Manufacturing device and manufacturing method of hairpin conductor

Abstract

A hairpin conductor manufacturing device (91) is provided with: an indexing table (71) that intermittently rotates around a rotation axis (CL7); a plurality of jigs (721-726) which are attached to the indexing table (71) at an angular pitch ([theta] p) and which are capable of gripping a linear cut wire (Wc) in a horizontal posture extending radially; and a plurality of station devices (1-5) which are provided around the indexing table (71) at an angular pitch ([theta] p) and which process the cut wire (Wc) held by the clamp (721) in stages to form a three-dimensional hairpin conductor (Wg). The plurality of station devices (1-5) comprise bending devices (1-3) and punching devices (4), and the arrangement sequence is set along the rotation direction of the indexing table (71).

Description

Technical Field

[0001] The present disclosure relates to a manufacturing device and a manufacturing method of a hairpin conductor. Background Art

[0002] As a coil constituting a stator of a motor, a segment coil is known in which a plurality of substantially U-shaped segment conductors (hereinafter referred to as hairpin conductors) made of a rectangular wire are connected and coiled.

[0003] Patent documents 1 and 2 describe a method for manufacturing a hairpin conductor. The method for manufacturing a hairpin conductor described in Patent document 1 includes: a step of bending the front end portion of a linear conductor material to form a predetermined two-dimensional shape; and a step of cutting the portion formed into a two-dimensional shape into a three-dimensional shape by clamping it with a mold, and then cutting it into a predetermined length to form a hairpin conductor. In the method for manufacturing a hairpin conductor described in Patent document 2, multiple steps of bending a linear conductor material to form a predetermined two-dimensional shape are performed at one station. Patent document 3 describes a device and method for manufacturing a component equivalent to a hairpin conductor called a hairpin element. In the device and method for manufacturing a hairpin conductor described in Patent document 3, a plurality of bending processing devices are arranged on a linear line, and a plurality of bending processing devices on the linear line are used to sequentially bend a linear bare wire to form a hairpin-shaped hairpin conductor.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2003-143818

[0007] Patent Document 2: Japanese Patent Application Publication No. 2019-033554

[0008] Patent Document 3: German Patent Application Publication No. 102018221152 Summary of the invention

[0009] In the method for manufacturing a hairpin conductor described in Patent Document 1, after a two-dimensional process based on bending and a three-dimensional process based on clamping of a mold are performed on a linear conductor material, the hairpin conductor monomer is cut into a predetermined length. Therefore, if the two-dimensional process and three-dimensional process of forming a hairpin conductor are completed but the cutting is not completed, the two-dimensional process of the next hairpin conductor cannot be started. In the method for manufacturing a hairpin conductor described in Patent Document 2, multiple two-dimensional processes based on bending relative to a linear conductor material are performed using one station. Therefore, if multiple processes at one station are not completed, the two-dimensional process of the next hairpin conductor cannot be started. In the manufacturing method using the manufacturing device for a hairpin conductor described in Patent Document 3, each time the processed wire is conveyed to an adjacent bending machine for the next bending process, it needs to be clamped again. Therefore, the methods for manufacturing hairpin conductors described in Patent Documents 1 to 3 have room for improvement in that it is not easy to shorten the production cycle time.

[0010] In order to solve the above-mentioned problems, one aspect of the present disclosure has the following 1) structure and 2) steps.

[0011] 1) A device for manufacturing a hairpin conductor, comprising:

[0012] An indexing table that intermittently rotates about a rotation axis extending vertically;

[0013] a plurality of clamps mounted on the indexing table at predetermined angular intervals with the rotation axis as the center, capable of holding a linear cut wire of a predetermined length in a radially extending horizontal posture; and

[0014] A plurality of station devices are arranged around the indexing table at the angular intervals with the rotation axis as the center, and the cut wire held by the clamp is processed in stages to form a hairpin conductor.

[0015] The plurality of workstation devices include a bending device and a punching device, and are arranged in a sequence along the rotation direction of the indexing table.

[0016] 2) A method for manufacturing a hairpin conductor, wherein:

[0017] A bending device and a punching device for processing the cut wire into a three-dimensional hairpin conductor in stages are pre-arranged around an intermittently rotating indexing table at predetermined angular intervals along the rotation direction of the indexing table.

[0018] A plurality of clamps mounted on the indexing table at the angular intervals are used to hold the linear cut wire of a predetermined length in a radially extending horizontal posture.

[0019] During the period of the intermittent rotation of the indexing table being stopped, the cut wire material held by the clamp is subjected to two-dimensional bending by the bending device.

[0020] During the next stop period, the cut wire material after the bending process is formed into the hairpin conductor having a three-dimensional shape by the press device.

[0021] According to one aspect of the present disclosure, it is possible to produce a hairpin conductor in a shorter tact time. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 1 is a diagram showing a manufacturing system ST including an example of a manufacturing apparatus for hairpin conductors according to an embodiment of the present disclosure.

[0023] Figure 2A 1 is a diagram showing a partially stripped wire material Wb that has been stripped by the stripping device 83 of the manufacturing system ST. Figure 2A (a) is a plane diagram, Figure 2A (b) is a side view.

[0024] Figure 2B yes Figure 2A Cross-sectional view at the 2B-2B position in (a).

[0025] Figure 2C It is a figure which shows the cut|disconnected wire material Wc cut|disconnected by the conveyance cutting apparatus 84 of the manufacturing system ST.

[0026] Figure 3 It is a top view showing the indexing table 71 of the wire processing device 91 in the manufacturing system ST.

[0027] Figure 4 It is a plan view showing the first station device 1 in the wire processing device 91.

[0028] Figure 5 It is a side view of the first working station device 1.

[0029] Fig. 6A It is a plan view showing the first stage of the processing process of the first station device 1.

[0030] Figure 6B It is a plan view showing the second stage in the processing step of the first station device 1.

[0031] Figure 6C It is a plan view showing the third stage in the processing process of the first station device 1.

[0032] Fig.6D It is a plan view showing the fourth stage in the processing process of the first station device 1.

[0033] Figure 7 It is a top view showing the processing steps of the second station device 2.

[0034] Fig. 8A It is a plan view showing the processing steps of the third station device 3.

[0035] Figure 8B It is a plan view showing the bent wire material Wf after being processed by the third station device 3.

[0036] Fig.9A It is a figure which shows the press working in the 4th station apparatus 4.

[0037] Fig. 9B 1 is a plan view showing the hairpin conductor Wg obtained by processing in the fourth station device 4 .

[0038] Fig. 9C It is a diagram showing deformation of the arm portion Wm1 of the bent wire material Wf during processing by the fourth station device 4 .

[0039] Fig.9D It is a diagram showing the operation corresponding to the deformation of the arm Wm1.

[0040] Fig.9E It is a side view of the fourth station device 4.

[0041] Fig.10 It is a diagram showing the operation of the fifth station device 5.

[0042] Fig.11 It is a block diagram of the wire processing device 91.

[0043] Fig.12 It is a block diagram of the first to third station devices 1 to 3.

[0044] Fig.13 It is a block diagram of the fourth station device 4. DETAILED DESCRIPTION

[0045] (Example)

[0046] An example of a manufacturing apparatus for a hairpin conductor according to an embodiment of the present disclosure is a wire processing apparatus 91 .

[0047] Figure 1 1 is a diagram showing a manufacturing system ST including an example of a manufacturing apparatus for hairpin conductors according to an embodiment of the present disclosure. Figure 2A 1 is a diagram showing a partially stripped wire material Wb that has been stripped by the stripping device 83 of the manufacturing system ST. Figure 2A (a) is a plane diagram, Figure 2A (b) is a side view. Figure 2B yes Figure 2A A cross-sectional view at the 2B-2B position in FIG. Figure 2C It is a figure which shows the cut|disconnected wire material Wc cut|disconnected by the conveyance cutting apparatus 84 of the manufacturing system ST.

[0048] Figure 1 The manufacturing system ST shown is a system for continuously manufacturing hairpin conductors from flat wires, and is equipped with a pre-processing device group 80 and a wire processing device 91. The hairpin conductor is a conductor formed into a hairpin shape by bending and punching a flat wire. A plurality of hairpin conductors are connected to form a hairpin coil. The hairpin coil is used for a motor for driving and regeneration of an automobile, etc. In the manufacturing system ST, the pre-processing device group 80 has an uncoiler 81, a wire straightening machine (straightening machine) 82, a stripping device 83, and a conveying and cutting device 84 from the upstream side of the process.

[0049] A flat wire is wound on the uncoiler 81. The wire straightening machine 82 straightens the flat wire Wa sent out from the uncoiler 81 in a flat posture in the vertical direction into a straight shape and sends it out. The stripping device 83 strips the coating Wb2 of a predetermined length range from the flat wire Wa sent out from the wire straightening machine 82 by punching or other processing methods. As shown in FIG. 2 , the flat wire Wa is sent out as a partially stripped wire Wb having a core wire exposed portion Wb1 repeatedly exposed within a predetermined length range at a predetermined pitch by the stripping device 83. Figure 2B 2 is a cross-sectional view of a core wire exposed portion Wb1 of a partially peeled wire Wb. The corners of the core wire exposed portion Wb1 may be chamfered.

[0050] like Figure 2C As shown, the transport cutting device 84 cuts the partially stripped wire Wb sent out from the stripping device 83 at the center position in the longitudinal direction of the core wire exposed portion Wb1, and sequentially sends out the cut wires Wc toward the wire processing device 91.

[0051] A wire processing device 91 is provided on the downstream side of the pre-processing device group 80. The wire processing device 91 is configured to include an indexing unit 7, a discharge unit 92, a control unit 93, and the like. The indexing unit 7 includes a base 73 provided on the floor FL, an indexing table 71, a support column 711, and a camera 712. The indexing table 71 is provided with a fixture group 72 including a fixture 721 for holding the cut wire Wc sent out from the conveying and cutting device 84.

[0052] (Wire material processing device 91)

[0053] Next, refer to Figure 3 to Figure 5 as well as Figure 11 to Figure 13 The detailed structure of the wire processing device 91 will be described. Figure 3It is a top view showing the indexing table 71 of the wire processing device 91 in the manufacturing system ST. Figure 4 It is a plan view showing the first station device 1 in the wire processing device 91. Figure 5 It is a side view of the first working station device 1. Fig.11 It is a block diagram of the wire processing device 91. Fig.12 It is a block diagram of the first to third station devices 1 to 3. Fig.13 It is a block diagram of the fourth station device 4.

[0054] like Figure 3 as well as Figure 5 As shown, the wire material processing device 91 includes a base portion 73, an indexing table 71, and first to fifth station devices 1 to 5. Figure 5 As shown, inside the base portion 73 provided on the floor FL, an indexing shaft motor 730, a shaft 731, a collector ring 732, and a collector ring shaft motor 733 are provided with a rotation axis CL7 extending in the vertical direction as the axis center. Fig.11 As shown, the operations of the indexing shaft motor 730 and the slip ring shaft motor 733 are controlled by the control unit 93 .

[0055] A flat indexing table 71 is disposed horizontally above the base 73. The indexing table 71 is connected to the output shaft of the indexing axis motor 730, and rotates about the rotation axis CL7 as the rotation axis by the operation of the indexing axis motor 730. Figure 3 As shown, the indexing table 71 has six protrusions 71a protruding radially outward at a predetermined angular pitch θp in the circumferential direction. In this example, the predetermined angular pitch θp is 60°. Clamps 721 to 726 are mounted on the upper surface of each of the six protrusions 71a. The clamps 721 to 726 are also collectively referred to as a clamp group 72.

[0056] The clamps 721 to 726 have a pair of clamping claws 72a and 72b (see Figure 5 The pair of clamps 72a and 72b are operated to contact each other from the positions separated from each other by the clamp driving parts 721D to 726D respectively provided in the clamps 721 to 726, so as to hold the cut wire Wc. In addition, the pair of clamps 72a and 72b rotate around the clamp axis CL1 (see arrow DR01).

[0057] Specifically, in Figure 5In the figure, when assuming an imaginary clamp axis CL1 that passes through the rotation axis CL7 corresponding to the protrusion 71a and extends horizontally in the radial direction, the clamp 721 can hold the cut wire Wc arranged in a manner extending on the clamp axis CL1 and perform a rotation equivalent to the twisting around the clamp axis CL1 (i.e., it can rotate freely). The clamp axis CL1 is consistent with the central axis of the cut wire Wc held by the clamp 721. The same is true for the clamps 722 to 726 and the corresponding clamp axes CL2 to CL6. The movement of the jaws 72a, 72b of the clamps 721 to 726 and the rotation around the clamp axis CL1 are performed by the clamp driving units 721D to 726D. Fig.11 As shown, the operations of the clamp driving units 721D to 726D are controlled by the control unit 93 .

[0058] The indexing table 71 is controlled by the control unit 93, and the indexing axis motor 730 is operated to intermittently rotate around the rotation axis CL7 at a predetermined angular pitch θp. In this example, the angular pitch θp is 60°. The electrical connection between the control unit 93 and the fixture drive units 721D to 726D is established through the slip ring 732 by the intermittent rotation of the indexing table 71 having the fixture drive units 721D to 726D relative to the base unit 73 (see Figure 5 In this example, a slip ring shaft motor 733 is used to rotate the shaft of the slip ring 732, and the rotation of the shaft of the slip ring 732 is synchronized with the rotation of the shaft of the indexing table 71 under the control of the control unit 93. As a result, the cables from the clamp driving units 721D to 726D are not twisted due to intermittent rotation.

[0059] Show Figure 3 The indexing table 71 of the indexing part 7 shown in FIG. 1 is stopped by intermittent rotation. In this state, the positions corresponding to the six protrusions 71a become one supply position and five station positions. Figure 3 The position corresponding to the clamp 726 is the supply position, and the positions corresponding to the clamps 721 to 725 are the first to fifth station positions. The first to fifth station positions are provided with the first to fifth station devices 1 to 5, respectively.

[0060] At the supply position, the cut wire Wc is fed from the pre-processing device group 80 toward the indexing section 7, so the clamp 726 holds the cut wire Wc. The control unit 93 intermittently rotates the indexing table 71 at a predetermined time interval and stop time set in advance ( Figure 3 In the intermittent rotation stop time, the workpieces respectively held by the clamps 721 to 725 are processed by the first to fifth station devices 1 to 5.

[0061] Each time the indexing table 71 stops by intermittent rotation, the clamp 726 at the supply position holds the cut wire Wc supplied from the pre-processing device group 80. That is, the workpiece held at the first station position performs five intermittent actions and rotates to the fifth station position. Figure 3 The clamps 721 to 726 are shown in their respective holding states.

[0062] The wire material processing device 91 performs the following operations under the control of the control unit 93. The first station device 1 to the third station device 3 are bending processing devices with the same structure, and perform two-dimensional bending processing on the workpiece in a horizontal plane. Figure 3 , the cut wire Wc moved from the sixth station position (supply position) to the first station position by intermittent rotation and held by the clamp 726 is subjected to two-dimensional bending processing by the first station device 1 to become the bent wire Wd. The bent wire Wd is conveyed to the second station position by the next intermittent rotation while being held by the clamp 726, and is subjected to two-dimensional bending processing by the second station device 2 to become the bent wire We. The bent wire We is conveyed to the third station position by the next intermittent rotation while being held by the clamp 726, and is subjected to two-dimensional bending processing by the third station device 3 to become the bent wire Wf.

[0063] The fourth station device 4 performs three-dimensional stamping including vertical deformation on the workpiece. When the bent wire Wf is transported to the fourth station position in the next intermittent operation, the fourth station device 4 performs stamping to form a three-dimensional hairpin conductor Wg.

[0064] The fifth station device 5 determines whether the hairpin conductor Wg is formed into a predetermined shape, and performs correction processing if it is determined to be negative. If the hairpin conductor Wg obtained by the fourth station device 4 is determined to be a qualified product in the fifth station device 5, the clamp 725 releases the grip and discharges it to the discharge unit 92. If it is determined to be a defective product, a corrected bending process is performed according to the defective content to form the hairpin conductor Wh. If it is determined to be a qualified product in the re-measurement, the clamp 725 releases the grip and discharges it to the discharge unit 92 as a qualified product. If it becomes a defective product in the re-measurement, it is discharged to the discharge unit 92 separately from the qualified products.

[0065] like Fig.11As shown, the control unit 93 includes a CPU (central processing unit) 931, a synchronization unit 932, a measurement and determination unit 933, a storage unit 934, a bending control unit 935, a punching control unit 936, and a correction operation unit 937. The synchronization unit 932 synchronizes the operation of the pre-processing device group 80 with the operation of the wire processing device 91, and synchronizes the intermittent operation of the indexing table 71 in the wire processing device 91 with the processing operation of the first to fifth station devices 1 to 5. The measurement and determination unit 933 determines whether to perform the correction processing at the fifth station position based on the image from the camera 712. In addition, a stop instruction for the bending operation in the first to third station devices 1 to 3 is issued based on the detection signal from the sensor 1S2. The storage unit 934 stores the shape of the hairpin conductor processed from the workpiece, the size range of the hairpin conductor determined to be a qualified product, etc. The bending control unit 935 controls the two-dimensional bending operation of the first to third station devices 1 to 3. The punching control unit 936 controls the three-dimensional bending operation of the fourth station device 4. The correction operation unit 937 controls the correction operation of the correction unit 51 of the fifth station device 5 .

[0066] Next, the detailed structure and specific operation of the first to fifth station devices 1 to 5 are described. As for the structure, the structure of the first to third station devices 1 to 3 is substantially common, so the first station device 1 is described as a representative. In the following description, the direction parallel to the fixture axes CL1 to CL6 is set as the X-axis direction, and the direction orthogonal to the X-axis direction in the horizontal plane is set as the Y-axis direction. In addition, the direction perpendicular to the X-axis direction and the Y-axis direction, that is, the vertical direction, is set as the Z-axis direction.

[0067] like Figure 4 as well as Figure 5 As shown, the first station device 1 includes a processing unit 1M and a measuring unit 1S.

[0068] (Processing Department 1M)

[0069] The processing unit 1M includes an X-axis arm 11, a Y-axis arm 12, a base 13, a support 14, and a biaxial rotation unit 15. The X-axis arm 11 is arranged on the rotation direction (arrow DR direction) side of the indexing table 71 relative to the fixture axis CL1. The X-axis arm 11 is a rail-shaped member extending parallel to the fixture axis CL1 at a position lower than the fixture axis CL1. The Y-axis arm 12 is an arm extending in the Y-axis direction and is supported by the X-axis arm 11 so as to be movable in the X-axis direction (see arrow DR1). The Y-axis arm 12 moves in the X-axis direction by the action of the X-axis drive unit MX.

[0070] The base 13 is supported by the Y-axis arm 12 so as to be movable in the Y-axis direction (see arrow DR2). The base 13 moves in the Y-axis direction by the operation of the Y-axis drive unit MY. In addition, the base 13 can move in the Z-axis direction by the Z-axis drive unit MZ (see arrow DR3). Thus, the base 13 can move in the three-axis directions of the X, Y, and Z directions.

[0071] like Figure 5 As shown, the support 14 and the biaxial rotation unit 15 are arranged on the upper part of the base 13. The support 14 can clamp and hold the cut wire Wc held by the clamp 721 and extending on the clamp axis CL1 in its width direction (Y-axis direction) by the operation of the support driving unit M14.

[0072] The biaxial rotating part 15 has an inner rotating part 151 that is concentric and rotates independently, and an outer rotating part 152 that has a larger diameter than the inner rotating part 151. The inner rotating part 151 has a pair of inner pins 151a that protrude upward and are located at positions offset by 180° when viewed from above. The inner rotating part 151 rotates at an arbitrary rotation angle and rotation direction by the action of the inner ring driving part M151. The inner distance between the pair of inner pins 151a is larger than the width of the cut wire Wc. The outer rotating part 152 has an outer pin 152a that protrudes upward. The outer rotating part 152 rotates at an arbitrary rotation angle and rotation direction by the action of the outer ring driving part M152. The base part 13 is raised and lowered by the action of the Z-axis driving part MZ (see arrow DR3).

[0073] That is, Figure 5 As shown in the two end positions of the lifting and lowering based on the solid line and the single-dot dash line, the support member 14 and the dual-axis rotating part 15 are lifted and lowered in the height direction between an ascending position that interferes with the flat wire (cut wire Wc) held by the clamp 721 in the height direction and a descending position that retreats downward in a non-interfering manner.

[0074] The measuring part 1S is arranged at a position above the horizontal plane SF including the clamp axis CL1. Specifically, the measuring part 1S is configured to include: a support arm 1S1, one end of which is supported by the support column 711 of the dividing part 7 and extends radially; and a sensor 1S2, which is mounted on the front end of the support arm 1S1, which is the other end. The sensor 1S2 is a photoelectric sensor that detects the presence or absence of an object by light, for example. The sensor 1S2 can be independently moved in the directions of the X, Y, and Z axes by the XYZ axis drive part 1S3 of the support arm 1S1 (refer to arrows DR4 to DR6). The sensor 1S2 detects the presence or absence of the cut wire at a position directly below the horizontal plane SF.

[0075] like Fig.12As shown, the operations of the X-axis drive unit MX, the Y-axis drive unit MY, the Z-axis drive unit MZ, the support member drive unit M14, the inner ring drive unit M151, the outer ring drive unit M152, and the XYZ-axis drive unit 1S3 of the measuring unit 1S are controlled by the bending control unit 935 of the control unit 93. In addition, after detecting the cut wire, the sensor 1S2 outputs the detection information to the control unit 93. After grasping the detection information from the sensor 1S2, the measurement determination unit 933 of the control unit 93 stops the outer ring drive unit M152.

[0076] The first station device 1 performs so-called roll bending on the cut wire Wc held by the clamp 721 to form a bent portion Wc1 at a portion of the front end side, and further forms a bent portion BP1 at the root side end of the bent portion Wc1. Figure 6A to Figure 6D This processing stroke is described in detail.

[0077] Fig. 6A It is a plan view showing the first stage of the processing process of the first station device 1. Figure 6B It is a plan view showing the second stage in the processing step of the first station device 1. Figure 6C It is a plan view showing the third stage in the processing process of the first station device 1. Fig.6D It is a plan view showing the fourth stage in the processing process of the first station device 1.

[0078] exist Fig. 6A In the first stage shown, the indexing table 71 rotates while the support member 14 and the biaxial rotating part 15 are retracted to the lower side of the Z axis, and the cut wire Wc moves to the first station position. The pair of inner pins 151a of the biaxial rotating part 15 are located at positions opposite to each other in the Y axis direction, and the outer pins 152a are located closer to the cut wire Wc than the cut wire Wc. Fig. 6A Next, the support member 14 and the biaxial rotating part 15 move and rise to a predetermined position close to the front end of the cut wire Wc. As a result, the cut wire Wc is located between a pair of inner pins 151a. The support member 14 is located on the indexing table 71 side relative to the biaxial rotating part 15 and holds the cut wire Wc.

[0079] exist Figure 6B In the second stage shown in FIG. 1 , the inner rotating part 151 rotates counterclockwise (see arrow DR7a) by the action of the inner ring driving part M151, clamping and holding the cut wire Wc. Then, the outer rotating part 152 rotates clockwise (see arrow DR7b) by the action of the outer ring driving part M152, and the cut wire Wc is moved to the inner pin 151a on the side close to the outer pin 152a by the outer pin 152a. Figure 6B Furthermore, the support member 14 weakens the force of clamping the cut wire Wc to such an extent that it can slide relative to the cut wire Wc, such as Figure 6C As shown, the biaxial rotating part 15 is moved toward the indexing table 71 in parallel with the X-axis and stopped at a predetermined position (see arrow DR7d). Thus, in the cut wire Wc, a curved portion Wc1 is formed within a range AR1 after the biaxial rotating part 15 moves in parallel with the X-axis. The linear portion on the indexing table 71 side that is not the curved portion Wc1 is set as the arm portion Wm1.

[0080] Next, the bending control unit 935 releases the bending based on the outer pin 152a and the gripping based on the inner pin 151a, and lowers the biaxial rotation unit 15, so that the outer pin 152a moves relative to the cut wire Wc. Figure 6C Then, the double-axis rotating part 15 is raised again, as shown in FIG. Fig.6D As shown in FIG. 1 , the inner ring driving unit M151 is operated to rotate the pair of inner pins 151a clockwise to hold the arm Wm1 of the cut wire Wc (see arrow DR7e). Then, the outer ring driving unit M152 is operated to rotate the outer pins 152a counterclockwise (see arrow DR7f) to move the bent portion Wc1 to the inner ring. Fig.6D Bend upward (see arrow DR7g).

[0081] When the curved portion Wc1 is bent to a predetermined position, the sensor 1S2 disposed above detects it. When the sensor 1S2 detects the curved portion Wc1, it sends a detection signal to the control unit 93. The measurement determination unit 933 of the control unit 93 receives the detection signal and stops the outer ring driving unit M152.

[0082] In this way, the cut wire Wc passes through the first station device 1 to become a bent wire Wd, which has a bent portion BP1 formed at the end of the indexing table 71 side of the bent portion Wc1, and a bent portion Wc1 bent at a predetermined angle at the bent portion BP1. According to the instruction of the bending control unit 935, the support member 14 and the two-axis rotating unit 15 retreat downward, and the bent wire Wd can be moved to the second station position. The time from the movement of the cut wire Wc to the first station position to the completion of the downward retreat of the two-axis rotating unit 15 is set to T1.

[0083] After the control unit 93 stops the indexing table 71 for at least the time T1, the indexing table 71 moves to the Figure 3 The bent wire Wd held by the fixture 721 is rotated 60° in the clockwise direction. As a result, the bent wire Wd held by the fixture 721 moves to the second station position. At the second station position, the bent wire Wd is subjected to two-dimensional bending processing by the second station device 2. In the following description, in order to avoid the complication of symbols, the symbols of the components of the second station device 2 are explained with the symbols of the components of the first station device 1.

[0084] like Figure 7As shown, the bending control unit 935 of the control unit 93 moves the lowered biaxial rotating unit 15 in the X-axis direction and the Y-axis direction to a predetermined position away from the fixture axis CL2. The predetermined position is the position that becomes the center of the bending portion Wc1. Similar to the two-dimensional bending process at the first station position, the biaxial rotating unit 15 is raised, the inner ring driving unit M151 is activated to rotate the inner rotating unit 151 clockwise, and the bending portion Wc1 is clamped by a pair of inner pins 151a (see arrow DR8a). Next, the outer ring driving unit M152 is activated to rotate the outer rotating unit 152 counterclockwise (see arrow DR8b), and the front end side of the bending portion Wc1 is bent toward the indexing table 71 side by the outer pin 152a (see arrow DR8c).

[0085] If the front end of the curved portion Wc1 is bent to a predetermined position, the sensor 1S2 disposed above detects it. When the curved portion Wc1 is detected, the sensor 1S2 sends a detection signal to the control unit 93, and the measurement determination unit 933 of the control unit 93 receives the detection signal and stops the outer ring drive unit M152. Thus, the curved wire Wd passes through the second station device 2 and becomes a curved wire We having a bent portion BP2 formed at the center of the curved portion Wc1.

[0086] Next, the biaxial rotating unit 15 retreats downward according to the instruction of the bending control unit 935, and the bent wire We can move to the third station position. The time from when the bent wire Wd moves to the second station position to when it can move to the third station position as the bent wire We is T2.

[0087] After the synchronization unit 932 of the control unit 93 stops the indexing table 71 for at least a longer period of time between the time T1 and the time T2, the indexing table 71 is moved to the right position. Figure 3 The bent wire material We held by the fixture 721 is rotated 60° in the clockwise direction. As a result, the bent wire material We held by the fixture 721 moves to the third station position. At the third station position, the bent wire material We is subjected to two-dimensional bending processing by the third station device 3. In the description of the third station device 3, in order to avoid the complication of symbols, the symbols of the components of the first station device 1 are used to describe the symbols of the components of the third station device 3.

[0088] like Fig. 8AAs shown, the bending control unit 935 moves the lowered biaxial rotating unit 15 in the X-axis direction and the Y-axis direction, the X-axis moves to a position corresponding to the bending portion BP1, and the Y-axis moves to a position twice the distance between the bending portion BP1 and the bending portion BP2. This position corresponds to the end of the front end side of the bending portion Wc1 in the bent wire We. The bending control unit 935 raises the biaxial rotating unit 15 in the same manner as the two-dimensional bending process at the first station position, and rotates the inner rotating unit 151 clockwise through the action of the inner ring driving unit M151 and clamps the bending portion Wc1 with a pair of inner pins 151a (see arrow DR9a). Next, the bending control unit 935 activates the outer ring driving unit M152 and rotates the outer rotating unit 152 counterclockwise (see arrow DR9b). By the outer pin 152a rotating in this way, the straight portion from the bending portion Wc1 to the front end side (hereinafter, the arm portion Wm2) is bent in a manner to become a predetermined bending angle (see arrow DR9c). In this example, the arm portion Wm2 is parallel to the arm portion Wm1.

[0089] When the bending portion BP3 is formed by the rotation of the outer pin 152a and the arm Wm2 is bent to a predetermined position, the sensor 1S2 arranged above detects it. When the sensor 1S2 detects the arm Wm2, it sends a detection signal to the control unit 93, and the measurement determination unit 933 of the control unit 93 receives the detection signal and stops the outer ring drive unit M152.

[0090] In this way, the bent wire We passes through the third station device 3 to become Figure 8B The bent wire Wf is shown. Figure 8B : is a plan view showing the bent wire Wf after processing by the third station device 3. The bent wire Wf is in the shape of a gate having parallel arms Wm1 and Wm2, and a connecting portion Wm3 connecting the bending portion BP1 and the bending portion BP3 at one end of each. After stopping the outer ring driving portion M152, the bending control portion 935 makes the double-axis rotating portion 15 retreat downward. Thus, the bent wire Wf can be moved to the fourth station position. The time from when the bent wire We moves to the third station position to when it can be moved to the fourth station position as the bent wire Wf is set to T3.

[0091] At the fourth station position, under the control of the stamping control unit 936 of the control unit 93, the fourth station device 4 performs three-dimensional stamping processing. FIG. 9A to FIG. 9E The structure and operation of the fourth station device 4 will be described. Fig.9A It is a figure which shows the press working in the 4th station apparatus 4. Fig. 9B 1 is a plan view showing a hairpin conductor Wg obtained by processing in the fourth station device 4 . Fig. 9Cis a diagram showing the deformation of the arm portion Wm1 of the bent wire Wf during processing by the fourth station device 4, which is similar to Fig.9A The C portion shown corresponds to the figure. Fig.9D It is a diagram showing the operation corresponding to the deformation of the arm Wm1. Fig.9E It is a side view of the fourth station device 4.

[0092] like Fig.9E As shown, the fourth station device 4 includes a die table 43, a punching drive unit 44 and an XYZ axis drive unit 45 (see Fig.13 The lower die 41 is detachably mounted on the die table 43. The upper die 42 is detachably connected to the punch driving unit 44.

[0093] The die table 43 and the punch drive unit 44 can be moved in the directions of the XYZ axes by the XYZ axis drive unit 45. The upper die 42 is raised and lowered relative to the lower die 41 by the punch drive unit 44 (see arrow DR10a), and when it is lowered, the upper surface 41a (see arrow DR10b) of the lower die 41 is moved. Fig.9A ) is subjected to three-dimensional stamping processing.

[0094] like Fig.9E As shown, the fourth station device 4 has an auxiliary clamping part 46 disposed between the mold table 43 and the clamp 721 in the X-axis direction. The auxiliary clamping part 46 is raised and lowered by the operation of the Z-axis driving part 461, and slowly holds the arm part Wm1 through a pair of clamping members 463 that approach and separate from each other in the Y-axis direction. The holding and releasing actions of the pair of clamping members 463 relative to the arm part Wm1 are performed by the clamping action part 462.

[0095] The synchronization unit 932 of the control unit 93 moves the indexing table 71 along the axis after the longest time between time T1 and time T3 has passed since the bent wire We was moved to the third station device 3. Figure 3 When the bent wire Wf moves to the fourth station, the die table 43 moves to the predetermined position through the action of the XYZ axis drive unit 45. Fig.9A As shown, the stamping surface of the upper surface 41a of the lower mold 41 becomes a predetermined curved surface recessed downward, so that the lower edge of the outer side of the arm Wm1 and the arm Wm2 abuts against the upper surface 41a of the lower mold 41, and the bent wire Wf shown by the double dotted line is placed in a horizontal posture.

[0096] Before the upper die 42 is lowered to perform the stamping process, the clamping piece 463 of the auxiliary clamping part 46 loosely holds the arm Wm1, and the clamp 721 releases the grip of the arm Wm1. The upper surface 41a of the lower die 41 is a surface that is concave downward. Therefore, when the upper die 42 is lowered to perform the stamping process, as shown in FIG. Fig. 9C As shown, the pair of arm portions Wm1 and Wm2 are arm portions Wg1 and Wg2 that are inclined at an angle θa so as to approach each other in the Y-axis direction and move downward so as to slightly lower their positions and raise their outer edges. Therefore, the clamp 721 is inclined at an angle θa in the same direction around the clamp axis CL4 so as to follow the inclination of the arm portion Wg1 caused by the plastic deformation of the bent wire Wf caused by the punching process.

[0097] After the stamping process is performed, the stamping control unit 936 operates the XYZ axis driving unit 45 to move the die table 43 three-dimensionally so that the center position CL4g of the arm Wg1, which is tilted and shifted inward and downward as described above, coincides with the center position CL4m of the bent wire Wf before the stamping process. Fig.9D As shown, the arm portion Wg1 is inclined at an angle θa, and the center position CL4g is located on the clamp axis CL4.

[0098] Next, the auxiliary clamping part 46 releases the grip of the arm Wg1, and rotates the gripping surface of the clamp 721 by an angle θa around the clamp axis CL4 to grip the arm Wg1. As a result, the hairpin conductor Wg can be moved to the fifth station position. The time from when the bent wire Wf moves to the fourth station position to when it can be moved to the fifth station position as the hairpin conductor Wg is set to T4.

[0099] The bent wire Wf is formed by the three-dimensional pressing process performed by the fourth station device 4. Fig. 9B The hairpin conductor Wg is shown in FIG. The hairpin conductor Wg has a gate shape having a pair of arm portions Wg1 and Wg2 extending in the X-axis direction and a connecting portion Wg3 connecting one end portions of the arm portions Wg1 and Wg2 to each other.

[0100] The synchronization unit 932 of the control unit 93 moves the bent wire Wf to the fourth station device 4 after a maximum time between time T1 and time T4 has passed. Figure 3 The hairpin conductor Wg is rotated 60° clockwise and moves to the fifth station position.

[0101] like Fig.10As shown, the fifth station device 5 has a correction part 51. The correction part 51 is moved in the X-axis direction and the Z-axis direction by the XZ driving part 52. In addition, the correction part 51 has contacts 511 and 512 that can move from a position separated in the Y-axis direction to contact and hold the arm part Wg2. Therefore, when the measurement and determination part 933 of the control part 93 determines that the hairpin conductor Wg needs to be corrected, the correction part 51, which is usually located at the retreat position below the hairpin conductor Wg, rises, and the arm part Wg2 is further bent and deformed in the Y-axis direction by the action of the contacts 511 and 512. The correction action part 937 controls this series of actions based on the determination that the correction process is required by the measurement and determination part 933.

[0102] The correction action at the fifth station position is described in detail. When the hairpin conductor Wg moves to the fifth station position, the camera 712 takes a picture of the hairpin conductor Wg in a bird's-eye view and sends the captured image to the control unit 93. The measurement and judgment unit 933 of the control unit 93 detects the posture state of the pair of arm parts Wg1 and Wg2 of the hairpin conductor Wg based on the image and determines whether it is qualified. In detail, the inner dimension Da at a position close to a predetermined distance from the front end of the pair of arm parts Wg1 and Wg2 to the connecting part Wg3 side is measured based on the image, and the inner dimension Da is compared with the allowable range of the dimension specified by the specification of the hairpin conductor Wg, and it is determined to be qualified if it is within the allowable range.

[0103] If the measurement determination unit 933 determines that the inner dimension Da is within the allowable range and is qualified, the clamp 721 releases the grip and discharges the hairpin conductor Wg to the qualified product receiving portion of the discharge unit 92. If the measurement determination unit 933 determines that the inner dimension Da is less than the allowable range or exceeds the allowable range, the correction operation unit 937 performs correction processing. Fig.10 As shown, the arm portion Wg2 of the hairpin conductor Wg whose arm portion Wg1 is gripped by the jig 721 is forcibly moved and deformed in the Y-axis direction by the contacts 511 and 512 , thereby performing correction processing.

[0104] The part after the correction processing of the hairpin conductor Wg is used as the hairpin conductor Wh. The camera 712 takes a top view image of the hairpin conductor Wh, and the measurement and judgment unit 933 judges whether the hairpin conductor Wh is qualified based on the obtained top view image. If the hairpin conductor Wh is judged to be qualified by the measurement and judgment unit 933, it is discharged to the qualified product receiving unit of the discharge unit 92. If the inner dimension Da is outside the allowable range and it is judged to be unqualified, it is discharged to the unqualified product receiving unit of the discharge unit 92. The time T5 of the correction processing action of the fifth station device 5 is set not to exceed the longest time among the time T1 to time T4.

[0105] As described in detail above, in the wire processing device 91 as a manufacturing device for hairpin conductors, the two-dimensional bending process for the cut wire is divided into a plurality of processes, and the divided plurality of two-dimensional bending processes and three-dimensional punching processes are allocated to a plurality of (n positions: n is a positive integer greater than or equal to 3) workstations arranged at equal angular intervals θp on the circumference. Moreover, a workstation device for performing respective processing is arranged at each workstation, and the indexing table 71 is intermittently rotated at the angular interval θp so that the clamping fixture group 72 is stopped corresponding to each workstation, and the indexing table 71 is provided with a fixture group 72 for holding a predetermined length of the flat wire cut in the pre-processing device group 80 as a workpiece at a predetermined angular interval θp. During the period of the stop of the intermittent rotation of the indexing table 71, the cut wire of a predetermined length is held at a workstation at one of the n positions, and (n-1) processes are simultaneously performed on the workpiece at the workstation at the (n-1) position. Therefore, the wire material processing device 91 can perform the bending processing and the pressing processing on different workpieces at the same time, so the productivity is improved.

[0106] The number of divisions of the two-dimensional bending process is set so that the difference between the longest time and the shortest time among the time T1 to T3 required for the processing of each process after division and the time T4 required for the three-dimensional stamping process is as small as possible. In addition, in the case where the time required for the three-dimensional stamping process is significantly long, the three-dimensional stamping process can also be divided. In addition, in the case where the time required for the two-dimensional bending process is significantly short, multiple bending processes can also be concentrated in one station.

[0107] As described above, one embodiment of the hairpin conductor manufacturing device disclosed herein is a hairpin conductor manufacturing device 91, which includes: a dividing table 71, which intermittently rotates around a rotation axis CL7 extending vertically; a plurality of clamps 721 to 726, which are installed on the dividing table 71 at a predetermined angular spacing θp with the rotation axis CL7 as the center, and can hold a linear cut wire Wc of a predetermined length in a radially extending horizontal posture; and a plurality of station devices 1 to 5, which are arranged around the dividing table 71 at the angular spacing θp with the rotation axis CL7 as the center, and the cut wire Wc held by the clamp 721 is staged into a three-dimensional hairpin conductor Wg, and the plurality of station devices 1 to 5 include bending processing devices 1 to 3 and a punching device 4, and the arrangement order is set along the rotation direction of the dividing table 71.

[0108] Thus, one embodiment of the hairpin conductor manufacturing apparatus 91 can perform a plurality of bending processes and punching processes on a plurality of processed wire materials at the same time, thereby shortening the production cycle time and achieving high productivity.

[0109] In addition, the bending processing devices 1 to 3 may include a plurality of two-dimensional bending processing devices.

[0110] Thereby, the difference between the processing times can be reduced, and the stop time of the intermittent rotation of the indexing table 71 can be shortened, and the productivity of one embodiment of the manufacturing apparatus 91 of the hairpin conductor can be further improved.

[0111] In addition, the hairpin conductor Wg may be formed into a three-dimensional shape by processing by the punching device 4, and the plurality of workstation devices 1 to 5 may include a correction portion 51 after the punching device 4 in the rotation direction, and the correction portion 51 may perform correction processing on the hairpin conductor Wg formed by the punching device 4.

[0112] Thus, one embodiment of the hairpin conductor manufacturing apparatus 91 improves the yield rate and achieves higher productivity.

[0113] In addition, during the stamping process of the stamping device 4, the clamp 721 releases its grip on the arm Wm1 of the cut wire Wc being stamped, and after the stamping process, the stamping device 4 moves the formed hairpin conductor Wg to a position where the clamp 721 can grip one arm Wg1 of a pair of arms of the hairpin conductor Wg.

[0114] Thus, the hairpin conductor Wg manufactured by one embodiment of the hairpin conductor manufacturing apparatus 91 has less deformation and higher precision.

[0115] On the other hand, according to one embodiment of the method for manufacturing a hairpin conductor disclosed herein, bending devices 1 to 3 and a punching device 4 for processing the cut wire Wc into a three-dimensional hairpin conductor Wg in stages at a predetermined angular pitch θp are pre-configured around an intermittently rotating indexing table 71 along the rotation direction of the indexing table 71. A plurality of clamps 721 to 726 mounted on the indexing table 71 at the angular pitch θp are used to hold a predetermined length of a straight cut wire Wc in a radially extending horizontal posture. During the stop period of the intermittent rotation of the indexing table 71, the bending devices 1 to 3 are used to perform two-dimensional bending on the cut wire Wc held by the clamps 721. During the next stop period, the punching device 4 is used to form the cut wire Wc after the bending process into the three-dimensional hairpin conductor Wg.

[0116] Thus, one aspect of the method for manufacturing a hairpin conductor can perform a plurality of bending processes and punching processes on a plurality of processed wire materials at the same time, and thus can achieve high productivity.

[0117] Alternatively, the two-dimensional bending process may be divided into a plurality of processing steps, and a plurality of bending devices 1 to 3 corresponding to the divided processing steps may be arranged at the predetermined angular pitch θp, so that the two-dimensional bending process is performed by the plurality of bending devices 1 to 3 .

[0118] Thereby, the difference between the processing times can be reduced, and the stop time of the intermittent rotation of the indexing table 71 can be shortened, and the productivity of one embodiment of the method for manufacturing the hairpin conductor can be further improved.

[0119] Furthermore, after the press working is performed by the press device 4 , a correction process may be performed on the hairpin conductor Wg formed by the press working.

[0120] Thus, one aspect of the method for manufacturing a hairpin conductor can improve the yield rate and achieve higher productivity.

[0121] In addition, during the punching process of the punching device 4, the clamp 721 releases the clamp 721 from holding the punched cut wire Wc, and after the punching process, the formed hairpin conductor Wg is moved to a position where the clamp 721 can hold one arm Wg1 of the pair of arms of the hairpin conductor Wg.

[0122] Therefore, the hairpin conductor Wg manufactured by one embodiment of the method for manufacturing a hairpin conductor has less deformation and higher precision.

[0123] The embodiments of the present disclosure are not limited to the above-described configurations, and modifications are possible without departing from the spirit of the present disclosure.

[0124] The disclosure of the present application is related to the subject matter described in Japanese Patent Application No. 2022-092381 filed on June 7, 2022, and all the disclosed contents are incorporated herein by reference.

Claims

1. A device for manufacturing a hairpin conductor, characterized in that: have: An indexing table that intermittently rotates about a rotation axis extending vertically; A plurality of clamps, which are mounted on the indexing table at predetermined angular intervals with the rotation axis as the center, and can hold a linear cut wire of a predetermined length in a horizontal posture extending radially; as well as A plurality of station devices are arranged around the indexing table at the angular intervals with the rotation axis as the center, and the cut wire held by the clamp is processed in stages to form a hairpin conductor. The plurality of workstation devices include a bending device and a punching device, and are arranged in a sequence along the rotation direction of the indexing table.

2. The manufacturing device of the hairpin conductor according to claim 1, characterized in that: The bending processing device includes a plurality of two-dimensional bending processing devices.

3. The manufacturing device of the hairpin conductor according to claim 1 or 2, characterized in that: The clamp holds the cut wire material so as to be rotatable around a central axis of the cut wire material.

4. The manufacturing device of the hairpin conductor according to claim 1 or 2, characterized in that: The hairpin conductor is formed into a three-dimensional shape by processing with the punching device, The plurality of station devices include a correction section that is arranged behind the punch device in the rotation direction and performs correction processing on the hairpin conductor formed by the punch device.

5. The manufacturing device of the hairpin conductor according to claim 1 or 2, characterized in that: During the punching process of the punching device, the clamp releases the clamping of the punched cut wire material, and after the punching process, the punching device moves the formed hairpin conductor to a position where the clamp can clamp one of the pair of arms of the hairpin conductor.

6. A method for manufacturing a hairpin conductor, characterized in that: A bending device and a punching device for processing the cut wire into a three-dimensional hairpin conductor in stages are pre-arranged around an intermittently rotating indexing table at predetermined angular intervals along the rotation direction of the indexing table. A plurality of clamps mounted on the indexing table at the angular intervals are used to hold the linear cut wire of a predetermined length in a radially extending horizontal posture. During the period of the intermittent rotation of the indexing table being stopped, the cut wire material held by the clamp is subjected to two-dimensional bending by the bending device. During the next stop period, the cut wire material after the bending process is formed into the hairpin conductor having a three-dimensional shape by the press device.

7. The method for manufacturing a hairpin conductor according to claim 6, characterized in that: The two-dimensional bending process is divided into a plurality of processing steps, and a plurality of bending processing devices corresponding to the divided processing steps are arranged at the predetermined angular intervals. The two-dimensional bending process is performed by the plurality of bending process devices.

8. The method for manufacturing a hairpin conductor according to claim 6 or 7, characterized in that: After the punching process is performed by the punching device, the hairpin conductor formed by the punching process is subjected to a trimming process.

9. The method for manufacturing a hairpin conductor according to claim 6 or 7, characterized in that: In the stamping process of the stamping device, it includes: (a): a step of positioning the cut wire; (b): After the step (a), a step of releasing the grip of the clamp; (c): After the process of (b), a stamping process is performed; (d): after the step (c), moving the formed hairpin conductor to a position where the fixture can hold one of the pair of arms of the hairpin conductor; (e): After the step (d), the clamp holds one of the arms.

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