Coil manufacturing device and coil manufacturing method

Abstract

To provide a coil manufacturing device and coil manufacturing method in which the space factor of a coil can be improved.SOLUTION: A coil manufacturing device 100 comprises: a transmission unit 130 for transmitting a lead wire 120; and a drive unit 140 for rotating a core 110 so that the transmitted lead wire 120 can be wound around the core. The drive unit 140 first rotates the core 110 in the reverse direction of the winding direction of the lead wire 120 when once bending the lead wire 120 transmitted from the transmission unit 130 to the second side 12 opposite to the first side 11 on which the core 110 is arranged, and after that, rotates the core 110 in the winding direction when bending the lead wire 120 to the first side 11.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present disclosure relates to a coil manufacturing apparatus and a coil manufacturing method. [Background technology]

[0002] Patent Document 1 discloses a winding device that alternately feeds out and bends a rectangular conductor wire. The winding device forms a rectangular coil by repeatedly moving and rotating a work chuck in accordance with the feeding out and bending of the rectangular conductor wire (see paragraph 0067). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2019-212770 A Summary of the Invention [Problem to be solved by the invention]

[0004] Since it is difficult to reduce the bending radius of the conductor wire, there is a problem of low space factor of the coil.

[0005] The present disclosure has been made to solve such problems, and has an object to provide a coil manufacturing apparatus and a coil manufacturing method that improve the space factor of a coil. [Means for solving the problem]

[0006] The coil manufacturing apparatus in this embodiment is A sending section for sending out a conductor; a driving unit that rotates the core so that the fed conductor is wound around the core; Equipped with The drive unit is When the conductor is first bent toward a second side opposite to the first side on which the core is disposed with respect to the delivery section, the core is rotated in a direction opposite to the winding direction of the conductor, and then when the conductor is bent toward the first side, the core is rotated in the winding direction.

[0007] The coil manufacturing method in this embodiment includes the steps of: a step of rotating the core in a direction opposite to a winding direction of the conductor when bending the conductor once to a second side opposite to a first side where the core is disposed with respect to a delivery section that delivers the conductor; after the step of rotating the core in the reverse direction, rotating the core in the winding direction while bending the conductor to the first side; Includes. Effect of the Invention

[0008] The present disclosure provides a coil manufacturing apparatus and a coil manufacturing method that improve the space factor of a coil. [Brief description of the drawings]

[0009] [Figure 1] FIG. 13 is a diagram for explaining the shape of a conventional coil. [Diagram 2] FIG. 1 is a diagram for explaining the shape of a conventional motor. [Diagram 3] FIG. 2 is a diagram for explaining the configuration of a coil manufacturing apparatus according to the first embodiment. [Figure 4] FIG. 2 is a diagram for explaining an example of a coil manufacturing method according to the first embodiment. [Diagram 5] FIG. 2 is a diagram for explaining the structure of a concentrated winding coil. [Figure 6] 1A and 1B are diagrams for explaining the relationship between stress and strain generated in a conductor; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Consideration leading to the embodiment First, the contents of the investigation carried out by the inventor of the present application will be explained. The left diagram of Fig. 1 shows the shape of a conventional coil 20. The coil is formed by bending a rectangular wire. The right diagram of Fig. 1 shows the shape of an ideal coil 20a with small bending. However, it is difficult to make the bending of the rectangular wire smaller than the thickness of the rectangular wire, so it is difficult to realize the shape of the coil 20a.

[0011] FIG. 2 shows the shape of a conventional motor 10. The motor 10 includes a coil 20 and a core 110. Since it is difficult to reduce the bending of the coil 20, a gap 30 exists between the coil 20 and the core 110. The gap 30 reduces the space factor of the coil 20, and the reluctance torque of the motor 10 decreases. This results in a problem that the torque of the motor 10 is small. Therefore, the present disclosure provides a coil manufacturing apparatus and a coil manufacturing method that improve the space factor of the coil 20.

[0012] The present invention will be described below through embodiments of the invention, but the invention according to the claims is not limited to the following embodiments. Furthermore, not all of the configurations described in the embodiments are necessarily essential as means for solving the problems.

[0013] EMBODIMENT 1 3 is an explanatory diagram showing the configuration of the coil manufacturing apparatus 100 according to the embodiment 1. The upper diagram of Fig. 3 shows the top surface of the coil manufacturing apparatus 100, and the lower diagram shows a side surface of the coil manufacturing apparatus 100. The coil manufacturing apparatus 100 includes a core 110, a conductive wire 120, a feed unit 130, and a drive unit 140.

[0014] The core 110 is an iron core portion of a stator or rotor included in a motor. The core 110 is formed, for example, by stacking a plurality of electromagnetic steel sheets. The core 110 may be a split core used in a split-core motor. FIG. 3 shows a configuration example of a coil manufacturing apparatus 100 for manufacturing a concentrated winding coil, and the shape of the core 110 is, for example, a rectangular parallelepiped shape. The core 110 is provided so as to be rotatable about a rotation axis C1 extending in the vertical direction. The rotation axis C1 may pass through the center of the core 110.

[0015] The conductor 120 is an electric wire wound in a coil shape around the core 110. The conductor 120 may be a rectangular wire. In FIG. 1, a portion of the conductor 120 is wound in a coil shape around the core 110. The conductor 120 is formed of, for example, pure copper, a copper alloy, iron, pure aluminum, an aluminum alloy, tin, zinc, or the like. Pure copper has a property that it has a low electrical resistance and is easily work-hardened compared to other metals. The conductor 120 is first bent to the opposite side (referred to as the second side) of the side where the core is arranged with respect to the sending section 130 (referred to as the first side), and then bent to the first side. The first side 11 and the second side 12 are indicated by arrows. This reduces the bending (also referred to as the bending radius) of the conductor 120.

[0016] The angle at which the conductor 120 is bent to the second side 12 may be 90 degrees, 60 degrees, or 30 degrees. The larger the angle, the greater the pre-strain of the conductor 120, making it easier for the Bauschinger effect to occur and allowing the conductor 120 to be bent less. However, it should be noted that the greater the strain, the more likely the conductor 120 is to break due to work hardening. Also, the number of times the conductor 120 is bent to the second side 12 is not limited to one time, and it may be multiple times. When the conductor 120 is bent multiple times, it should be noted that the conductor 120 is also more likely to break due to work hardening.

[0017] The feed unit 130 is a feeder that supplies the conductor 120 to the core 110. The feed unit 130 may be composed of, for example, two rotating units arranged to sandwich the conductor 120, and a driving source such as a motor that rotates these rotating units. The two rotating units rotate in opposite directions. The feed unit 130 functions as a bending die when bending the conductor 120 to the second side 12.

[0018] When bending the conductor 120 sent out from the sending unit 130 to the second side 12, the driving unit 140 rotates (spins) the core 110 around the rotation axis C1 in a direction opposite to the winding direction (also called the forward direction) of the conductor 120. Thereafter, when bending the conductor 120 to the first side 11, the driving unit 140 rotates the core 110 in the forward direction. The driving unit 140 may temporarily return the shape of the conductor 120 to its original straight shape, and then further rotate the core 110 in the forward direction. The driving unit 140 may include a servo motor that rotates the core 110 around the rotation axis C1.

[0019] The driving unit 140 may further have a function of translating the core 110. For example, when bending the conductor 120 to the second side 12, the driving unit 140 may move the core 110 to the second side 12. The conductor 120 may be bent to the second side 12 only by rotating the core 110. Furthermore, when feeding out the conductor 120 or when bending the conductor, the driving unit 140 may move the core 110 to an appropriate position.

[0020] The coil manufacturing apparatus 100 may include a control device (not shown) that transmits a drive signal to the drive unit 140. The control device is a computer including a processor, a memory, and the like. The control device repeats a first control for bending the conductor 120 to the second side 12 and a second control for bending the conductor 120 to the first side 11. In this way, the conductor 120 is wound around the core 110. The control device may further perform control for moving the core 110 in the vertical direction according to the number of windings of the conductor 120. The control device may also transmit a drive signal to the sending unit 130 to control the amount of the conductor 120 being sent out.

[0021] 4 is an explanatory diagram showing an example of the operation of the coil manufacturing apparatus 100. In step S101, the delivery unit 130 of the coil manufacturing apparatus 100 rotates, and the conductive wire 120 is supplied to the core 110.

[0022] In step S102, the operation of the delivery unit 130 is stopped, and the driving unit 140 of the coil manufacturing apparatus 100 rotates the core 110 in the reverse direction as indicated by the solid arrow while moving the core 110 along the curved track indicated by the dotted arrow. As a result, the conductive wire 120 is bent toward the second side 12 using the delivery unit 130 as a bending die. The original shape of the core 110 is shown diagrammatically by the two-dot chain line. Since the core 110 rotates (spins) in the reverse direction, the same portion as the portion bent toward the second side 12 can be bent toward the first side 11 in steps S103 to S104 described later. The driving unit 140 may rotate (spin) the core 110 in the reverse direction by revolving the core 110 around the delivery unit 130.

[0023] In step S103, driving unit 140 rotates core 110 in the forward direction while moving core 110 along the curved path indicated by the dotted arrow, thereby returning the shape of conductive wire 120 bent in step S102 to its original straight shape.

[0024] In step S104, the driving unit 140 rotates the core 110 in the forward direction. The conductive wire 120 is bent with a smaller bend because the same portion bent to the second side 12 in step S102 is bent to the first side 11.

[0025] In steps S102 to S104, the operation of the delivery unit 130 is stopped. This allows the portion bent toward the first side 11 to more accurately match the portion bent toward the second side 12. Note that if the speed at which the conductor 120 is delivered is sufficiently slow, the operation of the delivery unit 130 does not need to be stopped.

[0026] In step S105, the sending unit 130 resumes operation. After step S105, step S102 is executed. By repeating steps S102 to S105, the coil is manufactured. When the conductive wire 120 is wound around the core 110, the driving unit 140 may move the core 110 downward to change the height at which the conductive wire 120 is wound around the core 110.

[0027] The coil manufacturing apparatus 100 may manufacture a distributed winding coil instead of a concentrated winding coil. Fig. 5 is a diagram for explaining the shape of a distributed winding coil 20b. The distributed winding coil 20b has a crank portion 21 and a shoulder portion 22. In this case, for each of the crank portion 21 and the shoulder portion 22, the driving unit 140 first bends the conductor wire 120 to the second side 12, and then bends the conductor wire 120 to the first side 11.

[0028] FIG. 6 is a diagram for explaining the relationship between stress and strain in the conductor 120. The vertical axis represents stress, and the horizontal axis represents strain. First, the state of the conductor 120 before bending corresponds to point O. Point A represents the yield point when the conductor 120 is bent in advance to the second side 12 (e.g., the left side in FIG. 6). The yield stress at the yield point A is expressed as σ a Point B corresponds to the state of the conductor 120 when it returns to its original straight shape. Point C represents the yield point of the conductor 120 when it is bent to the first side 11 (e.g., the right side in FIG. 6). The yield stress at yield point C is -σ C Due to the Bauschinger effect, σ c is σ a Therefore, the bend in the conductor 120 bent towards the first side 11 is smaller.

[0029] The coil manufacturing apparatus according to the first embodiment can reduce the bending of the coil and improve the space factor of the coil. Since there is no need to increase the temperature of the conductor in the first embodiment, there is no risk of the insulation coating of the conductor melting.

[0030] The present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit and scope of the present invention. [Explanation of symbols]

[0031] 100 Coil manufacturing equipment 110 cores 120 Conductor 130 Sending Department 140 Drive unit 10 Motor 20, 20a, 20b Coil 21 Crank section 22 Shoulder 30 Gap 11 First Side 12 Second Side

Claims

1. A sending section that sends out a conductor; a driving unit that rotates the core so that the fed conductor is wound around the core; Equipped with The drive unit is When the conductor is bent once to a second side opposite to the first side on which the core is disposed with respect to the delivery section, the core is rotated in a direction opposite to the winding direction of the conductor, and then when the conductor is bent to the first side, the core is rotated in the winding direction. Coil manufacturing equipment.

2. While the core is rotating in the reverse direction, the delivery section is deactivated. The coil manufacturing apparatus according to claim 1 .

3. When bending the conductor once to the second side, the delivery portion functions as a bending die. The coil manufacturing apparatus according to claim 2 .

4. The conductor is made of pure copper. The coil manufacturing apparatus according to claim 1 or 2.

5. a step of rotating the core in a direction opposite to a winding direction of the conductor when bending the conductor once to a second side opposite to a first side on which the core is disposed with respect to a delivery section that delivers the conductor; after the step of rotating the core in the reverse direction, rotating the core in the winding direction while bending the conductor to the first side; A coil manufacturing method comprising:

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