Molding method of form block

Abstract

To provide a molding method which can mold a form block satisfying requirements of hardness, accuracy and surface roughness.SOLUTION: A molding method molding a form block 20 to mold a segment coil 10 of a motor comprises the steps of: creating slice data of the form block 20 to be molded; and molding the form block 20 consisting of high function resin through optical fabrication by a penetration type liquid crystal method or a digital mirror device method based on the slice data created by the creating step. Anti-iris processing is included when creating the slice data at the creating step.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present invention relates to a method for shaping a mold.

Background Art

[0002] Patent Document 1 discloses a technique for manufacturing a bending die having a concave portion with an opening width shorter than the groove width and having a three-dimensional profile for fitting a tube into the concave portion and performing shaping. In this manufacturing method, a smooth shape formed by virtually continuously moving a profile including a first closed curve having a substantially circular shape with a concave portion in a three-dimensional space is designed, data of the shape is obtained, and a bending die of the shape is manufactured by a three-dimensional printing technique based on the data.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in a mold for shaping a motor coil such as a segment coil, it is required to suppress the influence of molding load, springback, etc. However, in the method described in Patent Document 1 above, it is difficult to manufacture a mold that sufficiently satisfies requirements such as strength, accuracy, and surface roughness while suppressing the influence of molding load, springback, etc.

[0005] The present invention has been made in view of the above circumstances, and an object thereof is to provide a shaping method capable of shaping a mold that satisfies the requirements of strength, accuracy, and surface roughness.

Means for Solving the Problems

[0006] In order to achieve the above object, the method for shaping a mold of the present invention is A shaping method for shaping a mold for a motor coil, a generation step of generating slice data of the mold to be shaped; a shaping step of shaping the mold made of a high-performance resin by optical shaping using a transmissive liquid crystal method or a digital micromirror device method based on the slice data generated in the generation step; including anti-aliasing processing is incorporated during the generation of the slice data in the generation step.

[0007] According to the shaping method of the mold with this configuration, since the mold made of a high-performance resin is shaped by optical shaping using a transmissive liquid crystal method or a digital micromirror device method, the strength and dimensional accuracy can be improved, and moreover, the deterioration of the surface roughness can be reduced by incorporating anti-aliasing processing during the generation of slice data. Thereby, it is possible to shape a mold for a motor coil such as a segment coil that needs to sufficiently satisfy requirements such as strength, accuracy, and surface roughness while suppressing the influence of forming load and springback.

Advantages of the Invention

[0008] According to the present invention, it is possible to provide a shaping method capable of shaping a mold that satisfies the requirements of strength, accuracy, and surface roughness.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3A

Figure 3B

Figure 4A

Figure 4B

Figure 5A

Figure 5B

Figure 6A

Figure 6B

Figure 6C

Figure 7

Figure 8

Figure 9

MODE FOR CARRYING OUT THE INVENTION

[0010] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[0011] (Molded article) FIG. 1 is a perspective view of a segment coil 10 formed by a mold 20. As shown in FIG. 1, in this example, the molded article is a segment coil 10 used for a motor. This segment coil 10 is, for example, a coil assembled to a stator core constituting a stator of a motor. The segment coil 10 is formed of a wire made of a conductive metal material such as copper or a copper alloy.

[0012] The segment coil 10 has a first bent portion 11, a second bent portion 12, and a third bent portion 13. The first bent portion 11 is formed in the middle portion of the segment coil 10 and is bent in the horizontal direction (X-Y direction) and the vertical direction (Z direction). The second bent portion 12 is formed near both ends of the segment coil 10 and is bent in the horizontal direction (X-Y direction) such that both ends are close to each other. The third bent portion 13 is formed on the end side rather than the second bent portion 12 and is bent in the vertical direction (Z direction), respectively.

[0013] (Molding die) FIG. 2 is a perspective view of a molding die 20 for molding the segment coil 10. As shown in FIG. 2, the molding die 20 is composed of a lower die 21, an upper die 22, and a movable die 23. These lower die 21, upper die 22, and movable die 23 are formed of a high-functional resin such as super engineering plastic, for example.

[0014] The lower die 21 has a molding surface 30 as a surface facing the upper die 22. A first lower step portion 31 and a second lower step portion 32 are formed on this molding surface 30. Further, recessed portions 33 are formed on both side portions at the upper edge of the molding surface 30.

[0015] The upper die 22 is pressed against the lower die 21 from above. The upper die 22 has a molding surface 35 as a surface facing the lower die 21. A first upper step portion 36 is formed at a position corresponding to the first lower step portion 31 of the lower die 21 on this molding surface 35. Further, convex portions 37 are formed on both side portions at the lower edge of the molding surface 35.

[0016] The movable die 23 is pressed against the lower die 21 and the upper die 22 from one side. Pressing protrusions 38, 39 project from the surfaces of the movable die 23 facing the lower die 21 and the upper die 22.

[0017] (Molding procedure) Next, the molding procedure of the segment coil 10 by the above molding die 20 will be described. FIG. 3A and FIG. 3B, FIG. 4A and FIG. 4B are perspective views of a mold showing the forming procedure of the first bent portion 11. FIG. 5A and FIG. 5B are perspective views of a mold showing the forming procedure of the second bent portion 12. FIG. 6A and FIG. 6B are perspective views of a wire showing the forming procedure of the first bent portion 11. FIG. �C is a perspective view of a wire showing the forming procedure of the second bent portion 12.

[0018] As shown in FIG. 3A, a wire 10A that will become the segment coil 10 is disposed between the lower mold 21 and the upper mold 22. Here, a wire 10A in which a third bent portion 13 has been formed in advance is disposed between the lower mold 21 and the upper mold 22.

[0019] As shown in FIG. 3B, by lowering the upper mold 22, the upper mold 22 is pressed against the lower mold 21. Thereby, as shown in FIG. 6A, the middle portion of the wire 10A is bent by the first lower portion 31 of the lower mold 21 and the first upper portion 36 of the upper mold 22.

[0020] As shown in FIG. 4A, a movable mold 23 disposed on one side of the lower mold 21 and the upper mold 22 is moved toward the lower mold 21 and the upper mold 22 as shown in FIG. 4B, and the pressing protrusions 38, 39 of the movable mold 23 are inserted between the lower mold 21 and the upper mold 22. Thereby, the wire 10A is pressed by the pressing protrusions 38, 39, and as shown in FIG. 6B, the middle portion of the conductor 10A is bent in the horizontal direction (X-Y direction). Thereby, the first bent portion 11 is formed in the middle portion of the conductor 10A.

[0021] As shown in FIG. 5A, pressing rollers 40 are disposed on both side portions of the movable mold 23, and as shown in FIG. 5B, these pressing rollers 40 are rolled along the butting portions of the lower mold 21 and the upper mold 22 with each other.

[0022] Then, the end portion of the conducting wire 10A that protruded laterally from the abutting portion between the lower mold 21 and the upper mold 22 is pushed by the pressing roller 40 between the concave portion 33 of the lower mold 21 and the convex portion 37 of the upper mold 22. As a result, as shown in FIG. 6C, a second bent portion 12 is formed near both ends of the conductor 10A. Then, a first bent portion 11 is formed in the middle portion of the conductor 10A, and further, a second bent portion 12 is formed near both ends. Thereby, the conductor 10A is formed into the segment coil 10 having the first bent portion 11, the second bent portion 12, and the third bent portion 13.

[0023] In this way, the molding die 20 is a molding die that imparts a molding load to the conducting wire 10A from two directions, the vertical direction and the horizontal direction, to mold the segment coil 10.

[0024] (Modeling method) Next, a modeling method according to the present embodiment for modeling the molding die 20 for molding the segment coil 10 will be described with reference to the flowchart shown in FIG. 7.

[0025] (1) Mold design process Design the molding die 20 to be modeled, and create 3D data of the target shape of the molding die 20 using 3DCAD, 3DCG software, etc. (step S1).

[0026] (2) Generation process Based on the 3D data of the target shape of the created molding die 20, generate slice data obtained by slicing the 3D data layer by layer (step S2). In the generation of this slice data, anti-aliasing processing is incorporated. Thereby, jaggies (aliasing) generated at inclined portions in the slice data obtained by slicing the 3D data layer by layer are suppressed to make the inclined portions smooth.

[0027] (3) Modeling process Based on the generated slice data, the mold 20 is laminated and formed by stereolithography (step S3). For the formation of the mold 20, a high-performance resin such as super engineering plastic with excellent mechanical properties, heat resistance, and durability is used. Also, in stereolithography, a stereolithography apparatus (3D printer) of a transmissive liquid crystal method (LCD: Liquid Crystal Display) or a digital mirror device method (DLP: Digital Light Processing) with high forming accuracy is used.

[0028] (4) Correction processing step Regarding the formed mold 20, the dimensions of each part are measured, and the dimensional accuracy is determined by comparing with the target shape consisting of the designed 3D model. Then, based on the determined dimensional accuracy, correction processing is performed as necessary to ensure the accuracy of the mold 20 (step S4).

[0029] (5) Coil forming step The segment coil 10 is formed using the formed mold 20 (step S5).

[0030] (6) Springback determination step Regarding the formed segment coil 10, the springback amount generated after forming is measured, and it is determined whether this springback amount is within a preset threshold value (step S6). As a result of the determination of the springback amount, if the springback amount is within the threshold value (step S6: Yes), the mold 20 is used as a good product for forming the segment coil 10. Also, as a result of the determination of the springback amount, if the springback amount exceeds the threshold value (step S6: No), the processes from the mold design step (step S1) to the coil forming step (step S5) are repeated so that the springback amount is within the threshold value.

[0031] As described above, according to the method for fabricating a mold according to the present embodiment, since the mold 20 made of a high-performance resin is fabricated by optical shaping using a transmissive liquid crystal method or a digital micromirror device method, it is possible to improve the strength and dimensional accuracy. Moreover, by incorporating anti-aliasing processing when generating slice data to suppress jagging (aliasing), it is possible to suppress deterioration of the surface roughness on the molding surface of the mold 20. As a result, it is possible to fabricate the mold 20 for molding a motor coil such as the segment coil 10 that needs to sufficiently satisfy requirements such as strength, accuracy, and surface roughness while suppressing the effects of molding load and springback.

[0032] In addition, in a general manufacturing method for manufacturing the mold 20 made of a mold, a process of generating machining data is required together with the arrangement of the profile material, and then machining the mold is required. However, in the present embodiment where the mold 20 is fabricated from a high-performance resin using an optical shaping device (3D printer), compared with the general manufacturing method, the lead time for fabricating the mold 20 after design can be shortened.

[0033] In addition, when the springback amount of the formed segment coil 10 exceeds the threshold value, the process for fabricating the mold 20 that requires a lead time for fabrication is repeated. Therefore, particularly when the springback amount exceeds the threshold value, in the present embodiment, compared with the general manufacturing method, the lead time for fabrication can be significantly shortened. For example, in the general manufacturing method, the lead time for fabrication is about three weeks, whereas according to the present embodiment, it can be suppressed to about one week. Therefore, when the fabrication of the mold 20 is repeated with the springback amount exceeding the threshold value, compared with the lead time for fabrication of the general manufacturing method (three weeks × number of repetitions N), the lead time for fabrication in the present embodiment (one week × number of repetitions N) can be significantly shortened.

[0034] Here, FIG. 8 is a diagram showing the inclination angle θ with respect to the lamination direction A in laminated manufacturing. FIG. 9 is a graph showing the relationship between the inclination angle θ and the surface roughness Ra. As shown in FIG. 8, in laminated manufacturing, the angle formed by the outer surface So, which is the design surface, with respect to the surface S orthogonal to the lamination direction A is the inclination angle θ. Further, as shown in FIG. 9, in laminated manufacturing, the surface roughness Ra can be suppressed more as the lamination pitch is smaller, and can be suppressed more as the inclination angle θ is larger. By applying the manufacturing method according to this embodiment, the surface roughness Ra can be suppressed to 10 μm and dimensional accuracy of ±0.05 mm can be ensured.

Explanation of Signs

[0035] 10 Segment coil (coil) 20 Mold

Claims

Claim 1 A shaping method for shaping a mold for a motor coil, comprising: a generating step of generating slice data of the mold to be shaped; a shaping step of shaping the mold made of a high-performance resin by optical shaping using a transmissive liquid crystal method or a digital mirror device method based on the slice data generated by the generating step; wherein anti-aliasing processing is incorporated during the generation of the slice data in the generating step; a method for shaping a mold.

Images