Conductor molding device and conductor molding method

Abstract

A conductor forming apparatus includes: an interval maintaining jig configured to maintain an interval in an arrangement direction of linear portions in a conductor wire group; and a jig moving means for connecting the interval maintaining jigs and moving the interval maintaining jigs with respect to the conductor wire group. The interval maintaining jig is provided with a base which extends along the arrangement direction of the linear parts; and a plurality of protruding parts which are arranged in a row in the length direction of the base and can be inserted between the adjacent linear parts in the arrangement direction. The jig moving means includes: a first movable portion that moves the interval maintaining jig in a direction that advances and retreats in the arrangement direction of the linear portions with respect to a portion where the interval of the linear portions in the arrangement direction of the linear portions in the conductor wire group is easy to change, and a second movable portion that moves the interval maintaining jig in a direction that advances and retreats in the arrangement direction of the linear portions; and a second movable part for moving the interval maintaining jig, which is arranged at a position where the interval between the linear parts is easy to change, in the direction in which the protruding parts are inserted into and separated from the linear parts.

Description

Technical Field

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

[0002] In the past, it is known that a conductor is formed by folding a conductor wire group composed of multiple conductor wires in the thickness direction, wherein the conductor has multiple straight portions arranged at intervals and multiple oblique portions arranged at both ends of the straight portions, and the straight portions are doubly stacked (for example, refer to patent document 1).

[0003] [Prior Technical Literature]

[0004] (Patent Document)

[0005] Patent Document 1: Japanese Patent Application Publication No. 2021-058076 Summary of the invention

[0006] [Problems to be solved by the invention]

[0007] Since the conductor wire group is formed by folding back in the thickness direction, the arrangement pitch of the straight line portion may be disturbed due to the springback of the conductor wire group after folding back. If the arrangement pitch of the straight line portion is disturbed, the straight line portion may interfere with the jig used during forming, or when the straight line portion is inserted into the slot of the stator core, the straight line portion may interfere with the wall surface of the slot, etc. If such interference occurs, unnecessary contact pressure will be applied to the conductor wire, and there is a possibility that the conductor wire will be deformed or the insulating film covering the surface of the conductor wire will be damaged.

[0008] An object of the present invention is to provide a conductor shaping device and a conductor shaping method, which can perform folding shaping on a conductor wire group without causing a disorder in the arrangement pitch of straight line portions.

[0009] [Technical means to solve the problem]

[0010] (1) A conductor forming device (e.g., conductor forming device 400 described below) that forms a conductor (e.g., conductor 100 described below) by folding a conductor wire group (e.g., conductor wire group 10 described below) composed of a plurality of conductor wires (e.g., conductor wire 1 described below) multiple times in a thickness direction, wherein the conductor has a plurality of straight portions (e.g., straight portions 101 described below) arranged at intervals and oblique portions (e.g., oblique portions 102a described below) arranged at both ends of the straight portions, and The linear portion is double-stacked, and the conductor forming device is characterized in that it comprises: a spacing maintaining jig (for example, a spacing maintaining jig 420 described later) for maintaining the spacing of the linear portion in the arrangement direction (for example, the X direction described later) of the conductor wire group; and a jig moving means (for example, a jig moving device 430 described later) for connecting the spacing maintaining jig and moving it relative to the conductor wire group; the spacing maintaining jig has: a base (for example, a base 4211, 4221 described later) , 4231), extending along the arrangement direction of the aforementioned straight portions; and, a plurality of protrusions (for example, the protrusions 4212, 4222, 4232 described later) are arranged in a row along the length direction of the aforementioned base and can be respectively inserted between the aforementioned straight portions adjacent in the arrangement direction; the aforementioned jig moving means comprises: a first movable portion (for example, a portion composed of the slider 432, the spring 4322, and the first cylinder 435 described later), which enables the aforementioned interval maintaining jig to move in the direction of advance and retreat along the arrangement direction of the aforementioned straight portions relative to a portion in the arrangement direction of the aforementioned straight portions in the aforementioned conductor wire group where the aforementioned interval of the aforementioned straight portions is easily changed; and, a second movable portion (for example, a portion composed of the lifting operation rod 436, the spring 4361, the L-shaped piece 433, and the second cylinder 437 described later), which enables the aforementioned interval maintaining jig arranged at the portion where the aforementioned interval of the aforementioned straight portions is easily changed to move in the direction of insertion and separation of the aforementioned protrusion relative to the aforementioned straight portions.

[0011] According to the above (1), the spacing maintaining jig can prevent the arrangement pitch of the straight line portions from being disturbed, so that a conductor having straight straight line portions and high precision can be formed.

[0012] (2) The conductor forming device according to the above (1) is characterized in that the aforementioned spacing maintaining jig is provided with at least two of a first spacing maintaining jig (for example, the first spacing maintaining jig 421 described later) and a second spacing maintaining jig (for example, the second spacing maintaining jig 422 described later), the first spacing maintaining jig is configured to be able to insert the aforementioned protrusion from one side surface of the aforementioned straight portion in the aforementioned conductor wire group, and the second spacing maintaining jig is configured to be able to insert the aforementioned protrusion from the other side surface.

[0013] According to the above (2), the arrangement pitch of the straight line portions can be effectively prevented from being disturbed from both sides of the conductor wire group by at least two spacing maintaining jigs.

[0014] (3) The conductor forming device according to (2) above is characterized in that the first spacing maintaining jig and the second spacing maintaining jig are arranged along the length direction of the straight portion at a spacing corresponding to the spacing between one end and the other end in the extension direction of the straight portion (for example, the Y direction described later).

[0015] According to the above (3), a region for moving the conductor wire group and holding the straight portion while maintaining the interval between the straight portion can be ensured between the first interval maintaining jig and the second interval maintaining jig.

[0016] (4) A conductor forming device according to any one of (1) to (3) above, characterized in that the first interval maintaining jig and the second interval maintaining jig are arranged to be able to rotate around the folding line in conjunction with the folding action of the conductor wire group.

[0017] According to the above (4), the first interval maintaining jig and the second interval maintaining jig can prevent the intervals of the straight line portions from being disturbed during the folding operation of the conductor wire group.

[0018] (5) The conductor forming device according to the above (4) is characterized in that the above-mentioned spacing maintaining jig comprises: a third spacing maintaining jig, which is arranged on the side of the above-mentioned fixed side holding device along the arrangement direction of the above-mentioned straight line portion, and on the opposite side of the above-mentioned straight line portion of the above-mentioned conductor wire group from the above-mentioned first spacing maintaining jig and the above-mentioned second spacing maintaining jig; the third spacing maintaining jig is operated by the above-mentioned jig moving means in the following manner: with respect to the above-mentioned spacing of the above-mentioned straight line portion in the above-mentioned conductor wire group after folding, the above-mentioned spacing is temporarily maintained during the period from the start of conveyance of a prescribed distance along the length direction of the above-mentioned straight line portion for the next folding action.

[0019] (6) A conductor forming method, wherein a conductor wire group (e.g., conductor wire group 10 described below) composed of a plurality of conductor wires (e.g., conductor wire 1 described below) is folded back multiple times in a thickness direction (e.g., Z direction described below) to form a conductor (e.g., conductor 100 described below), wherein the conductor has a plurality of straight portions (e.g., straight portion 101 described below) arranged at intervals, and a plurality of oblique portions (e.g., oblique portions 102a described below) arranged at both ends of the straight portions, and the straight portions are doubly stacked, the conductor forming method being characterized in that: A jig 420 is provided for folding the conductor wire group while maintaining the interval of the portion where the interval of the straight line portions in the arrangement direction of the straight line portions in the conductor wire group is easily changed, wherein the interval maintaining jig comprises: a base (for example, a base 4211, 4221, 4231 described later) extending along the arrangement direction of the straight line portions (for example, the X direction described later); and a plurality of protrusions (for example, protrusions 4212, 4222, 4232 described later) protrudingly arranged in a row along the length direction of the base and capable of being respectively inserted between the adjacent straight line portions in the arrangement direction.

[0020] According to the above (6), the spacing maintaining jig can prevent the arrangement pitch of the straight line portions from being disturbed, so that a conductor with neat straight line portions can be formed with high precision.

[0021] (7) The conductor forming method according to the above (6) is characterized in that the above-mentioned interval maintaining jig is used to maintain the above-mentioned interval from both sides of the above-mentioned conductor wire group by at least two of the above-mentioned interval maintaining jigs, namely a first interval maintaining jig (for example, the first interval maintaining jig 421 described later) and a second interval maintaining jig (for example, the second interval maintaining jig 422 described later), wherein the first interval maintaining jig is inserted into the above-mentioned protrusion from one side of the above-mentioned straight portion in the above-mentioned conductor wire group, and the second interval maintaining jig is inserted into the above-mentioned protrusion from the other side.

[0022] According to the above (7), the arrangement pitch of the straight line portions can be effectively prevented from being disturbed from both sides of the conductor wire group by using at least two spacing maintaining jigs.

[0023] (8) The conductor forming method according to (7) above is characterized in that the interval at one end and the other end of the straight portion in the extension direction (for example, the Y direction described later) is maintained by the first interval maintaining jig and the second interval maintaining jig.

[0024] According to the above (8), a region for moving the conductor wire group and holding the straight portion while maintaining the interval between the straight portion can be ensured between the first interval maintaining jig and the second interval maintaining jig.

[0025] (9) The conductor forming method according to (7) or (8) above is characterized in that, with respect to the aforementioned interval of the aforementioned straight portion in the aforementioned conductor wire group after folding back, the aforementioned interval is temporarily maintained by a third interval maintaining jig (for example, the third interval maintaining jig 423 described later) during the period from the start of transportation of a predetermined distance along the length direction of the aforementioned straight portion for the next folding action.

[0026] (Effects of the Invention)

[0027] According to the present invention, it is possible to provide a conductor shaping device and a conductor shaping method that can perform folding shaping on a conductor wire group without causing a disorder in the arrangement pitch of the straight line portions. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a front view showing an example of a conductor in this embodiment.

[0029] Figure 2 is a plan view showing a stator equipped with conductors.

[0030] Figure 3 The figure shows a method of forming a conductor line.

[0031] Figure 4 It is along Figure 3 Cross-section view of line AA in .

[0032] Figure 5 It is a front view showing a state where conductor lines are overlapped to form a conductor line group.

[0033] Figure 6 This is a schematic plan view showing an example of a conductor forming device for carrying out the conductor forming method according to the present embodiment.

[0034] Figure 7 It is a perspective view showing the structure of the holding device.

[0035] Figure 8 It is a three-dimensional diagram showing the structure of the interval maintaining jig.

[0036] Fig. 9 The first and second interval maintaining jigs are shown in plan view.

[0037] Fig.10 The first interval maintaining jig is shown in a side view.

[0038] Fig.11 It is an enlarged view showing a part of the jig moving device.

[0039] Fig.12 This is a diagram showing the conductor housing portion as viewed from a direction along the return line.

[0040] Fig.13 This is a longitudinal sectional view of the conductor housing portion as viewed from a direction perpendicular to the return line.

[0041] Fig.14 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0042] Fig.15 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0043] Fig.16 When viewed from the direction of arrangement of the straight line portion of the conductor wire group Fig.15 Diagram of the conductor wire group shown.

[0044] Fig.17 This is a diagram showing a state where the protrusion of the gap maintaining jig is inserted between the straight line portions of the conductor wire group.

[0045] Fig.18 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0046] Fig.19 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0047] Fig. 20 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0048] Fig.21 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0049] Fig. 22 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0050] Fig.23 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0051] Fig.24 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0052] Fig.25 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0053] Fig.26 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0054] Fig. 27 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0055] Fig.28 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0056] Fig.29 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0057] Fig.30 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0058] Fig.31 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0059] Fig.32 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0060] Fig.33 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0061] Fig.34 It is a diagram for explaining a conductor shaping method using a conductor shaping device.

[0062] Fig.35 This is a diagram of a conductor after being formed and attached with a coil end holding jig, as viewed from the direction in which the straight portions are arranged.

[0063] Fig.36 The figure shows the arrangement relationship between the conductor and the conductor receiving portion to which the coil end portion holding jig is attached. DETAILED DESCRIPTION

[0064] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Figure 1 An example of a conductor 100 formed by the conductor forming device and the conductor forming method of this embodiment is shown. The conductor 100 is formed by bending a plurality of conductor wires 1. The conductor 100 of this embodiment is formed in one direction ( Figure 1 A strip-shaped coil that is long and thin in the X direction.

[0065] Here, the directions shown in the figure are defined as follows. The X direction and the X1-X2 direction are the length directions of the conductor 100 formed into a strip shape. This direction corresponds to the width direction of the conductor line 1 constituting the conductor 100, and corresponds to the arrangement direction of the straight line portion 101 formed in the conductor 100. The Y direction and the Y1-Y2 direction are the width directions of the conductor 100. This direction corresponds to the length direction of the conductor line 1, and corresponds to the extension direction of the straight line portion 101 formed in the conductor 100. The Z direction and the Z1-Z2 direction are the thickness directions of the conductor 100. This direction corresponds to the thickness direction of the conductor line 1. In the present embodiment, the Z direction and the Z1-Z2 direction are the directions along gravity. The Z1 direction indicates the top, and the Z2 direction indicates the bottom.

[0066] The conductor 100 has: a plurality of straight portions 101 arranged in parallel at a fixed interval in the longitudinal direction of the conductor 100; and a plurality of coil end portions 102 arranged at both ends of the extending direction of each straight portion 101. The straight portion 101 extends along the width direction of the conductor 100. The coil end portion 102 connects one end and the other end of two straight portions 101, 101 arranged at a distance in the longitudinal direction of the conductor 100 alternately in a mountain shape along the longitudinal direction of the conductor 100.

[0067] The coil end portion 102 is formed into a mountain shape, and the mountain shape has an oblique portion 102a extending obliquely from the boundary portion 103 with the straight portion 101, and a vertex 102b formed by connecting the front ends of the oblique portions 102a, 102a connected to the two straight portions 101, 101. In the conductor 100, the two legs 12, 12 of the outer conductor wire 1 of the double structure of the conductor wire 1, 1 having the inner side and the outer side are respectively formed. Figure 3 and Figure 5 ) are arranged every 7 in the length direction of the conductor 100, and the straight line portions 101, 101 formed by the two legs 12, 12 of the inner conductor line 1 are arranged every 5 in the length direction of the conductor 100. That is, between the two legs 12, 12 of the outer conductor line 1, six legs 12 of other conductor lines 1 are arranged, and between the two legs 12, 12 of the inner conductor line 1, four legs 12 of other conductor lines 1 are arranged.

[0068] Conductor 100, such as Figure 2 As shown, the stator core 201 is assembled to form a stator 200 of a rotating electrical machine. The stator core 201 has a direction in the axial direction (relative to Figure 2 The conductor 100 is provided with a plurality of teeth 203 protruding radially from the axial hole 202 penetrating in the vertical direction of the paper surface. A plurality of slots 204 opening toward the axial hole 202 are formed between the teeth 203, 203 adjacent in the circumferential direction. The conductor 100 is assembled to surround the stator core 201 for several times by inserting the straight portions 101 into the slots 204 one by one. The coil end portions 102 of the conductor 100 protrude in an annular shape from the two axial end surfaces 201a of the stator core 201.

[0069] The conductor line 1 constituting the conductor 100 is a continuous line that is continuous without interruption in the length direction of the conductor 100. The straight conductor line 1, such as Figure 3 As shown, the conductor wire 1 is bent and shaped at the substantially middle portion in the longitudinal direction by a U-shaped portion forming jig 300. Thus, the conductor wire 1 is formed into a U-shaped shape having a single U-shaped portion 11 and a pair of linear leg portions 12, 12.

[0070] Conductor line 1, such as Figure 4 As shown, the conductor wire 1 is composed of a plurality of flat wires 1a. The flat wire 1a is a metal wire such as a copper wire having a substantially rectangular cross section. The surface of the flat wire 1a is covered with a resin insulating film not shown. The conductor wire 1 of this embodiment is a dividing line in which two flat wires 1a, 1a are closely connected and arranged in parallel in the width direction of the conductor wire 1. The conductor wire 1 is bent in the parallel direction of the flat wires 1a, 1a, that is, in the width direction of the conductor wire 1 by the U-shaped portion forming jig 300.

[0071] The conductor wires 1 are formed into a U shape, such as Figure 5 As shown, the U-shaped portions 11 are arranged in a doubly configuration with two each on the inside and outside while being aligned on the same side. Three combinations of two conductor wires 1, 1 each arranged in a similar doubly configuration are overlapped and staggered in the width direction in a manner that 12 legs 12 are arranged in parallel at fixed intervals. In the present embodiment, a conductor wire group 10 consisting of 12 U-shaped conductor wires 1 is formed by arranging two six U-shaped conductor wires 1 formed in the same manner. The conductor wire group 10 having 12 U-shaped conductor wires 1 arranged in parallel has 24 legs 12. The conductor 100 is formed by using the conductor wire group 10. Figure 6 The conductor forming device 400 is shown.

[0072] Figure 6 The schematic structure of the conductor shaping device 400 is shown in a top view. The conductor shaping device 400 includes a holding device 410, a gap maintaining jig 420, a jig moving device 430, a conductor accommodating portion 440, a coil end holding jig supply device 450, and a control device 460 that controls the operation of the conductor shaping device 400 in an overall manner.

[0073] In addition, the X direction in the conductor shaping device 400, i.e., the X1-X2 direction, is the arrangement direction of the legs 12 of the conductor wire group 10. The Y direction in the conductor shaping device 400, i.e., the Y1-Y2 direction, is the direction along the conveying direction of the shaped conductor wire group 10. The Y1 direction indicates the downstream direction of the conveyed conductor wire group 10, and the Y2 direction indicates the upstream direction of the conveyed conductor wire group 10. The Z direction in the conductor shaping device 400 is relative to the Figure 6 In the conductor shaping device 400, a virtual return line J for performing return shaping on the conductor wire group 10 is fixedly set along the X1-X2 direction.

[0074] The conductor shaping device 400 includes a conveying device for conveying the conductor wire group 10 to the holding device 410, and other holding devices for holding the conductor wire group 10 on the upstream side of the holding device 410, but the illustration of these devices is omitted. In order to simplify the illustration of the conductor wire group 10, a plurality of U-shaped portions 11 arranged in parallel in the conductor wire group 10 disposed in the conductor shaping device 400 are shown by a trapezoidal dot-dash line.

[0075] The holding device 410 is a member for holding the conductor wire group 10 in order to shape the conductor wire group 10 and folding the conductor wire group 10. The holding device 410 includes a pair of holding devices, namely, a movable side holding device 411 and a fixed side holding device 412. In the initial state of the conductor shaping device 400, the movable side holding device 411 and the fixed side holding device 412 are arranged in parallel with a predetermined separation distance W1 in the Y1-Y2 direction. The movable side holding device 411 is arranged on the Y1 direction side of the fixed side holding device 412.

[0076] The movable side holding device 411 is configured to be able to be rotated by a rotating device (not shown) to Figure 6 The conductor wire group 10 shown has the return line J as the rotation center, and rotates in a manner overlapping with the fixed side holding device 412, and can be moved in the X2 direction along the extension direction of the return line J and the Y2 direction intersecting the extension direction of the return line J by driving the oblique mechanism part not shown. The fixed side holding device 412 is configured to remain stationary during the return action of the movable side holding device 411. The movable side holding device 411 holding the leg 12 of the conductor wire group 10 moves in the X2 and Y2 directions relative to the fixed side holding device 412, thereby, the leg 12 of the conductor wire group 10 between the movable side holding device 411 and the fixed side holding device 412 is bent in a manner inclined relative to the length direction of the leg 12. The oblique process is thus performed.

[0077] The folding line J is set at the middle position between the movable side holding device 411 and the fixed side holding device 412. The middle position is a position corresponding to the position of the vertex 102b of the coil end portion 102 after the conductor wire group 10 is folded back. The folding line J is arranged in a direction perpendicular to the length direction of the leg portion 12 of the conductor wire group 10, and is arranged parallel to the length direction of the movable side holding device 411 and the fixed side holding device 412. The movable side holding device 411 holding the leg portion 12 of the conductor wire group 10 rotates around the folding line J as an axis, thereby, the leg portion 12 of the conductor wire group 10 is folded back at the center between the movable side holding device 411 and the fixed side holding device 412. The folding process is thus performed. By folding back the oblique leg portion 12, a mountain-shaped coil end portion 102 is formed.

[0078] like Figure 6 As shown, the width W2 of the fixed side holding device 412 along the Y1-Y2 direction is equal to the length L of the straight portion 101 of the formed conductor 100 in the extending direction (refer to Figure 1 ). The width W3 of the movable-side holding device 411 along the Y1 -Y2 direction is smaller than the width W2 of the fixed-side holding device 412 .

[0079] Since the structures for holding and releasing the conductor wire group 10 in the movable side holding device 411 and the fixed side holding device 412 are the same, Figure 7 , taking the movable side holding device 411 as an example, the structure of the holding device 410 is described. Figure 7 A part of the gripping portion of the movable-side gripping device 411 is shown.

[0080] The movable-side holding device 411 includes: a fixed block 4111 formed in a slender rectangular parallelepiped shape spanning the 24 legs 12 arranged in the conductor wire group 10; and a plurality of movable blocks 4112 movably provided on the fixed block 4111.

[0081] The fixed block 4111 is provided with 24 grooves 4113 for receiving the 24 legs 12 of the conductor wire group 10. The movable blocks 4112 are movably received in the grooves 4113 of the fixed block 4111 with gaps G for fitting the legs 12. All the movable blocks 4112 can be driven by a driving mechanism (not shown) controlled by the control device 460, such as Figure 7 As shown by the blank arrow in , they move simultaneously in the direction of clamping the leg portion 12. Thus, the movable side holding device 411 clamps the leg portion 12 of the conductor wire group 10 fitted in each gap G between the fixed block 4111 and the movable block 4112 for holding.

[0082] The movable side holding device 411 holds the leg 12 in a direction that is configured Figure 4 The two flat wires 1a, 1a of the conductor wire 1 are arranged in parallel. Therefore, the movable side holding device 411 and the fixed side holding device 412 hold the leg 12 of the conductor wire 1 in the width direction of the conductor wire 1. In the initial state of the conductor shaping device 400, the position of the gap G of the movable side holding device 411 and the gap G of the fixed side holding device 412 are arranged at the same position along the Y direction. Therefore, the gaps G of the movable side holding device 411 and the fixed side holding device 412 are spaced apart by a predetermined interval (width W) in the extension direction of the leg 12 to hold the same leg 12 of the conductor wire 1.

[0083] The interval maintaining jig 420 is a jig for maintaining the interval of the leg portion 12 and the straight portion 101 in the arrangement direction at a fixed interval so as to prevent the leg portion 12 of the conductor wire group 10 and the straight portion 101 after the formation from being disordered when the conductor wire group 10 is folded back and formed. The conductor forming device 400 is provided with three interval maintaining jigs 420, namely, a first interval maintaining jig 421, a second interval maintaining jig 422 and a third interval maintaining jig 423. The first interval maintaining jig 421 and the second interval maintaining jig 422 are both arranged in the conductor receiving portion 440. The third interval maintaining jig 423 is arranged on the side opposite to the side where the first interval maintaining jig 421 and the second interval maintaining jig 422 are arranged, across the holding device 410.

[0084] The first interval maintaining jig 421, the second interval maintaining jig 422 and the third interval maintaining jig 423 are substantially of the same structure, and therefore refer to Figure 8 The specific structure of each interval maintaining jig 421, 422, 423 is described.

[0085] The interval maintaining jig 420 (the first interval maintaining jig 421, the second interval maintaining jig 422, and the third interval maintaining jig 423) comprises a base 4211, 4221, 4231, and a plurality of block-shaped protrusions 4212, 4222, 4232 protruding from one surface of the base 4211, 4221, 4231. The base 4211, 4221, 4231 is a narrow plate-like body extending elongatedly along the X direction. The length direction of the base 4211, 4221, 4231 is along Figure 6 The conductor shaping device 400 shown in the figure is arranged in the direction of the legs 12 perpendicular to the length direction of the legs 12 of the conductor wire group 10 in the X1-X2 direction. A plurality of protrusions 4212, 4222, 4232 are arranged in a row at regular intervals on one surface of the base 4211, 4221, 4231 along the length direction of the base 4211, 4221, 4231.

[0086] The width W11 of each protrusion 4212, 4222, 4232 along the length direction of the base 4211, 4221, 4231 is equal to the interval between the adjacent legs 12, 12 along the arrangement direction of the legs 12 of the conductor wire group 10. The interval W12 between the adjacent protrusions 4212, 4222, 4232 along the length direction of the base 4211, 4221, 4231 is equal to the width of the legs 12. Therefore, the first interval maintaining jig 421, the second interval maintaining jig 422, and the third interval maintaining jig 423 can respectively insert the protrusions 4212, 4222, 4232 between the legs 12, 12 of the conductor wire group 10. When the protrusions 4212, 4222, 4232 are inserted between the legs 12, 12, the legs 12 of the conductor wire group 10 are sandwiched between the adjacent protrusions 4212, 4222, 4232. Thus, the legs 12 of the conductor wire group 10 are prevented from being displaced in the arrangement direction and the intervals are maintained.

[0087] exist Figure 6 In the initial state of the conductor forming device 400 shown, the protrusions 4212, 4222, 4232 in the first interval maintaining jig 421, the second interval maintaining jig 422, and the third interval maintaining jig 423 protrude from the bases 4211, 4221, 4231 in the first interval maintaining jig 421 in the upward direction ( Figure 6 The second interval maintaining jig 422 and the third interval maintaining jig 423 are in the downward direction ( Figure 6 The direction that goes toward the depth in the direction perpendicular to the paper surface).

[0088] The jig moving device 430 constitutes a jig moving means for the gap maintaining jig 420 in the conductor forming device 400. The jig moving device 430 connects the base ends of the first gap maintaining jig 421, the second gap maintaining jig 422, and the third gap maintaining jig 423 individually. Fig. 9 The first interval maintaining jig 421 and the second interval maintaining jig 422 and two jig moving devices 430 connected to them individually are shown. The jig moving device 430 moves the first interval maintaining jig 421, the second interval maintaining jig 422 and the third interval maintaining jig 423 forward and backward along the X1-X2 direction, and moves the protrusion 4212 to the conductor wire group 10 in a manner of being inserted into and removed from the leg portions 12, 12, respectively.

[0089] Since the jig moving devices 430 for connecting the first interval maintaining jig 421, the second interval maintaining jig 422, and the third interval maintaining jig 423 are of the same structure, Fig.10 and Fig.11, the structure of the jig moving device 430 connected to the first interval maintaining jig 421 will be described.

[0090] like Fig.10 As shown, the jig moving device 430 has a slider 432 on a device base 431 extending slenderly in the X1-X2 direction. The slider 432 is composed of a rod-shaped body slender in the length direction of the device base 431. The interval maintaining jig 420 is connected to the front end 432a of the slider 432. On both side surfaces of the slider 432, guide grooves 4321 along the length direction of the slider 432 are respectively recessed. A spring 4322 is connected to the rear end 432b of the slider 432. The spring 4322 is composed of a tension spring, which is installed on the fixed portion 430a provided on the device base 431 or the conductor forming device 400, and applies force to the slider 432 in the direction of pulling toward the fixed portion 430a.

[0091] like Fig.10 and Fig.11 As shown, L-shaped pieces 433 are respectively arranged on both side surfaces of the front end side and the rear end side of the slider 432. The L-shaped piece 433 is mounted on a support plate 434 vertically arranged on the device base 431 in a manner that it can rotate by a rotation axis 4331 in the center of the L-shaped piece 433. One end of the L-shaped piece 433 extends toward the interval maintaining jig 420 side relative to the rotation axis 4331. A guide roller 4332 is provided at one end of the L-shaped piece 433. The guide roller 4322 is engaged with the guide groove 4321 of the slider 432, and supports the slider 432 so that it can slide on the device base 431.

[0092] A protrusion 4323 protruding downward is provided in the middle of the length direction of the slider 432. The lower end of the protrusion 4323 is arranged to protrude downward of the device base 431 via the side of the device base 431.

[0093] On the device base 431, a first air cylinder 435 is arranged along the length direction of the device base 431. The first air cylinder 435 is arranged below the device base 431 on the opposite side of the protruding portion 4323 and the interval maintaining jig 420. The movable end 4351 of the first air cylinder 435 is arranged toward the front to which the interval maintaining jig 420 is connected, and faces the protruding portion 4323. The first air cylinder 435 is driven and controlled by the control device 460, and the protruding portion 4323 is pressed by protruding the movable end 4351. As a result, the slider 432 is guided by the guide roller 4332 and moves forward, and the interval maintaining jig 420 moves forward along the X direction.

[0094] A stopper 4311 is provided at the front end of the device base 431. The advancing protrusion 4323 abuts against the stopper 4311 to limit the advancing distance FD of the interval maintaining jig 420. The advancing distance FD is set to different distances according to the first interval maintaining jig 421, the second interval maintaining jig 422, and the third interval maintaining jig 423. When the movable end 4351 of the first cylinder 435 retreats, the slider 432 retreats due to the applied force of the spring 4322 and returns to the initial position.

[0095] Below the slider 432 on the device base 431, a lifting operation rod 436 extending along the length direction of the device base 431 is arranged. The other end of the L-shaped piece 433 extends downward from the rotation shaft 4331 and is rotatably connected to the lifting operation rod 436 via the connecting portion 4333. Thus, the lifting operation rod 436 is supported below the slider 432 in parallel with the slider 432 via the L-shaped piece 433.

[0096] A spring 4361 is provided at the rear end of the lifting operation rod 436. The spring 4361 is disposed between the lifting operation rod 436 and the fixing portion 430a, and applies a force to the lifting operation rod 436 in a direction to move forward toward the gap maintaining jig 420. Furthermore, a protrusion 4362 protruding downward is provided at the rear end of the lifting operation rod 436.

[0097] A second cylinder 437 is arranged below the device base 431, further to the rear than the first cylinder 435. The movable end 4371 of the second cylinder 437 is arranged to face the rear, facing the protrusion 4362. The second cylinder 437 is driven and controlled by the control device 460, and the protrusion 4362 is pressed by protruding the movable end 4371. As a result, the lifting operation rod 436 moves backward against the force applied by the spring 4361. When the lifting operation rod 436 moves backward, the L-shaped piece 433 rotates around the rotating shaft 4331 so as to move the guide roller 4332 downward. When the L-shaped piece 433 rotates, the slider 432 engaged with the guide roller 4332 moves downward, and the interval maintaining jig 420 connected to the slider 432 moves downward. When the movable end 4371 of the second air cylinder 437 is retracted, the lifting operation rod 436 is advanced by the urging force of the spring 4361. As a result, the slider 432 moves upward via the guide roller 4332, and the interval maintaining jig 420 moves upward.

[0098] In the jig moving device 430, the slider 432 supported by the guide roller 4332, the spring 4322, and the first cylinder 435 constitute the first movable part. In the jig moving device 430, the lifting operation rod 436, the spring 4361, the L-shaped piece 433, and the second cylinder 437 constitute the second movable part.

[0099] The conductor receiving portion 440 receives the conductor 100, which is formed by folding the conductor wire group 10. Figure 6 , Fig.12 and Fig.13 As shown, the conductor housing portion 440 has a cylindrical frame portion 441. The central axis of the frame portion 441 coincides with the extension line of the return line J. The length of the frame portion 441 along the X1-X2 direction is substantially equal to the length of the jig moving device 430 along the X1-X2 direction.

[0100] Inside the frame portion 441, a pair of upper and lower partition walls 4411, 4411 are formed to divide the internal space of the frame portion 441 into three parts. A jig holding frame 442 is arranged between the upper and lower partition walls 4411, 4411. The jig holding frame 442 is arranged closer to the Y1 direction than the center axis (return line J) of the frame portion 441. The first interval maintaining jig 421, the second interval maintaining jig 422 and their jig moving devices 430 are arranged on the jig holding frame 442. The first interval maintaining jig 421 and the second interval maintaining jig 422 are arranged to sandwich a virtual straight line 440a along the Y1-Y2 direction from the top and bottom along the Z1-Z2 direction through the center axis (return line J) of the frame portion 441. The interval between the first interval maintaining jig 421 and the second interval maintaining jig 422 along the Y1-Y2 direction is approximately equal to the length L in the extension direction of the straight portion 101 of the conductor 100 (refer to Figure 1 ).

[0101] A pair of sliding rails 4412, 4412 are provided on a pair of partition walls 4411, 4411, respectively. Each pair of sliding rails 4412, 4412 is arranged on the facing surfaces of the pair of partition walls 4411, 4411, and extends parallel to the Y direction. Sliding guides 4421, 4421 engaging with the sliding rails 4412, 4412 are provided on the upper and lower surfaces of the jig holding frame 442, respectively. Furthermore, a rodless cylinder 4413 extending along the Y direction is provided on the lower surface of the partition wall 4411 arranged on the lower side. The sliding shaft 4413a of the rodless cylinder 4413 passes through the sliding groove 4411a formed in the partition wall 4411 along the Y direction and is connected to the jig holding frame 442. When the rodless cylinder 4413 is driven by the control of the control device 45, the sliding shaft 4413a moves in the Y direction along the sliding groove 4411a. Thus, the jig holding frame 442 connected to the slide shaft 4413 a can move in the Y1 direction and the Y2 direction.

[0102] like Figure 6 and Fig.12As shown, in the initial state of the conductor forming device 400 before forming the conductor wire group 10, the first interval maintaining jig 421 is arranged on the Y1 direction side farther from the central axis (return line J) of the frame portion 441 than the second interval maintaining jig 422. In the jig holding frame 442, the first interval maintaining jig 421 is arranged below the virtual straight line 440a, and the second interval maintaining jig 422 is arranged above the virtual straight line 440a.

[0103] like Fig.12 As shown, a coil end holding jig 451 described later is shown in the jig holding frame 442. The coil end holding jig 451 is a jig for clamping the coil end 102 in the thickness direction to hold it so as to prevent the conductor 100 from loosening after forming. Figure 6 and Fig.12 In the state of the coil end portion 102 of the conductor 100 after being formed (not shown), the conductor 100 is accommodated in the jig holding frame 442 together with the conductor 100 as the conductor 100 moves in the X2 direction.

[0104] The frame portion 441, such as Fig.12 As shown, it is rotatably supported by a pair of support rollers 443, 443. A motor 444 is arranged on the outer side of the frame portion 441. A pinion 4441 is mounted on the shaft of the motor 444. The pinion 4441 meshes with a gear portion (not shown) formed along the outer peripheral surface of the frame portion 441. When the motor 444 is driven by the control of the control device 460, the driving force of the motor 444 is transmitted via the pinion 4441. Thus, the frame portion 441 can rotate in the D1-D2 direction around the central axis (return line J).

[0105] The coil end holding jig supply device 450 is arranged between the conductor housing portion 440 and the holding device 410 and does not interfere with the position of either the holding device 410 or the conductor housing portion 440. The two coil end holding jig supply devices 450, 450 are arranged to clamp the formed conductor 100 from both sides in the width direction (Y1 direction side and Y2 direction side). The two coil end holding jig supply devices 450, 450 are arranged on the outside of the conductor housing portion 440 in the Y1-Y2 direction so as not to hinder the forming action of the conductor wire group 10.

[0106] The coil end holding jig supply devices 450, 450 each have a plurality of coil end holding jigs 451. The coil end holding jig supply devices 450, 450 each supply the coil end holding jigs 451 toward the coil end portions 102, 102 of the conductor 100 that moves toward the conductor receiving portion 440 in the X2 direction as the forming operation of the conductor 100 proceeds, by means of a supply mechanism such as a pusher (not shown).

[0107] The coil end holding fixture 451, such as Fig.12 As shown, the coil end holding jig 451 is formed into a substantially U-shape that is open in mutually opposing directions. The length of the coil end holding jig 451 in the X1-X2 direction has a length that spans 12 straight portions 101 along the length direction of the conductor 100. The coil end holding jig supplying device 450, 450 sequentially supplies the coil end holding jig 451 toward the conductor 100 as it moves in the X2 direction accompanying the progress of the forming operation of the conductor 100, and holds the coil end portion 102 by clamping it. Thus, the conductor 100 is prevented from loosening when it moves in the X2 direction as the forming operation of the conductor 100 progresses.

[0108] The control device 460 controls the overall operation of the conductor shaping device 400. The control device 460 includes a central processing unit (CPU) for generating operation instructions to be output to the respective drive units of the conductor shaping device 400, and a memory for storing programs and various parameters required for generating the operation instructions. The control device 460 may be integrally provided on a base or a housing (not shown) of the conductor shaping device 400, or may be configured by, for example, a personal computer independent of the conductor shaping device 400.

[0109] Next, refer to Figure 14 to Figure 35 , a method for forming the conductor 100 from the conductor wire group 10 using the conductor forming device 400 is described.

[0110] First, the conductor shaping device 400 is used to Figure 6 The conductor wire group 10 waiting on the upstream side of the holding device 410 shown in FIG. 1 is formed into the initial coil end portion 102, and as shown in FIG. Fig.14 As shown, the conductor wire group 10 is moved a predetermined distance along the Y1 direction by a conveying device (not shown). At this time, the first coil end portion forming area 10A after the U-shaped portion 11 in the conductor wire group 10 is arranged between the movable side holding device 411 and the fixed side holding device 412, and the leg portion 12 is held by the movable side holding device 411 and the fixed side holding device 412, respectively. At this time, a predetermined gap S is provided between the U-shaped portion 11 of the conductor wire group 10 and the movable side holding device 411, into which the base 4211 of the first interval maintaining jig 421 can be inserted.

[0111] [First return process]

[0112] After the coil end portion forming area 10A is arranged between the movable side holding device 411 and the fixed side holding device 412, the first folding process is started for the coil end portion forming area 10A. In the folding process, Fig.15 As shown, on the upper surface of the leg 12 held by the fixed side holding device 412, a folding jig 413 is arranged by a moving mechanism not shown. The folding jig 413 is rectangular in shape when viewed from a plane, as shown in FIG. Fig.16 As shown, the folding jig 413 is formed into a triangular shape with a pointed front end 413a when viewed from the side, that is, a wedge shape. The folding jig 413 is arranged on the upper surface of the fixed side holding device 412 and the leg 12 of the coil end forming area 10A on the upstream side of the folding line J in a manner such that the front end 413a is consistent with or close to the folding line J.

[0113] While inserting the return fixture 413, Fig.15 and Fig.16 As shown, the first interval maintaining jig 421 is inserted into the gap S between the U-shaped portion 11 of the conductor wire group 10 and the movable side holding device 411. The first interval maintaining jig 421 is moved forward in the X1 direction by the jig moving device 430 and is arranged on the lower surface side of the leg 12. Thereafter, the first interval maintaining jig 421 is moved up in the Z1 direction by the jig moving device 430, as shown in FIG. Fig.17 As shown, each protrusion 4212 is inserted between adjacent legs 12, 12. Thus, the interval between adjacent legs 12 is maintained.

[0114] The first interval maintaining jig 421 is inserted into a position where the interval between the straight portions 101 of the formed conductor 100 is easily changed in the arrangement direction of the straight portions 101. Fig.15 As shown, the arrangement is to maintain the interval of 10 leg portions 12 from the X2 direction side. The reason is that in the initial folding process, the movable side holding device 411 moves in the X2 direction relative to the fixed side holding device 412, and thus extends further to the X2 direction side than the fixed side holding device 412, and the intervals between adjacent straight portions 101 after forming are easily disturbed.

[0115] Afterwards, if Fig.18 As shown, the movable side holding device 411 rotates in the D1 direction with the folding line J as the center in a manner overlapping with the fixed side holding device 412, and folds back the leg 12 of the coil end portion forming area 10A in the conductor wire group 10. The leg 12 is folded back with the front end 413a of the folding jig 413 as the folding starting point. Therefore, the leg 12 is folded back smoothly and with high precision. Thus, the leg 12 is bent in a direction in which it overlaps with each other (a first folding process).

[0116] In addition, at this time, the frame portion 441 of the conductor receiving portion 440 is driven by the motor 444 to rotate in the D1 direction in conjunction with the movable side holding device 411 around the return line J. As a result, the jig holding frame 442 in the frame portion 441 also rotates in the D1 direction. Therefore, during the return action, the first interval maintaining jig 421 also continuously maintains the interval between the legs 12.

[0117] A return process, such as Fig.19 As shown, the leg portion 12 of the folded conductor wire group 10 ends before it is completely folded back. Specifically, the movable side holding device 411, from Fig.16 In the state before folding shown, after rotating 150 degrees about the folding line J as an axis, one folding process is completed.

[0118] After the first folding process is completed, the folding jig 413 retreats from the coil end portion forming area 10A, and the movable side holding device 411 maintains the rotation angle at the end of the first folding process. Fig. 20 As shown, it moves in parallel in the X2 direction. The X2 direction is the direction along the arrangement direction of the legs 12 of the conductor wire group 10, and is a direction parallel to the return line J. The parallel movement amount of the movable side holding device 411 here is equivalent to the distance of 10 legs 12. At this time, the movable side holding device 411 also moves slightly in the Y2 direction as the legs 12 tilt. The first interval maintaining jig 421 also moves in the X2 direction in conjunction with the parallel movement of the movable side holding device 411 while maintaining the interval between the legs 12 by the retreat of the movable end 4351 of the first cylinder 435. Furthermore, in conjunction with the movement in the Y2 direction during the tilting action of the movable side holding device 411, the jig holding frame 442 also moves in the Y2 direction along the sliding rail 4412 by the drive of the rodless cylinder 4413 controlled by the control device 460, the same moving distance as the movable side holding device 411.

[0119] By the parallel movement of the movable side holding device 411 , the leg portions 12 of the conductor wire group 10 in the coil end portion forming region 10A are inclined in a mountain shape so as to cross each other with the portion along the return line J as the vertex. Thus, the inclined step starts.

[0120] By starting the oblique process, the coil end portion 102 is formed by each leg portion 12. The coil end portion 102, such as Figure 1 As shown, it has a vertex 102b along the return line J and two oblique portions 102a, 102a obliquely intersecting the vertex 102b. The straight portion 101 is formed by the area held by the movable side holding device 411 between the U-shaped portion 11 and the coil end portion 102.

[0121] After the inclined process is completed, Fig.21 As shown in FIG. 1 , the movable side holding device 411 further rotates in the D1 direction with the return line J as the axis until it overlaps with the fixed side holding device 4122. In conjunction with this, the jig holding frame 442 also rotates in the D1 direction. Fig.16 In the state shown, the leg portion 12 of the conductor wire group 10 is rotated 180 degrees with the return line J as the center, and the leg portion 12 of the conductor wire group 10 is returned. As a result, the conductor wire group 10 is completely returned with the return line J as the center. The leg portion 12 held by the movable side holding device 411 and the leg portion 12 held by the fixed side holding device 412 are completely overlapped (secondary return process). As a result, the first return process of the coil end portion forming area 10A of the conductor wire group 10 is completed.

[0122] At the end of the first return process, if Fig. 22 As shown, among the 24 legs 12 held by the fixed-side holding device 412, 12 legs 12 on the X2 direction side overlap with the folded-back legs 12 (straight portion 101) by the folding process and are double-stacked. However, 10 legs 12 on the X1 direction side do not overlap with the folded-back legs 12 (straight portion 101). Among the legs 12 on the folded-back side, 10 legs 12 whose intervals are maintained by the first interval maintaining jig 421 extend in the X2 direction relative to the legs 12 held by the fixed-side holding device 412. Therefore, the first interval maintaining jig 421 does not interfere with the fixed-side holding device 412.

[0123] After the first return process is completed, if Fig.23 As shown, the third interval maintaining jig 423 moves in a manner facing the first interval maintaining jig 421 from the X1 direction, and is inserted into the gap S between the U-shaped portion 11 of the conductor wire group 10 and the movable side holding device 411. The third interval maintaining jig 423 moves in the X2 direction by the jig moving device 430, and is arranged on the upper surface side of the folded leg 12 (the straight portion 101 adjacent to the U-shaped portion 11) held by the movable side holding device 411. Thereafter, the third interval maintaining jig 423 moves downward in the Z2 direction by the jig moving device 430, and each protrusion 4232 is inserted between the adjacent legs 12, 12. Thus, the interval between the adjacent legs 12 is maintained.

[0124] The insertion position of the third spacing maintaining jig 423 is a position where the spacing of the straight portions 101 of the formed conductor 100 is easily changed in the arrangement direction of the straight portions 101. Here, the third spacing maintaining jig 423 is configured to maintain the spacing of the remaining 14 legs 12 that are not maintained by the first spacing maintaining jig 421. This is because the spacing of the straight portions 101 is easily disturbed after the movable side holding device 411 is released to return to the initial position. In addition, at Fig. 22and Fig.23 In the figure, the movable side holding device 411 is omitted.

[0125] After the third interval maintaining fixture 423 is configured, Fig.24 As shown, the movable side holding device 411 releases the holding of the leg 12, rotates in the D2 direction and returns to the initial position. Even if the movable side holding device 411 releases the holding of the leg 12, the first interval maintaining jig 421 and the third interval maintaining jig 423 will continue to maintain the intervals of the 24 legs 12 held by the movable side holding device 411. At this time, the jig holding frame 442 is still rotated 180 degrees in the D1 direction and is arranged on the Y2 direction side of the frame portion 441.

[0126] After the movable side holding device 411 returns to the initial position, the third interval maintaining jig 423 releases the holding of the leg 12 and moves in the X1 direction to return to the initial position. Fig.25 As shown, the jig is held by a conveying device (not shown) and conveyed a predetermined distance in the Y1 direction in order to form the next coil end portion 102. As a result, in the conductor wire group 10, the second formed coil end portion forming area 10B is arranged between the movable side holding device 411 and the fixed side holding device 412, and the 24 legs 12 are held by the movable side holding device 411 and the fixed side holding device 412 respectively. At the same time, the jig holding frame 442 is driven by the rodless cylinder 4413 to move to the end closest to the Y1 direction in the frame portion 441 and return to the initial position.

[0127] In addition, the jig holding frame 442 at the end of the first return process is Fig.12 The initial state shown is rotated 180 degrees in the D1 direction around the return line J. Therefore, the first interval maintaining jig 421 is arranged above the virtual straight line 440a (Z1 direction), and the second interval maintaining jig 422 is arranged below the virtual straight line 440a (Z2 direction).

[0128] [Second return process]

[0129] After the coil end portion forming area 10B is arranged between the movable side holding device 411 and the fixed side holding device 412, the second folding process is started for the coil end portion forming area 10B. In the second folding process, similarly to the first folding process, Fig.26As shown, a folding jig 413 is arranged on the upper surface of the leg 12 held by the fixed side holding device 412. At the same time, the second interval maintaining jig 422 is inserted into the gap S between the coil end portion 102 initially formed in the conductor wire group 10 and the movable side holding device 411. The second interval maintaining jig 422 is advanced in the X1 direction by the jig moving device 430 and arranged on the lower surface side of the leg 12. Thereafter, the second interval maintaining jig 422 is moved up in the Z1 direction by the jig moving device 430, and each protrusion 4222 is inserted between the adjacent legs 12, 12. Thus, the interval between the adjacent legs 12 is maintained.

[0130] The insertion position of the second interval maintaining jig 422 is a position where the interval of the straight portions 101 in the arrangement direction of the straight portions 101 of the formed conductor 100 is likely to change. Here, the second interval maintaining jig 422 is configured to maintain the interval of 14 legs 12 from the X2 direction side among the 24 legs 12 held by the movable side holding device 411. This is because this position is a position where the movable side holding device 411 moves in the X2 direction relative to the fixed side holding device 412 during the second folding process, thereby extending further to the X2 direction side than the fixed side holding device 412, and the intervals of adjacent straight portions 101 after forming are likely to be disturbed.

[0131] Afterwards, if Fig. 27 As shown, similar to the first folding process, the first folding process, the oblique process and the second folding process are sequentially performed. The first folding process is to rotate the movable side holding device 411 and the jig holding frame 442 in the D1 direction with the folding line J as the center in a manner overlapping with the fixed side holding device 412, and fold back the leg 12 of the coil end portion forming area 10B in the conductor wire group 10. The oblique process is to move the movable side holding device 411 parallel to the X2 direction. When performing the second folding process, the first interval maintaining jig 421 and the second interval maintaining jig 422 continuously maintain the interval of the leg 12 closer to the Y1 direction side than the folding line J, so the interval of the leg 12 cannot be disordered.

[0132] In the oblique movement process of the second folding process, the parallel movement amount of the movable side holding device 411 is equivalent to the distance of 14 legs 12. When the second folding process is completed, Fig.28As shown, among the 24 legs 12 held by the fixed-side holding device 412, 10 legs 12 on the X2 direction side overlap with the folded-back legs 12 (straight portion 101) by the folding process, and are double-stacked. However, 14 legs 12 on the X1 direction side do not overlap with the folded-back legs 12 (straight portion 101). When the second folding process is completed, the second spacing maintaining jig 422 maintains the spacing of the straight portion 101 extending from the fixed-side holding device 412 in the X2 direction, so that it does not interfere with the fixed-side holding device 412.

[0133] In addition, the jig holding frame 442 at the end of the second return process is Fig.12 The state shown in the initial state is rotated 360 degrees in the D1 direction around the return line J. Therefore, the first interval maintaining jig 421 is arranged below the virtual straight line 440a (Z2 direction), and the second interval maintaining jig 422 is arranged above the virtual straight line 440a (Z1 direction).

[0134] After the second return process is completed, if Fig.29 As shown, the third interval maintaining jig 423 moves in a manner opposite to the second interval maintaining jig 422 from the X1 direction, and is inserted into the gap between the coil end portion 102 formed by the coil end portion forming area 10B of the conductor wire group 10 and the movable side holding device 411. Thus, the third interval maintaining jig 423 inserts each protrusion 4232 between the straight portions 101 whose interval is not maintained by the second interval maintaining jig 422, and maintains the interval of the straight portions 101. In addition, Fig.28 and Fig.29 In the figure, the movable side holding device 411 is omitted.

[0135] After the third interval maintaining fixture 423 is configured, Fig.30 As shown, the movable side holding device 411 releases the holding of the leg 12, rotates in the D2 direction and returns to the initial position. Even if the movable side holding device 411 releases the holding of the leg 12, the first interval maintaining jig 421, the second interval maintaining jig 422 and the third interval maintaining jig 423 continue to maintain the intervals of the 24 legs 12 (straight portions 101) held by the movable side holding device 411. After the movable side holding device 411 returns to the initial position, the third interval maintaining jig 423 releases the holding of the leg 12 and moves in the X1 direction to return to the initial position.

[0136] After the movable side holding device 411 and the third interval maintaining fixture 423 are restored to their initial positions, the conductor wire group 10, such as Fig.31As shown, the conductor wire assembly 10 is held by a conveying device (not shown) and conveyed a predetermined distance in the Y1 direction in order to form the next coil end portion 102. As a result, in the conductor wire assembly 10, the third formed coil end portion forming area 10C is arranged between the movable side holding device 411 and the fixed side holding device 412, and the 24 legs 12 are held by the movable side holding device 411 and the fixed side holding device 412, respectively. At the same time, the jig holding frame 442 of the conductor receiving portion 440 is moved in the Y1 direction by the drive of the rodless cylinder 4413 and returns to the initial position.

[0137] [Third return process]

[0138] After the coil end portion forming area 10C is arranged between the movable side holding device 411 and the fixed side holding device 412, the third folding process is started for the coil end portion forming area 10C. In the third folding process, similarly to the first and second folding processes, Fig.32 As shown, a folding jig 413 is arranged on the upper surface of the leg 12 held by the fixed side holding device 412. At the same time, the first interval maintaining jig 421 is inserted into the gap S between the coil end portion 102 and the movable side holding device 411. The first interval maintaining jig 421 is advanced in the X1 direction by the jig moving device 430 and arranged on the lower surface side of the leg 12. Thereafter, the first interval maintaining jig 421 is moved up in the Z1 direction by the jig moving device 430, and each protrusion 4222 is inserted between the adjacent legs 12, 12. Thus, the interval between the adjacent legs 12 is maintained.

[0139] The insertion position of the first interval maintaining jig 421 is a position where the interval of the straight portions 101 in the arrangement direction of the straight portions 101 of the formed conductor 100 is likely to change. Here, the first interval maintaining jig 421 is configured to maintain the interval of 10 legs 12 from the X2 direction side among the 24 legs 12 held by the movable side holding device 411. This is because this position is a position where the movable side holding device 411 moves in the X2 direction relative to the fixed side holding device 412 during the third folding process, thereby extending further to the X2 direction side than the fixed side holding device 412, and the intervals of adjacent straight portions 101 after forming are likely to be disturbed.

[0140] Thereafter, similarly to the first and second folding steps, a first folding step, an oblique step, and a second folding step are sequentially performed. The first folding step is to rotate the movable side holding device 411 and the jig holding frame 442 in the D1 direction with the folding line J as the center so as to overlap with the fixed side holding device 412, and fold back the leg 12 of the coil end portion forming area 10B in the conductor wire group 10. The oblique step is to move the movable side holding device 411 parallel to the X2 direction. When performing the third folding step, the first interval maintaining jig 421 and the second interval maintaining jig 422 continuously maintain the interval of the leg 12 on the Y1 direction side relative to the folding line J, so that the interval of the leg 12 cannot be disordered.

[0141] In the oblique movement process in the third folding process, the parallel movement amount of the movable side holding device 411 is the same as the first folding process, which is equivalent to the distance of 10 legs 12. Fig.33 As shown, among the 24 legs 12 held by the fixed-side holding device 412, 14 legs 12 on the X2 direction side overlap with the folded-back legs 12 (straight portion 101) by the folding process, and are double-stacked. However, 10 legs 12 on the X1 direction side do not overlap with the folded-back legs 12 (straight portion 101). At the end of the third folding process, the first spacing maintaining jig 421 maintains the spacing of the straight portion 101 extending from the fixed-side holding device 412 in the X2 direction, so that it does not interfere with the fixed-side holding device 412.

[0142] As the folding process proceeds, the formed conductor 100 slowly moves in the X1 direction where the conductor receiving portion 440 is configured. When the third folding process is completed, the formed conductor 100 moves to the area where the two coil end holding jig supply devices 450, 450 face each other. At this time, the coil end holding jig supply devices 450, 450, such as Fig.34 and Fig.35 As shown, the coil end holding jigs 451, 451 are pushed out to clamp and hold the coil end portions 102, 102 on the front end side of the moving direction of the conductor 100. The coil end holding jigs 451, 451 hold the coil end portions 102, 102 that span the length of the 12 straight line portions 101 along the length direction of the conductor 100. In addition, Fig.33 and Fig.34 In the figure, the movable side holding device 411 is omitted.

[0143] Thereafter, the conductor wire group 10 is held by a conveying device not shown in the figure, and is conveyed a predetermined distance in the Y1 direction in order to form the next coil end portion 102. Thereafter, the same action as described above is repeated on the conductor wire group 10, and the fourth, fifth, sixth, etc. folding processes are performed in sequence. However, in the oblique process of each folding process, the parallel movement amount of the movable side holding device 411 is equivalent to the distance of 10 legs 12 in the odd-numbered folding process, and is equivalent to the distance of 14 legs 12 in the even-numbered folding process. That is, the movable side holding device 411 in the oblique process alternately switches between the parallel movement amount of 10 legs 12 and the parallel movement amount of 14 legs in each folding process.

[0144] As the folding process proceeds, the formed conductor 100 gradually moves toward the conductor receiving portion 440 in the X2 direction. Fig.36 As shown, the coil end holding jigs 451, 451 are continuously installed at the coil end portions 102, 102 spanning the length of the 12 straight portions 101 adjacent to the previously installed coil end holding jigs 451, 451. The formed conductor 100, while being held by the coil end holding jigs 451, 451, moves toward the conductor receiving portion 440 without loosening as the folding process proceeds, and is received in the jig holding frame 422.

[0145] As described above, according to the conductor forming device 400 and the conductor forming method of the present embodiment, when the conductor wire group 10 is folded back, the first interval maintaining jig 421, the second interval maintaining jig 422, and the third interval maintaining jig 423 always continuously maintain the interval at the position where the interval of the straight portion 101 of the formed conductor 100 is likely to change. Therefore, the arrangement pitch of the straight portion 101 of the formed conductor 100 is prevented from being disordered, and the conductor 100 with high precision can be formed.

[0146] Reference numerals

[0147] 1 conductor wire

[0148] 10-conductor wire set

[0149] 100 conductors

[0150] 101 Linear Department

[0151] 102a oblique part

[0152] 400 conductor forming device

[0153] 420 interval maintenance fixture

[0154] 421 First Interval Maintenance Fixture

[0155] 422 Second interval maintenance fixture

[0156] 423 Third Interval Maintenance Fixture

[0157] 4211,4221,4231 abutment

[0158] 4212,4222,4232 protrusion

[0159] 430 fixture moving device

[0160] 432 Slider (first movable part)

[0161] 4322 Spring (first movable part)

[0162] 433L type piece (second movable part)

[0163] 435 first cylinder (first movable part)

[0164] 436 lifting operation rod (second movable part)

[0165] 4361 Spring (second movable part)

[0166] 437 Second cylinder (second movable part).

Claims

1. A conductor shaping device, wherein a conductor is folded back multiple times in a thickness direction by a conductor wire group composed of multiple conductor wires to shape a conductor, wherein the conductor has multiple straight portions arranged at intervals and multiple oblique portions arranged at both ends of the straight portions, and the straight portions are double-stacked, the conductor shaping device comprising: A spacing maintaining jig for maintaining the spacing of the straight line portions in the conductor wire group in the arrangement direction; and A jig moving means connects the aforementioned gap maintaining jig and moves it relative to the aforementioned conductor wire group; The aforementioned interval maintaining fixture has: A base extending along the arrangement direction of the straight line portions; and A plurality of protrusions are arranged in a row along the length direction of the base, and can be inserted between the adjacent straight line portions in the arrangement direction; The aforementioned fixture moving means has: The first movable part moves the interval maintaining jig in a direction forward and backward along the arrangement direction of the linear portions relative to a portion of the conductor wire group where the interval of the linear portions is easily changed in the arrangement direction of the linear portions; and The second movable portion moves the interval maintaining jig disposed at a location where the interval of the linear portion is likely to change in a direction in which the protrusion is inserted into and removed from between the linear portions.

2. The conductor shaping device according to claim 1, in, The interval maintaining jig includes at least two of a first interval maintaining jig and a second interval maintaining jig, wherein the first interval maintaining jig is configured to be inserted into the protrusion from one side of the straight portion of the conductor wire group, and the second interval maintaining jig is configured to be inserted into the protrusion from the other side.

3. The conductor shaping device according to claim 2, in, The first interval maintaining jig and the second interval maintaining jig are arranged side by side along the longitudinal direction of the linear portion at an interval corresponding to the interval between one end and the other end in the extending direction of the linear portion.

4. The conductor shaping device according to any one of claims 1 to 3, in, The first interval maintaining jig and the second interval maintaining jig are provided so as to be rotatable about the folding line in conjunction with the folding action of the conductor wire group.

5. The conductor shaping device according to claim 4, in, The aforementioned interval maintaining fixture has: a third interval maintaining jig disposed on the side of the fixed-side holding device along the arrangement direction of the straight line portion and on the opposite side of the first interval maintaining jig and the second interval maintaining jig across the straight line portion of the conductor wire group; The third interval maintaining jig is operated by the jig moving means in the following manner: temporarily maintaining the interval of the straight portion in the folded conductor wire group until the conveyance of a predetermined distance along the extending direction of the straight portion for the next folding action.

6. A conductor forming method, wherein a conductor wire group composed of a plurality of conductor wires is folded back multiple times in a thickness direction to form a conductor, wherein the conductor has a plurality of straight portions arranged at intervals and a plurality of oblique portions arranged at both ends of the straight portions, and the straight portions are double-layered, the conductor forming method being characterized in that: The conductor wire group is folded back while maintaining the interval at a location where the interval of the straight line portions in the arrangement direction of the straight line portions in the conductor wire group is easily changed by a spacing maintaining jig, wherein the spacing maintaining jig comprises: a base extending along the arrangement direction of the straight line portions; and a plurality of protrusions protruding in a row along the length direction of the base and capable of being respectively inserted between the adjacent straight line portions in the arrangement direction.

7. The conductor forming method according to claim 6, in, The interval is maintained from both sides of the conductor wire group by at least two interval maintaining jigs, namely, a first interval maintaining jig and a second interval maintaining jig, wherein the first interval maintaining jig is inserted into the protrusion from one side of the straight portion of the conductor wire group, and the second interval maintaining jig is inserted into the protrusion from the other side.

8. The conductor forming method according to claim 7, in, The interval at one end and the other end of the extending direction of the straight portion is maintained by the first interval maintaining jig and the second interval maintaining jig.

9. The conductor forming method according to claim 7 or 8, in, The interval of the straight portion in the folded-back conductor wire group is temporarily maintained by a third interval maintaining jig until the straight portion is conveyed a predetermined distance along an extending direction for the next folding operation.

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