamp section 204 (refer to...) Figure 9 , Figure 24 () is the boundary line, such as Figure 25 As shown, the third clamping part 204 rotates and moves in a manner that overlaps the second clamping part 203, thereby folding back the initial inclined part 15A (folding back process).

[0119] By rotating the third clamping part 204, the initial oblique portion 15A of the conductor assembly 100 is folded back in the thickness direction of the conductor assembly 100. The folding line R is arranged along the D2-D3 direction in the width direction of the conductor assembly 100 and intersects the oblique portion 15A. Therefore, by folding back the oblique portion 15A, this folded portion forms 12 new rotating portions 12 (second rotating portions 12B) in a mountain-shaped (triangular) shape with the folding line R as the vertex (vertex 12c). In this embodiment, by rotating the third clamping part 204, the oblique portion 15A is folded back along the folding line R. Figure 24 Fold the paper in the forward direction (R1 direction) of the paper.

[0120] Figure 27 Only the conductor group 100 after the initial diagonal section 15A has been folded back is shown. (As...) Figure 27 As shown, when the initial inclined section 15A is folded back, a portion of the gripped portions 140, 140 of the straight section 14 held by the second clamping section 203 and the third clamping section 204 overlaps with each other. Specifically, 6 of the 12 gripped portions 140 held by the second clamping section 203 overlap with 6 of the 12 gripped portions 140 held by the third clamping section 204. Thus, a slot arrangement section 11 with a width equivalent to 18 straight sections 14 is formed.

[0121] Furthermore, in this embodiment, two oblique portions 15 (oblique portions 15A, 15B) are formed before the initial folding process for the conductor group 100. Therefore, as Figure 26 As shown, the rotating portion 12 (first rotating portion 12A) of the folded-back conductor assembly 100 is arranged to overlap the oblique portion 15 (oblique portion 15B) formed in the second step. Therefore, the folded-back rotating portion 12 will not interfere with the straight portion 14 of the conductor assembly 100.

[0122] When turning back the diagonal section 15, as Figure 25As shown, a folding fixture 220 can also be inserted between the second clamping part 203 and the third clamping part 204. The folding fixture 220 is formed in a triangular cross-section, with the edge 220a on the vertex side of the acute angle inserted along the folding line R of the inclined part 15. Thus, the third clamping part 204 can fold the inclined part 15 back with high precision along the folding line R. Before the folding action is completed, the folding fixture 220 is removed from between the second clamping part 203 and the third clamping part 204.

[0123] Additionally, after the turnaround of the diagonal section 15 is completed, as follows: Figure 28 As shown, while holding the conductor assembly 100, the third clamping part 204 can be slightly moved relative to the second clamping part 203 along the arrangement direction of the straight sections 14 in the width direction (D2-D3 direction) of the folded portion. This suppresses the springback that occurs when the rotating part 12 is opened after the diagonal section 15 has been folded back. Furthermore, the spacing between the six folded straight sections 14 can be adjusted.

[0124] In the reversing process, after the inclined section 15 is reversed, in the state where the second clamping section 203 and the third clamping section 204 overlap, as follows: Figure 29 As shown, the pressing member 203D of the second clamping part 203 rises relative to the second clamping part 203, and the pressing member 204D of the third clamping part 204 rises relative to the third clamping part 204. The rotating part 12, which is the folded-back part of the conductor assembly 100, is clamped between the pressing members 203D and 204D and pressed along the thickness direction. As a result, the expansion of the rotating part 12 in the thickness direction due to springback can be suppressed, and the forming accuracy of the rotating part 12 is further improved. In addition, since the rotating part 12 can be directly pressed after being formed by the second clamping part 203 and the third clamping part 204, there is no need to set up a separate pressing station, which simplifies the device and process.

[0125] After the second rotating section 12B is formed, the holding mechanism 205 further conveys the conductor assembly 100 in the D1 direction, positioning the second-formed inclined section 15B between the second clamping section 203 and the third clamping section 204. Subsequently, with... Figure 24 The same applies to the straight section 14 disposed between the first clamping section 202 and the second clamping section 203, as shown in the diagram. Figure 30 As shown, the third oblique section 15 (oblique section 15C) is formed.

[0126] Subsequently, similarly as described above, the folding process for the second inclined section 15B, the inclined section forming process for the fourth inclined section, the folding process for the third inclined section 15C, and so on, are alternately and repeatedly performed until the wave winding coil 1 formed by the conductor group 100 reaches the prescribed length of four turns around the stator core 20. As a result, the forming slot arrangement section 11 forms a sheet-like wave winding coil 1 with 6 staggered and overlapping layers of 8 layers (8 turns). Thus, in the wave winding coil 1 formed by the conductor forming device 200, which alternately and repeatedly forms and folds the inclined section 15, the forming error generated when folding the coil wire 10 does not accumulate in the inclined section 15. Therefore, the forming accuracy of the slot arrangement section 11 and the rotating section 12 is good.

[0127] Furthermore, as shown in this embodiment, when the coil wire 10 is constructed by arranging multiple individual wires 10a in the thickness direction (Y direction), when the inclined section 15 is folded back, due to the angle difference between the extension direction of the inclined section 15 before folding back and the folding direction, a circumference difference inevitably occurs between each individual wire 10a. In the conventional case where all inclined sections are formed first, the circumference difference generated between each individual wire 10a during folding back affects the already formed inclined sections, causing the shoulder bends (the starting points of the bends in the inclined sections) of the formed inclined sections to be misaligned. However, by alternately performing the inclined section forming process and the folding process as described in this embodiment, the effect of the circumference difference between individual wires 10a caused by folding back can be substantially eliminated by forming the next inclined section 15. Therefore, even when the coil wire 10 is constructed by arranging multiple individual wires 10a in the thickness direction, a wave winding coil 1 with good forming accuracy can be manufactured.

[0128] Furthermore, the sheet-like wave winding coil 1 obtained above forms a double-layer structure overlapping the slot arrangement section 11, such as... Figure 1 As shown, there is a layer-changing section Ta that switches layers (turns) radially in each turn of the stator core 20. In the case of forming this wave winding coil 1, in order to avoid interference between layers in the layer-changing section Ta, it can also be explained as follows: in the folding process corresponding to the layer-changing section Ta, the folding direction of the slant section 15 is folded back in the opposite direction (R2 direction) of the previous folding direction (R1 direction).

[0129] like Figure 31 As shown, in the folding process where the oblique portion 15 corresponding to the layer change portion Ta is folded back along the folding line R, the oblique portion 15 is folded in the opposite direction (R2 direction) to the folding direction (R1 direction) of the oblique portion 15 in the previous folding process. That is, in the case of the wave winding coil 1 shown in this embodiment, as Figure 1As shown, there are three locations with layer variation sections Ta: between layers 7 (7T) and 6 (6T), between layers 5 (5T) and 4 (4T), and between layers 3 (3T) and 2 (2T). Therefore, only in the folding process of the oblique section 15 corresponding to these layer variation sections Ta, as described above, is the oblique section 15 folded in the reverse direction. Thus, as... Figure 32 As shown, in each layer of the variable section Ta, the thickness direction of the rotating section 12 (radial direction of the stator core 20, radial ... rotating section 12) is as follows: Figure 32 The offset direction of the X direction in the wave winding coil 1 is the opposite direction, which can avoid the interference between layers in the layer change section Ta when the wave winding coil 1 is assembled on the stator core 20.

[0130] The above-mentioned sheet-shaped wave winding coil 1, when installed in the slot of the stator, does not require the technology commonly used in society, which involves dividing the coil into multiple segments and welding the ends of the coil after inserting it into the slot. Therefore, for example, it is no longer necessary to use high-purity copper material in the coil to cope with the heat treatment of the welding parts, and it is also possible to use recycled copper material containing impurities, which can contribute to the realization of resource recycling.

[0131] The wave winding coil 1 described above is constructed by arranging six coil wires 10 in parallel, but the number of coil wires 10 arranged in parallel is not limited to six and can be increased or decreased appropriately. Additionally, the coil wires 10 can be constructed by arranging three single wires 10a, but the number of single wires 10a is not limited to three and can be increased or decreased appropriately. For example, the number of single wires 10a can be two or more.

[0132] The wave winding coil is not limited to forming a generally U-shaped coil wire 10, but can also be formed by alternately performing a slant section forming process and a folding process on a straight coil wire.

[0133] In the foregoing embodiments, such as Figures 11-15 As shown, the holding device 210 is configured to press multiple movable blocks 215 from one side in the D2-D3 direction to hold multiple straight sections 14 constituting multiple coil wire assemblies, but it is not limited to this. For example, it can also be as follows: Figure 33 As shown in the modified gripping device 210A, it is configured to press multiple movable blocks 215 from both sides in the D2-D3 direction to grip multiple straight sections 14 that constitute multiple coil wire 10 straight section assemblies.

[0134] Figure 33 The gripping device 210A shown in the modified form is based on the aforementioned embodiment. Figures 11-15 In the gripping device 210 shown, which has a configuration that presses down on one side of a plurality of movable blocks 215 in the D2-D3 direction, an additional feature is added that allows the aforementioned embodiment to... Figures 11-15 The gripping device 210 shown has a left-right reversible structure that presses multiple movable blocks 215 from the other side in the D2-D3 direction, and a structure that grips multiple straight sections 14 by pressing multiple movable blocks 215 from both sides separated by the central fixed part 219. For points not described in the description of the modified gripping device 210A, the description of the gripping device 210 of the aforementioned embodiment can be referenced.

[0135] like Figure 33 As shown, in the deformable gripping device 210A, a central fixing part 219 is provided in the center along the D2-D3 direction. In the gripping device 210A, the drive members 217A of the drive mechanisms 216A, located on both sides of the central fixing part 219 in the D2-D3 direction, press multiple movable blocks 218 toward the central fixing part 219, thereby causing multiple movable blocks 215 to move from both sides of the central fixing part 219 toward the central fixing part 219 across the D2-D3 direction. This causes the groove 214a of the fixing block 214 (see reference...) to... Figure 12 Within the unit, multiple movable blocks 215 move toward the central fixed part 219, thereby allowing the multiple straight sections 14 that constitute the multiple coil wires 10 to be held.

[0136] Figure Labels

[0137] 10. Coil wire (conductor)

[0138] 14. Straight Section

[0139] 200 Conductor Forming Apparatus

[0140] 210 Holding device (holding mechanism)

[0141] 214 Fixing Block

[0142] 214a slot

[0143] 214e Fixed side abutment part

[0144] 215 movable blocks

[0145] 215h Movable side contact part

[0146] 216 Drive mechanism (drive means)

[0147] 216a Press Adjustment Spring (Force Application Part)

Claims

1. A conductor forming apparatus comprising a holding mechanism, the holding mechanism holding a group of straight sections constituting a plurality of conductors arranged in parallel for holding such a group, the conductor forming apparatus being characterized in that the holding mechanism comprises: The fixing block is provided with a plurality of slots at equal intervals, and each slot has a fixing side abutting part that freely abuts against one end of the aforementioned straight portion in the width direction; Multiple movable blocks are freely movably arranged in the aforementioned groove of the aforementioned fixed block, and are provided with a movable side abutting part that freely abuts against the other end of the aforementioned straight section in the width direction; The force-applying part applies force to each of the aforementioned movable blocks in the opposite direction to the direction in which the movable blocks are clamped and pressed between the aforementioned movable blocks and the aforementioned fixed block; and, The driving means is capable of moving all of the aforementioned plurality of movable blocks in a direction that clamps and presses the aforementioned straight portion between the aforementioned movable blocks and the aforementioned fixed block. When all of the aforementioned plurality of movable blocks are moved in the direction that clamps and presses the aforementioned straight portion between the aforementioned movable blocks and the aforementioned fixed block, the aforementioned driving means overcomes the force applied by each force-applying part to drive the aforementioned movable blocks, thereby freely driving the aforementioned movable blocks in an independent state.

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