Conductor wire manufacturing method and conductor wire manufacturing device

Abstract

To provide a conductor wire manufacturing method which contributes to improvement of yield.SOLUTION: A conductor wire manufacturing method according to one embodiment of the present disclosure is a method for manufacturing a conductor wire used in a motor, the method comprising the steps of: forming slits (2) in a strip-shaped conductive member (1); cutting out a pine-needle-shaped wire (3) having the slits (2) from the conductive member (1); and expanding the slits (2) of the wire (3). The method may further comprise the step of covering the wire (3) having the expanded slits (2) with an insulation coating (17).SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a method and an apparatus for manufacturing a conductor used in a motor. [Background technology]

[0002] It is desirable to efficiently manufacture conductors for use in motors. For example, in Patent Document 1, a continuous coil wire in a U-shaped zigzag pattern is punched out of a winding material, and the coil wire is folded into a coil shape to form a winding subassembly. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2002-95226 A Summary of the Invention [Problem to be solved by the invention]

[0004] The present applicant has found the following problems: The technique of Patent Document 1 has a problem of low yield because a continuous coil wire in a U-shaped zigzag pattern is punched out from a winding material.

[0005] The present disclosure has been made in consideration of such problems, and provides a conductor wire manufacturing method and apparatus that contribute to improving yields. [Means for solving the problem]

[0006] A method for manufacturing a conductor according to one aspect of the present disclosure is a method for manufacturing a conductor used in a motor, comprising the steps of: forming slits in a strip-shaped conductive member; cutting out a pine-needle-shaped wire having the slits from the conductive member; widening the slit in the wire; Equipped with.

[0007] The above-mentioned method for producing a conductor preferably includes a step of covering the wire with the widened slit with an insulating coating.

[0008] In the above-mentioned method for producing a conductor, it is preferable that a plurality of the wires are overlapped and the slits of the plurality of wires are simultaneously widened.

[0009] In the above-mentioned method for manufacturing a conductor, it is preferable to form alternating slits in the conductive member, cut between adjacent slits having an opening on one side to reach a slit having an opening on the other side, and cut out the wire.

[0010] A conductor manufacturing apparatus according to one aspect of the present disclosure is an apparatus for manufacturing a conductor used in a motor, comprising: a cutting unit that cuts out a pine-needle-shaped wire having slits from a strip-shaped conductive member having slits; A first holding portion that holds an end portion of the wire rod on a side of the connecting portion; a second holding portion that holds one end of the wire on the side of the open portion; a third holding portion that holds the other end of the wire on the side of the open portion; a drive unit that moves the second holding unit and the third holding unit so as to widen the slit in the wire; Equipped with. Effect of the Invention

[0011] According to the present disclosure, it is possible to realize a conductor wire manufacturing method and a conductor wire manufacturing apparatus that contribute to improving yield. [Brief description of the drawings]

[0012] [Figure 1] 11A to 11C are diagrams for explaining a process of cutting wire material from a conductive member and stacking the wire material in the conductive wire manufacturing method according to the embodiment. [Diagram 2] 5A to 5C are diagrams for explaining how wire is cut out from a conductive member in the conductor manufacturing method of the embodiment. [Diagram 3]11A to 11C are diagrams for explaining a step of widening slits in overlapping wires in the conductor manufacturing method of the embodiment. [Figure 4] 11A to 11C are diagrams for explaining a process of covering the wire with an expanded slit with an insulating coating in the conductor manufacturing method of the embodiment. [Diagram 5] 13A and 13B are diagrams for explaining a state in which a wire is cut out from a conductive member in another embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Hereinafter, specific embodiments to which the present disclosure is applied will be described in detail with reference to the drawings. However, the present disclosure is not limited to the following embodiments. In addition, in order to clarify the description, the following description and drawings are appropriately simplified. Here, in the following description, in order to clarify the description, a three-dimensional (XYZ) coordinate system is used.

[0014] Fig. 1 is a diagram for explaining the process of cutting wire from a conductive member and stacking the wire in the conductor manufacturing method of the present embodiment. Fig. 2 is a diagram for explaining the state of cutting wire from a conductive member in the conductor manufacturing method of the present embodiment.

[0015] Fig. 3 is a diagram for explaining a step of widening the slits in the stacked wires in the conductor manufacturing method of the present embodiment. Fig. 4 is a diagram for explaining a step of covering the wires with the widened slits with an insulating coating in the conductor manufacturing method of the present embodiment.

[0016] The conductor manufacturing method and conductor manufacturing device of this embodiment are suitable for manufacturing conductors such as U-shaped or V-shaped segment coils wound around the stator core or rotor core of a motor. In the conductor manufacturing method of this embodiment, first, a conductive member 1 such as a wound strip-shaped copper plate as shown in Fig. 1(a) is prepared.

[0017] Next, as shown in Figures 1(b) and 1(c), the conductive member 1 is sent to the Y-axis + side and passed through a roller leveler 11 of a conductor manufacturing apparatus 10 to adjust the parallelism between the Z-axis + side surface and the Z-axis - side surface of the conductive member 1. The conductive member 1 after the adjustment is then passed through a cutting section 12 of the conductor manufacturing apparatus 10 to form a slit 2 and cut out a wire 3 from the conductive member 1.

[0018] In detail, the cutting section 12 of the conductor manufacturing apparatus 10 is equipped with, for example, a press machine, and as shown in FIG. 2, in the conductive member 1, starting from the Y-axis + side, alternately forms, as slits 2, a first slit 4 having an opening on the X-axis + side and being approximately isosceles triangular when viewed from the Z-axis direction, and a second slit 5 having an opening on the X-axis - side and being approximately isosceles triangular when viewed from the Z-axis direction.

[0019] 2, the first slits 4 are disposed between the oblique sides of the second slits 5 adjacent to each other in the Y-axis direction. Incidentally, it is preferable that the length of the second slits 5 in the X-axis direction is longer than the length of the first slits 4 in the X-axis direction.

[0020] Then, as shown in FIG. 2, the cutting unit 12 of the conductor manufacturing apparatus 10 cuts between adjacent second slits 5 in the Y-axis direction of the conductive member 1, starting from the Y-axis + side, until it reaches the end of the first slit 4 on the X-axis - side, and cuts out a wire 3 as shown in FIG. 1(c).

[0021] 2, the cut portion of the conductive member 1 is indicated by a dashed line, and for example, the cut portion is substantially parallel to the XZ plane and extends substantially in the X-axis direction. Also, in FIG. 1(c), the upper side shows a view of the wire 3 seen from the Z-axis + side, and the lower side shows a view of the wire 3 seen from the X-axis + side.

[0022] As shown in FIG. 1(c), the wire 3 has, for example, a second slit 5 (i.e., slit 2) and is formed into a pine-needle-shaped rectangular wire having a connecting portion on the X-axis + side and an open portion on the X-axis - side.

[0023] Next, as shown in Fig. 1(d), the wires 3 are stacked in the Z-axis direction in an equal arrangement to each other. Here, Fig. 1(d) shows a view of the wire 3 stacked on the upper side as seen from the Z-axis + side, and a view of the wire 3 stacked on the lower side as seen from the X-axis + side.

[0024] Next, as shown in FIG. 3(a), a first holding unit 13 of the conductor manufacturing apparatus 10 holds the end portion of the stacked wire 3 on the connection side, a second holding unit 14 of the conductor manufacturing apparatus 10 holds the end portion of the stacked wire 3 on the + side of the Y axis on the open portion side, and a third holding unit 15 of the conductor manufacturing apparatus 10 holds the end portion of the stacked wire 3 on the - side of the Y axis on the open portion side.

[0025] The first holding portion 13, the second holding portion 14 and the third holding portion 15 of the conductor manufacturing apparatus 10 are configured to hold the ends of the stacked wire 3, for example, using a collet chuck, and the second holding portion 14 and the third holding portion 15 can be moved toward and away from each other in the Y-axis direction by a drive portion not shown.

[0026] Next, as shown in FIG. 3(b), the drive unit of the conductor manufacturing apparatus 10 separates the second holding units 14 from each other in the Y-axis direction, thereby widening the slits 2 in the stacked wires 3 to the desired size.

[0027] 3(c), the end of the wire 3 is released from the first holding unit 13, the second holding unit 14, and the third holding unit 15 of the conductor manufacturing apparatus 10. Thereafter, for example, a crank portion formed in a typical segment coil may be formed in the wire 3.

[0028] Next, the wire 3 with the widened slits 2 is covered with an insulator. In detail, for example, as shown in Fig. 4(a) to Fig. 4(c), an insulating coating 17 having high self-adhesive properties such as polyimide is floated on hydraulic oil (such as ATF) 16, and the wire 3 with the widened slits 2 is moved to the side of the hydraulic oil 16 and inserted into the hydraulic oil 16 so that the wire 3 is covered with the insulating coating 17.

[0029] In this way, the wire 3 covered with the insulating coating 17 can be obtained as a conductor for use in a motor. At this time, the wire 3 can be covered with the insulating coating 17 while the air is pushed out by the hydraulic pressure. Note that the end of the wire 3 on the side of the open portion may be masked so that the end of the wire 3 on the side of the open portion is not covered with the insulating coating 17.

[0030] In this manner, the conductor manufacturing method and conductor manufacturing apparatus 10 of the present embodiment cuts out pine-needle-shaped wire 3 having slits 2 from the conductive material 1, and then widens the slits 2 in the wire 3. As a result, compared to the case of punching out a continuous coil wire in a U-shaped zigzag pattern from a winding material as in Patent Document 1, the wire 3 can be obtained more efficiently from the conductive material 1, which contributes to improving yields.

[0031] Furthermore, if the wire 3 is covered with the insulating coating 17 and then the slit 2 in the wire 3 is widened, the area of ​​the insulating coating 17 covering the bent portion of the wire 3 will become thin-walled. However, in this embodiment, the slit 2 in the wire 3 is widened and then the wire 3 is covered with the insulating coating 17, so that the insulating coating 17 can be prevented from becoming thin-walled. Moreover, by cutting out the wire 3 from the conductive member 1, a rectangular wire can be easily obtained.

[0032] In this embodiment, one wire 3 is cut out in sequence from the Y-axis + side of the conductive member 1; however, for example, as shown in FIG. 5, two wires 3 may be cut out from a conductive member 1 in which the first slit 4 and the second slit 5 are arranged in line symmetry with respect to the axis AX extending in the Y-axis direction when viewed from the Z-axis direction, and the number of wires 3 to be cut out is not limited.

[0033] In addition, in this embodiment, the wire rod 3 is cut out from the conductive member 1 by a progressive press, but for example, a transfer press or a tandem press may be used to cut out the wire rod 3 from the conductive member 1. Also, the wire rod 3 may be cut out from the conductive member 1 by an NC lathe, a CO2 laser, metal cutting scissors, or the like. In short, the means for cutting out the wire rod 3 from the conductive member 1 is not limited.

[0034] In the present embodiment, the wires 3 are stacked in the Z-axis direction to widen the slits 2 of the wires 3, but the slits 2 may be widened for each wire 3.

[0035] In addition, in this embodiment, the wire 3 is covered with the insulating coating 17 by hydraulic transfer, but the wire 3 may be covered with the insulating coating 17 by UV curing, injection molding, transfer molding, vacuum forming, casting, or the like. In addition, the material of the insulating coating 17 is not limited to thermoplastic resin or thermosetting resin, and may be insulating ceramics such as glass or enamel.

[0036] At this time, the conductor manufacturing method of this embodiment can prevent the insulating coating 17 from becoming thin, as described above, so that an inexpensive ceramic coating can be used as the insulating coating 17.

[0037] In the present embodiment, the first slit 4 and the second slit 5 are formed in the conductive member 1, but it is sufficient that at least one of them is formed.

[0038] The present disclosure is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit and scope of the present disclosure. [Explanation of symbols]

[0039] 1 Conductive material 2 slit, 4 first slit, 5 second slit 3 wire rod 10 Conductor manufacturing device, 11 Roller leveller, 12 Cutting section, 13 First holding section, 14 Second holding section, 15 Third holding section 16 Hydraulic oil 17 Insulation coating

Claims

1. A method for manufacturing a conductor used in a motor, comprising the steps of: forming slits in a strip-shaped conductive member; cutting out a pine-needle-shaped wire having the slits from the conductive member; widening the slit in the wire; A method for manufacturing a conductor comprising:

2. The method for manufacturing a conductor wire according to claim 1 , further comprising the step of covering the wire with the widened slits with an insulating coating.

3. The method for producing a conductor wire according to claim 1 or 2, further comprising overlapping a plurality of the wires and simultaneously widening the slits of the plurality of wires.

4. 3. The method for manufacturing a conductor according to claim 1 or 2, further comprising forming alternating slits in the conductive member, and cutting between adjacent slits having an opening on one side to reach a slit having an opening on the other side to cut out the wire.

5. A manufacturing device for a conductor used in a motor, comprising: a cutting unit that cuts out a pine-needle-shaped wire having slits from a strip-shaped conductive member having slits; a first holding portion that holds an end portion of the wire rod on a side of the connecting portion; a second holding portion that holds one end of the wire on the side of the open portion; a third holding portion that holds the other end of the wire on the side of the open portion; a drive unit that moves the second holding unit and the third holding unit so as to widen the slit in the wire; A conductor manufacturing apparatus comprising:

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