Flat wire distortion removal device

Abstract

To provide a flat wire distortion removal device contributing to suppression of processing failure of the flat wire.SOLUTION: A flat wire distortion removal device (1) according to an embodiment of the disclosure has a roller leveler (3) for allowing a flat wire (5) to pass between paring rollers (31, 32), and correcting mutual parallelism between side faces arranged on both sides in the width direction of the flat wire (5). The roller leveler (3) includes a press member (33) for suppressing rotation of the flat wire (5) around a shaft extending in the long direction of the flat wire (5).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a distortion removal device for flat square wire, for example, a distortion removal device for flat square wire having a roller leveler that passes the flat square wire between a pair of rollers to adjust the parallelism of the side surfaces located on both sides of the flat square wire in the width direction. [Background technology]

[0002] Generally, flat wires are delivered wound on a reel, and before bending the flat wire to form an edgewise coil, they are processed using a roller leveler to remove distortion. In this case, as disclosed in Patent Document 1, for example, the flat wire is passed between a pair of rollers of the roller leveler to remove distortion. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-235560 Summary of the Invention [Problem to be solved by the invention]

[0004] The applicant has discovered the following problem. To improve motor output, it is necessary to increase the number of turns of the rectangular wire. Therefore, it is preferable to reduce the thickness of the rectangular wire. In this case, because the corners of the rectangular wire are rounded, the flat portions of the side surfaces located on both sides of the rectangular wire in the width direction are reduced.

[0005] Therefore, as shown in Figure 5, when a roller leveler is used to achieve parallelism on the sides of the flat wire 5 on both sides in the width direction, that is, to remove distortion in the width direction of the flat wire 5, the flat wire 5 may tilt between the rollers 101, resulting in poor processing of the flat wire 5.

[0006] The present disclosure has been made in consideration of such problems, and realizes a distortion removal device for flat wire that contributes to suppressing processing defects in flat wire. [Means for solving the problem]

[0007] The flat wire distortion removal device according to one aspect of the present disclosure is a flat wire distortion removal device having a roller leveler that passes the flat wire between a pair of rollers and performs parallelism of the side surfaces arranged on both sides of the flat wire in the width direction, The roller leveler includes a pressing portion for suppressing rotation of the rectangular wire around an axis extending in the length direction of the rectangular wire. [Effects of the Invention]

[0008] According to the present disclosure, it is possible to realize a distortion removal device for flat wire that contributes to suppressing processing defects in flat wire. [Brief explanation of the drawings]

[0009] [Figure 1] (a) is a diagram showing a flat wire distortion removal device of embodiment 1, (b) is a diagram showing the roller arrangement of the first roller leveler of the flat wire distortion removal device of embodiment 1 as viewed from the X-axis + side, (c) is a diagram showing the first roller leveler of the flat wire distortion removal device of embodiment 1 as viewed from the Y-axis - side, and (d) is a diagram showing the second roller leveler of the flat wire distortion removal device of embodiment 1 as viewed from the Y-axis - side. [Figure 2] FIG. 1 is a diagram showing a typical rectangular wire. [Figure 3] 10 is a view of the second roller leveler of the flat wire distortion removal device of the second embodiment, seen from the Y-axis - side. FIG. [Figure 4] 11 is a view of the second roller leveler of the flat wire distortion removal device of the third embodiment, seen from the Y-axis - side. FIG. [Figure 5] 1A and 1B are diagrams for explaining problems with a general roller leveler. DETAILED DESCRIPTION OF THE INVENTION

[0010] Specific embodiments to which the present disclosure is applied will be described in detail below with reference to the drawings. However, the present disclosure is not limited to the following embodiments. For clarity of explanation, a three-dimensional (XYZ) coordinate system will be used for explanation, and the following description and drawings will be simplified as appropriate.

[0011] <First Embodiment> First, the structure of the flat wire distortion elimination device (hereinafter, sometimes simply referred to as distortion elimination device) of this embodiment will be described. The distortion elimination device of this embodiment is suitable for removing distortion from a flat wire before bending the flat wire to form an edgewise coil used in a motor, for example.

[0012] Figure 1(a) is a diagram showing a strain relief device of this embodiment, Figure 1(b) is a diagram showing the roller arrangement of the first roller leveler of the strain relief device of this embodiment as seen from the X-axis + side, Figure 1(c) is a diagram showing the first roller leveler of the strain relief device of this embodiment as seen from the Y-axis - side, and Figure 1(d) is a diagram showing the second roller leveler of the strain relief device of this embodiment as seen from the Y-axis - side. Figure 2 is a diagram showing a general rectangular wire. Note that Figure 1(a) shows a simplified view of the strain relief device.

[0013] As shown in Figure 1(a), the distortion removal device 1 of this embodiment is equipped with a first roller leveler 2, a second roller leveler 3, and a feeding device 4, and is configured so that the flat wire 5 is fed from a reel 6 on which the flat wire 5 is wound to the first roller leveler 2 and the second roller leveler 3 by the feeding device 4.

[0014] 2, the flat wire 5 has a conductor 51 covered with an insulating coating 52. For example, the flat wire 5 is a long member whose XZ cross section is substantially rectangular, and R portions (curved portions) 53 are formed at the corners of the flat wire 5. In this case, when the so-called aspect ratio of the flat wire 5, which is expressed by the width dimension in the X-axis direction (width direction) / thickness dimension in the Z-axis direction (thickness direction), is larger than that of a general flat wire 5, the distortion removal device 1 of this embodiment is particularly suitable.

[0015] The first roller leveler 2 adjusts the parallelism between the surface of the rectangular wire 5 on the +Z-axis side and the surface of the rectangular wire 5 on the -Z-axis side, i.e., removes distortion in the Z-axis direction of the rectangular wire 5. As shown in Figure 1(a), the first roller leveler 2 is disposed on the +Y-axis side of the reel 6. As shown in Figures 1(b) and 1(c), the first roller leveler 2 includes a first roller 21 and a second roller 22.

[0016] The first roller 21 is, for example, as shown in Figures 1(b) and 1(c), a roughly cylindrical member made of metal extending in the X-axis direction, and the width dimension of the first roller 21 in the X-axis direction is equal to or greater than the width dimension of the flat wire 5 in the X-axis direction.

[0017] As shown in Fig. 1(c), the first roller 21 is rotatably supported on a rotary shaft 24 via a bearing 23. The rotary shaft 24 extends in the X-axis direction, and the end of the rotary shaft 24 on the negative X-axis side is fixed to a side wall portion 25 of the first roller leveler 2. As shown in Fig. 1(b), the first rollers 21 are arranged at predetermined intervals in the Y-axis direction.

[0018] 1(b) and 1(c), the second roller 22 is disposed on the positive side of the Z axis relative to the first roller 21 when viewed from the Y axis direction, and is disposed with a predetermined distance (e.g., a desired thickness dimension of the rectangular wire 5) between it and the first roller 21 in the Z axis direction. In other words, the first roller 21 and the second roller 22 form a pair when viewed from the Y axis direction. In this case, the peripheral surfaces of the first roller 21 and the second roller 22 are disposed approximately parallel when viewed from the Y axis direction, and are also approximately parallel to the X axis.

[0019] The second rollers 22 have substantially the same configuration as the first rollers 21, and therefore will not be described here. However, they are substantially cylindrical metal members extending in the X-axis direction, and as shown in FIG. 1(c), are rotatably supported on a rotation shaft 27 via a bearing 26. As shown in FIG. 1(b), the second rollers 22 are arranged at a predetermined interval in the Y-axis direction. In this case, the second rollers 22 are arranged between the first rollers 21 when viewed from the Z-axis direction.

[0020] The second roller leveler 3 adjusts the parallelism between the surface of the rectangular wire 5 on the positive side of the X axis and the surface of the rectangular wire 5 on the negative side of the X axis, i.e., removes distortion in the X axis direction of the rectangular wire 5. As shown in FIG. 1(a), the second roller leveler 3 is disposed on the positive side of the Y axis relative to the first roller leveler 2. As shown in FIG. 1(d), the second roller leveler 3 includes a first roller 31, a second roller 32, and a pressing portion 33.

[0021] The first roller 31 is, for example, as shown in FIG. 1(d), a substantially cylindrical member made of metal extending in the Z-axis direction, and the height dimension of the first roller 31 in the Z-axis direction is equal to or greater than the thickness dimension of the rectangular wire 5 in the Z-axis direction.

[0022] As shown in Fig. 1(d), the first roller 31 is rotatably supported on a rotating shaft 35 via a bearing 34. The rotating shaft 35 extends in the Z-axis direction, and the end of the rotating shaft 35 on the negative Z-axis side is fixed to a bottom 36 of the second roller leveler 3. As shown in Fig. 1(a), the first rollers 31 are arranged at predetermined intervals in the Y-axis direction.

[0023] 1(d), the second roller 32 is disposed on the negative side of the X-axis relative to the first roller 31 when viewed from the Y-axis direction, and is disposed with a predetermined distance (e.g., the desired width dimension of the rectangular wire 5) between it and the first roller 31 in the X-axis direction. In other words, as shown in FIG. 1(d), the first roller 31 and the second roller 32 form a pair when viewed from the Y-axis direction. In this case, the circumferential surfaces of the first roller 31 and the second roller 32 are disposed approximately parallel when viewed from the Y-axis direction, and are also approximately parallel to the Z-axis.

[0024] The second rollers 32 have substantially the same configuration as the first rollers 31, and therefore a description thereof will be omitted, but as shown in FIG. 1(d), they are substantially cylindrical metal members extending in the Z-axis direction, and are rotatably supported on a rotation shaft 38 via a bearing 37. As shown in FIG. 1(a), the second rollers 32 are arranged at a predetermined interval in the Y-axis direction. In this case, the second rollers 32 are arranged between the first rollers 31 when viewed from the X-axis direction.

[0025] The pressing portion 33 suppresses rotation of the rectangular wire 5 around the Y-axis, i.e., tilt of the rectangular wire 5. As shown in Fig. 1(d), the pressing portion 33 includes a first pressing plate 39 and a second pressing plate 40. The first pressing plate 39 is, for example, a substantially rectangular plate extending in the Y-axis direction when viewed from the Z-axis direction, and the surface of the first pressing plate 39 on the +Z-axis side has a flat surface that is substantially parallel to the XY plane.

[0026] As shown in Fig. 1(d), the width dimension of the first pressing plate 39 in the X-axis direction should be approximately equal to the width dimension of the rectangular wire 5 in the X-axis direction. Also, as shown in Fig. 1(a), the length of the first pressing plate 39 in the Y-axis direction should be long enough to cover the area where the first roller 31 and the second roller 32 of the second roller leveler 3 are arranged when viewed from the Y-axis direction.

[0027] However, the width dimension of the first pressing plate 39 in the X-axis direction and the length of the first pressing plate 39 in the Y-axis direction may be set appropriately so that when the flat wire 5 tries to tilt, it comes into contact with the flat wire 5 to suppress the tilt.

[0028] The first pressing plate 39 is preferably made of, for example, metal, but may be made of any material that does not wear down when it comes into contact with the rectangular wire 5. The first pressing plate 39 is fixed to, for example, the bottom 36 of the second roller leveler 3.

[0029] The second pressure plate 40 is arranged on the positive side of the Z axis relative to the first pressure plate 39 when viewed from the Y axis direction, as shown in Figure 1(d), for example, and is arranged at a predetermined distance from the first pressure plate 39 in the Z axis direction (for example, a distance at which the flat wire 5 does not substantially come into contact when the flat wire 5 moves).

[0030] The second pressure plate 40 is symmetrical with respect to the first pressure plate 39, with an axis extending in the Y-axis direction as the axis of symmetry, so a detailed explanation will be omitted, but it is an approximately rectangular plate extending in the Y-axis direction when viewed from the Z-axis direction, and is fixed, for example, to the ceiling part (not shown) of the second roller leveler 3.

[0031] The feeding device 4 pulls out the rectangular wire 5 from the reel 6 and feeds it between the first roller 21 and the second roller 22 of the first roller leveler 2 and between the first roller 31 and the second roller 32 of the second roller leveler 3.

[0032] As shown in Fig. 1(a), the feeding device 4 is disposed on the + side of the Y axis relative to the second roller leveler 3. The feeding device 4 is equipped with a clamping mechanism that grips the rectangular wire 5, and is configured so that the rectangular wire 5 is drawn into the + side of the Y axis by the feeding device 4 being drawn into the + side of the Y axis as shown by the dashed line in Fig. 1(a).

[0033] Next, we will explain the process of parallelizing the rectangular wire 5 using the distortion removal device 1 of this embodiment. First, the rectangular wire 5 is drawn to the +Y axis side by the feed device 4 and fed between the first roller 21 and the second roller 22 of the first roller leveler 2.

[0034] The first roller 21 of the first roller leveler 2 rotates while contacting the negative Z-axis surface of the rectangular wire 5, and the second roller 22 of the first roller leveler 2 rotates while contacting the positive Z-axis surface of the rectangular wire 5. This ensures parallelism between the positive Z-axis surface and the negative Z-axis surface of the rectangular wire 5. In other words, distortion of the rectangular wire 5 in the Z-axis direction is removed.

[0035] Next, the rectangular wire 5 drawn to the +Y-axis side by the feeder 4 is fed between the first roller 31 and the second roller 32 of the second roller leveler 3. The first roller 31 of the second roller leveler 3 rotates while contacting the +X-axis side surface of the rectangular wire 5, and the second roller 32 of the second roller leveler 3 rotates while contacting the -X-axis side surface of the rectangular wire 5. This ensures the parallelism between the +X-axis side surface and the -X-axis side surface of the rectangular wire 5. In other words, the distortion of the rectangular wire 5 in the X-axis direction is removed.

[0036] At this time, since the first pressing plate 39 and the second pressing plate 40 of the pressing part 33 are arranged with the flat wire 5 between them in the Z-axis direction, it is possible to prevent the flat wire 5 from tilting around the Y-axis when the flat wire 5 passes between the first roller 31 and the second roller 32. Therefore, it is possible to ensure good parallelism between the surface of the flat wire 5 on the X-axis + side and the surface on the X-axis - side, and it is possible to prevent poor processing of the flat wire 5.

[0037] In addition, the first roller leveler 2 is disposed on the negative Y-axis side relative to the second roller leveler 3, and distortion in the Z-axis direction of the flat wire 5 is removed when the flat wire 5 is fed into the second roller leveler 3. Therefore, when the flat wire 5 is fed into the second roller leveler 3, the surfaces on the positive Z-axis side and the negative Z-axis side of the flat wire 5 can be prevented from coming into strong contact with the first pressing plate 39 and the second pressing plate 40 of the pressing section 33. Therefore, processing defects of the flat wire 5 can be further reduced.

[0038] In this way, the distortion removal device 1 of this embodiment is configured so that when the flat wire 5 passes through the second roller leveler 3, the first pressing plate 39 and the second pressing plate 40 of the pressing section 33 are arranged in the Z-axis direction with the flat wire 5 between them.

[0039] This prevents the flat wire 5 from tilting around the Y-axis when it passes between the first roller 31 and the second roller 32. This ensures good parallelism between the surface of the flat wire 5 on the positive side of the X-axis and the surface on the negative side of the X-axis, preventing defective processing of the flat wire 5.

[0040] <Embodiment 2> 3 is a view of the second roller leveler of the strain relief device of this embodiment as seen from the Y-axis - side. The strain relief device of this embodiment has substantially the same configuration as the strain relief device 1 of embodiment 1, so duplicated explanations will be omitted and the same members will be described using the same reference numerals.

[0041] The strain relief device of this embodiment differs from the strain relief device 1 of embodiment 1 in the configuration of the pressing unit. As shown in Fig. 3, the pressing unit 201 includes a pressing plate 202 and a pressing roller 203. The pressing plate 202 has substantially the same configuration as the first pressing plate 39 of embodiment 1.

[0042] 3, the pressure roller 203 sandwiches the rectangular wire 5 fed into the second roller leveler in the Z-axis direction between the pressure plate 202 and the pressure roller 203, thereby suppressing tilt of the rectangular wire 5 around the Y-axis. The pressure roller 203 is disposed on the positive side of the Z-axis relative to the pressure plate 202 when viewed from the Y-axis direction.

[0043] 3, the pressure roller 203 is a substantially cylindrical member made of metal that extends in the X-axis direction, and is rotatably supported on a rotation shaft 205 via a bearing 204. The rotation shaft 205 extends in the X-axis direction, and the end of the rotation shaft 205 on the positive side of the X-axis is fixed to the side wall of the second roller leveler.

[0044] At this time, the peripheral surface of the pressure roller 203 is approximately parallel to the X-axis when viewed from the Y-axis direction, as shown in Fig. 3. The pressure roller 203 is disposed so as to be able to press the rectangular wire 5 fed into the second roller leveler at approximately the center in the Y-axis direction.

[0045] Here, the width dimension of the pressure roller 203 in the X-axis direction may be appropriately set so that the flat wire 5 fed into the second roller leveler is sandwiched between the pressure plate 202 and the pressure roller 203 in the Z-axis direction, thereby suppressing the tilt of the flat wire 5. In this case, the pressure rollers 203 are preferably arranged at intervals in the Y-axis direction.

[0046] The pressing unit 201 of this configuration is configured to sandwich the flat wire 5 sent into the second roller leveler between the pressing plate 202 and the pressing roller 203 in the Z-axis direction. This can prevent the flat wire 5 from tilting around the Y-axis when passing between the first roller 31 and the second roller 32. Therefore, the strain removal device of this embodiment can also ensure good parallelism between the surface of the X-axis + side and the surface of the X-axis - side of the flat wire 5, and can prevent poor processing of the flat wire 5.

[0047] Although the pressing portion 201 of this embodiment includes the pressing plate 202, the pressing plate 202 may be replaced with a pressing roller.

[0048] <Third Embodiment> 4 is a view of the second roller leveler of the strain relief device of this embodiment as seen from the Y-axis - side. The strain relief device of this embodiment has substantially the same configuration as the strain relief device 1 of embodiment 1, so duplicated explanations will be omitted and the same members will be described using the same reference numerals.

[0049] 4, the strain relief device of this embodiment is configured such that the first pressing plate 39 and the second pressing plate 40 are omitted from the strain relief device 1 of embodiment 1, and the first groove 301 formed in the first roller 31 and the second groove 302 formed in the second roller 32 function as the pressing section 303. In other words, the pressing section 303 of this embodiment includes the first groove 301 and the second groove 302.

[0050] 4, the first grooves 301 are generally rectangular and are formed on the circumferential surface of the first roller 31. The first grooves 301 are arranged in the circumferential direction of the first roller 31. The height dimension of the first grooves 301 in the Z-axis direction is preferably approximately equal to the thickness dimension of the rectangular wire 5 in the Z-axis direction.

[0051] 4, the second grooves 302 are generally rectangular and are formed on the circumferential surface of the second roller 32. The second grooves 302 are arranged in the circumferential direction of the second roller 32. The height dimension of the second grooves 302 in the Z-axis direction is preferably approximately equal to the thickness dimension of the rectangular wire 5 in the Z-axis direction.

[0052] The first groove 301 and the second groove 302 are disposed at approximately the same height in the Z-axis direction. When the rectangular wire 5 passes between the first roller 31 and the second roller 32, the side surface of the rectangular wire 5 on the +X-axis side contacts the bottom surface of the first groove 301 (i.e., the surface extending in the Z-axis direction), and the side surface of the rectangular wire 5 on the -X-axis side contacts the bottom surface of the second groove 302.

[0053] The pressing portion 303 having such a configuration is configured so that the end portion on the +X-axis side of the flat wire 5 fed into the second roller leveler is inserted into the first groove portion 301, and the end portion on the -X-axis side of the flat wire 5 is inserted into the second groove portion 302.

[0054] This can prevent the flat wire 5 from tilting around the Y-axis when passing between the first roller 31 and the second roller 32. Therefore, the strain removal device of this embodiment can also ensure the parallelism between the surface of the X-axis + side and the surface of the X-axis - side of the flat wire 5, and can prevent the processing defects of the flat wire 5.

[0055] The present disclosure is not limited to the above-described embodiment, and can be modified as appropriate within the scope of the present disclosure. For example, the configuration of the pressing portion in the above embodiment is merely an example, and any configuration may be used as long as it can suppress the inclination of the rectangular wire 5 fed into the second roller leveler about the Y axis. For example, the arrangement and materials of the rollers of the first roller leveler 2 in the above embodiment are examples and can be changed as needed. Similarly, the arrangement and materials of the rollers of the second roller leveler 3 in the above embodiment are examples and can be changed as needed. [Explanation of symbols]

[0056] 1. Rectangular wire distortion removal device 2. First Roller Leveler 21 First Roller 22 The Second Roller 23 Bearings 24 Rotation Axis 25 Side wall portion of second roller leveler 26 Bearings 27 Rotation axis 3 Second Roller Leveler 31 First Roller 32 Second Roller 33 Presser foot 34 Bearings 35 Rotation axis 36 Bottom of the second roller leveler 37 Bearings 38 Rotation axis 39 First holding plate 40 Second pressure plate 4 Feeder 5. Flat wire 51 Conductor 52 Insulation coating 53 R part of rectangular wire 6 reels 201 Holding part 202 Presser plate 203 Presser roller 204 Bearings 205 Rotational Axis 301 First groove 302 Second groove 303 Holding part

Claims

[Claim 1] A flat wire distortion removal device having a roller leveler that passes a flat wire between a pair of rollers to make the sides of the flat wire parallel to each other, which are arranged on both sides in the width direction of the flat wire, The roller leveler includes a pressing portion for suppressing rotation of the flat wire around an axis extending in the length direction of the flat wire, The flat wire distortion removal device is characterized in that the pressing section comprises a first pressing plate arranged to face a first surface arranged on one side of the flat wire in the thickness direction, and a second pressing plate arranged to face a second surface arranged on the other side of the flat wire in the thickness direction, and the first pressing plate and the second pressing plate are arranged at a distance greater than the thickness of the flat wire.

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