Flat wire processing apparatus and flat wire processing method

Abstract

To provide a flat wire processing device that can accurately shape flat wire. [Solution] A flat wire processing apparatus 10 is provided with a molding die 20 that presses and plastically deforms a flat wire 1, wherein the molding die 20 is arranged opposite to each other along the longitudinal direction of the flat wire 1 and clamps two main surfaces 2,2 that face each other in the short direction of the flat wire 1, and each of the pair of holding parts 21,21 is provided on both ends of the holding part 21 in the longitudinal direction and protrudes from the holding part 21 toward the main surfaces 2,2. The pair of protrusions 25,25 have a first inclined portion 26 that is inclined inward in the longitudinal direction of the holding part 21 toward the holding part 21 toward the holding part 21 toward the protruding end and a second inclined portion 28 that has a surface that faces outward in the longitudinal direction of the holding part 21 toward the holding part 21 toward the protruding end 25a toward the holding part 21.

Description

Technical Field

[0001] The present invention relates to a flat angle wire processing apparatus and a flat angle wire processing method for processing flat angle wires.

Background Art

[0002] Conventionally, motors used in electric vehicles, hybrid vehicles, etc. have stator coils incorporated therein. In order to form the above-mentioned stator coils, flat angle wires with a rectangular cross-section are used (for example, Patent Document 1). The prior art described in Patent Document 1 is supposed to remove an insulating film (insulator) coated on the surface of the flat angle wire and perform chamfering of the terminals.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Incidentally, the prior art described in Patent Document 1, as shown in Figure 11, involves removing the insulating coating 501 from the longitudinal side of the rectangular wire 500, and then forming the rectangular wire 500 by clamping it in the longitudinal direction between a pair of concave upper and lower molding dies 550, 550 to perform chamfering. In the molding process described above, as shown in Figure 11(a), the molding surface 551 of the molding die 550 is provided with a pair of inclined surfaces 552, 552 that are tapered inclined from the opening end of the molding die 550 toward the inside of the bottom surface. Therefore, as shown in Figure 11(b), when the two main surfaces 502, 502 facing each other in the longitudinal direction of the rectangular wire 500 are clamped by the pair of molding dies 550, 550, the material of the rolled rectangular wire 500 flows toward the longitudinal side of the main surfaces 502, 502 along the inclination of each inclined surface 552. Therefore, in the prior art described in Patent Document 1 mentioned above, there was a problem in that the two main surfaces 502, 502 of the molded rectangular wire 500 expanded and curved, as shown in Figure 11(c).

[0005] Therefore, the present invention aims to provide a flat wire processing apparatus and flat wire processing method that can accurately form flat wires, as well as a flat wire processing apparatus and flat wire processing method that can reduce costs. [Means for solving the problem]

[0006] (1) The present invention, provided to solve the above-mentioned problems, is a flat wire processing apparatus comprising a molding die for pressing and plastically deforming a flat wire, wherein the molding die comprises a pair of holding parts arranged opposite to each other along the longitudinal direction of the flat wire and clamping two main surfaces facing each other in the short direction of the flat wire, and a pair of protruding parts provided on both ends of the holding part in the longitudinal direction and protruding from the holding part toward the main surface, wherein the pair of protruding parts comprises a first inclined part that inclins inward in the longitudinal direction of the holding part toward the holding part side from the protruding end, and a second inclined part having a surface that faces outward in the longitudinal direction of the holding part toward the holding part side from the protruding end.

[0007] The flat wire processing apparatus of the present invention suppresses the expansion of the two main surfaces of the flat wire by the holding part, and the first and second inclined parts of the protruding part can distribute the flow of the flesh (material) in the flat wire to the first inclined part side and the second inclined part side. As a result, the flat wire processing apparatus of the present invention can suppress the concentration of the flesh in the flat wire on the two main surface side, and thus suppress the expansion of the two main surfaces. Therefore, the flat wire processing apparatus of the present invention can accurately shape the flat wire. Here, the flat wire is defined as having a rectangular cross-section (including those with chamfered edges).

[0008] (2) The flat wire processing apparatus of the present invention described above is preferably characterized in that the first inclined portion and the second inclined portion are arranged such that their inclination angles are symmetrical to each other.

[0009] As described above, the flat wire processing apparatus of the present invention, when configured as described in (2) above, can cause the material in the flat wire to flow along the first and second inclined sections in a balanced manner (for example, evenly). Therefore, the flat wire processing apparatus of the present invention can perform molding with greater precision.

[0010] (3) The flat wire processing apparatus of the present invention described above is preferably characterized in that either one or both of the first inclined portion and the second inclined portion are formed in a curved shape.

[0011] The flat wire processing apparatus of the present invention described above, when configured as described in (3) above, allows the material (thickness) of the flat wire to flow smoothly along the curvature of either one or both of the first and second inclined sections. Therefore, the flat wire processing apparatus of the present invention, when configured as described in (3) above, can accurately form flat wires. Here, the first and second inclined sections are surfaces formed from the protruding end toward the holding section, when configured as described in (3) above, and are formed as curved surfaces. The degree of curvature of the first and second inclined sections can be set to various curvatures depending on the material and size of the flat wire. Furthermore, the first and second inclined sections can be formed in various shapes and sizes, such as having surfaces that are symmetrical to each other or surfaces that have different shapes.

[0012] (4) In the flat wire processing apparatus of the present invention described above, it is preferable that the pair of protrusions are able to move toward and toward the two main surfaces along the first inclined portion, while moving toward and away from each other.

[0013] The flat wire processing apparatus of the present invention, as described above, can be configured as shown in (4) above, allowing the two main surfaces of the flat wire to be clamped in the holding section beforehand, and then the protruding section to be applied to perform the molding process. This allows the flat wire processing apparatus of the present invention to suppress the expansion of the two main surfaces of the flat wire. Furthermore, as described in (4) above, the flat wire processing apparatus of the present invention can allow the pair of protruding sections to be applied along the inclination of the first inclined section, thereby allowing the flesh portion of the flat wire to flow outward in the longitudinal direction (outward in the longitudinal direction relative to the main surface). This allows the flat wire processing apparatus of the present invention to efficiently suppress the expansion of the two main surfaces of the flat wire.

[0014] (5) In the flat wire processing apparatus of the present invention described above, the molding die is formed to extend in the axial direction of the flat wire, and a plurality of protrusions are formed along a direction intersecting the axial direction at predetermined intervals in the axial direction.

[0015] The flat wire processing apparatus of the present invention described above can suppress the axial displacement of the flat wire when forming a flat wire extending in the axial direction by friction caused by multiple protrusions. Therefore, the flat wire processing apparatus of the present invention can form flat wires with high precision.

[0016] (6) The flat wire processing method of the present invention, provided to solve the above-mentioned problems, is a flat wire processing method using a molding die that presses and plastically deforms a flat wire, wherein the molding die is provided with a pair of holding parts that are arranged opposite to each other along the longitudinal direction of the flat wire and clamp two main surfaces that are opposite to each other in the short direction of the flat wire, and each of the pair of holding parts is provided with a pair of protruding parts that are provided on both ends of the holding part in the longitudinal direction and protrude from the holding part toward the main surface, and a first inclined part that is inclined in the longitudinal direction of the holding part toward the holding part toward the protruding end, and The present invention is characterized by the following steps: forming a second inclined portion having a surface facing outward in the longitudinal direction of the holding portion toward the holding portion, a holding step of clamping the two main surfaces with the pair of holding portions, a molding step of forming a pair of grooves along the first inclined portion and the second inclined portion on each of the two main surfaces by pressing the pair of protrusions on each of the pair of holding portions toward the two main surfaces as the holding step is performed, and a first chamfering step of forming a first chamfered portion by cutting the flat rectangular wire in the short direction along the bottom of the grooves.

[0017] The flat wire processing method of the present invention, as described above, can be configured as described in (6) above, so that a molding process can be performed to form a pair of grooves while holding the two main surfaces during the holding process. In other words, since the flat wire processing method of the present invention can perform the molding process together with the holding process, the flat wire can be molded efficiently. Furthermore, since the pair of protrusions in the flat wire processing method of the present invention have the first inclined portion and the second inclined portion described above, the material portion of the flat wire can be distributed to the first inclined portion side and the second inclined portion side during the molding process. Therefore, the flat wire processing method of the present invention can suppress the concentration of the material portion of the flat wire inward in the longitudinal direction of the two main surfaces, thus suppressing the expansion of the two main surfaces. Furthermore, since the flat wire processing method of the present invention can form a first chamfered portion by cutting the groove formed in the molding process along the bottom in the short direction, the cutting process can be performed while utilizing the groove for positioning. Therefore, the flat wire processing method of the present invention can process flat wires with high precision.

[0018] (7) The flat wire processing method of the present invention described above is characterized in that the surface of the flat wire is covered with a covering member, and prior to the holding step, a first covering member removal step is performed to remove the covering member from at least the two main surfaces of the flat wire that are to be held by the holding portion, and the first chamfering step includes a second covering member removal step to remove the covering member from the pair of side surfaces of the flat wire.

[0019] The flat wire processing method of the present invention described above includes a second coating removal step in which the first chamfering step removes the coating material from a pair of side surfaces of the flat wire, thus shortening the processing steps. Therefore, cost reduction can be expected with the flat wire processing method of the present invention. Herein, the flat wire processing method of the present invention may also be modified in which, for example, the execution order of the first coating removal step and the second coating removal step is reversed. That is, the flat wire processing method of the present invention may also be modified in which the processing order of the main surface in the longitudinal direction and the side surfaces in the short direction is reversed.

[0020] (8) The flat angle wire processing method of the present invention described above is provided with a burr crushing and forming die that sandwiches and holds the outer shape of the flat angle wire formed with the first chamfered portion so as to surround it by being combined with each other. After the execution of the first chamfering step, a burr crushing step of performing burr crushing by sandwiching the flat angle wire with the burr crushing and forming die, and a tip processing step of cutting the tip side in the axial direction of the flat angle wire are executed. The tip processing step preferably includes a second chamfering processing step of forming a second chamfered portion that inclines in the radial direction at the tip of the flat angle wire.

[0021] The flat angle wire processing method of the present invention described above can be configured as in (8) above, so that burr-free and highly accurate molding processing can be performed, and terminals of the flat angle wire (for example, terminals of a stator coil) can be formed with high accuracy.

Effects of the Invention

[0022] According to the present invention, it is possible to provide a flat angle wire processing apparatus and a flat angle wire processing method capable of accurately molding a flat angle wire, and it is also possible to provide a flat angle wire processing apparatus and a flat angle wire processing method capable of reducing costs.

Brief Description of the Drawings

[0023] [Figure 1] (a) is a schematic front view of a flat angle wire processing apparatus according to an embodiment of the present invention, and (b) is an enlarged explanatory view of a main part of (a). [Figure 2] (a) to (c) are explanatory views of a flat angle wire processing method using the flat angle wire processing apparatus of the present invention. [Figure 3] (a) to (c) are explanatory views of a flat angle wire processing method following FIG. 2. [Figure 4] (a) to (c) are explanatory views of a flat angle wire processing method following FIG. 3. [Figure 5] (a) to (c) are explanatory perspective views showing the processing state of a flat angle wire by the flat angle wire processing method of the present invention. [Figure 6](a) and (b) are explanatory perspective views showing the processing state of the rectangular wire by the rectangular wire processing method, following Figure 5. [Figure 7] This is a perspective view of a partially cut-out flat wire processed using the flat wire processing apparatus and flat wire processing method of the present invention. [Figure 8] (a) and (b) are explanatory diagrams showing a flat wire processing apparatus according to a first modified example of the present invention and its operation. [Figure 9] (a) to (c) are explanatory diagrams showing a flat wire processing apparatus according to a second modified example of the present invention and its operation. [Figure 10] This is a partially cutaway perspective view of a flat wire processing apparatus according to a third modified example of the present invention. [Figure 11] (a) to (c) are explanatory diagrams relating to a conventional flat wire processing apparatus. [Modes for carrying out the invention]

[0024] The following describes in detail a flat wire processing apparatus 10 and a flat wire processing method according to one embodiment of the present invention, with reference to the drawings. Note that the figures are schematic representations for ease of understanding and may differ from the actual shape, size, and arrangement of components. Also note that some reference numerals have been omitted for similar parts. Also note that cross-sectional hatching may be omitted in some figures. In this embodiment, the case in which the flat wire 1 is used in the stator coil (not shown) of a motor used in electric vehicles, etc., will be described as an example.

[0025] First, the rectangular wire 1 processed by the rectangular wire processing apparatus 10 of the present invention will be described below with reference to the drawings.

[0026] As shown in Figure 5(a), the rectangular wire 1 is composed of rectangular wires with a rectangular cross-section that extend in a linear manner. Note that the length shown in the illustration is a portion of the wire, and the actual length may be longer than shown. As shown in Figure 2(a), the surface of the rectangular wire 1 is covered with a covering member 1a (for example, an insulating coating). In the following description, the longitudinal direction in the cross-section of the rectangular wire 1 will be simply referred to as the longitudinal direction, and the short direction in the cross-section of the rectangular wire 1 will be simply referred to as the short direction.

[0027] The details of the processing steps (processing methods) will be described later, but prior to being fed into the flat wire processing apparatus 10 of the present invention, the flat wire 1 is compressed and rolled from the outer circumference, as shown in Figures 2(a) and 2(b). Subsequently, as shown in Figure 2(c), the covering members 1a on two main surfaces 2,2 that are arranged opposite each other along the longitudinal direction of the flat wire 1 and face each other in the short direction of the flat wire 1 are peeled off. This forms the flat wire 1 to be processed by the flat wire processing apparatus 10. In other words, in this embodiment, the flat wire 1 fed into the flat wire processing apparatus 10 has the covering member 1a peeled off on the two main surfaces 2,2, while the covering member 1a on the pair of side surfaces 3,3 located between the two main surfaces 2,2 is maintained.

[0028] The above is a general overview of the configuration of the rectangular wire 1 used in the rectangular wire processing apparatus 10. Next, the details of the rectangular wire processing apparatus 10 will be explained with reference to the drawings.

[0029] As shown in Figure 1(a), the flat wire processing apparatus 10 is equipped with a pair of molding dies 20, 20 that press and plastically deform the flat wire 1. The molding die 20 is equipped with a pair of holding parts 21, 21. In addition to the above, the molding die 20 is also equipped with a pair of protrusions 25, 25 provided on each of the pair of holding parts 21, 21.

[0030] The pair of holding parts 21, 21 are arranged opposite each other along the longitudinal direction of the rectangular wire 1 and are designed to clamp two main surfaces 2, 2 that are opposite each other in the short direction of the rectangular wire 1. In other words, in this embodiment, the pair of holding parts 21, 21 are arranged symmetrically vertically across the rectangular wire 1. Although not shown in the illustration, the holding parts 21, 21 are formed to extend for a predetermined length in the axial direction (depth direction in the illustration) of the rectangular wire 1.

[0031] The pair of holding parts 21, 21 are configured to move up and down using an appropriate drive source (e.g., a hydraulic pump, motor, etc., not shown). Therefore, the pair of holding parts 21, 21 can move closer to and further away from each other in the vertical direction. Since the pair of holding parts 21, 21 are arranged vertically symmetrically, unless otherwise specified, one side (the upper side) of the holding part 21 will be described below.

[0032] The holding portion 21 has a flat surface, and by moving the holding portion 21 closer to (downward) the rectangular wire 1, the flat surface comes into contact with the main surface 2 of the rectangular wire 1. As a result, the pair of holding portions 21, 21 can clamp (hold) the two main surfaces 2, 2 of the rectangular wire 1 from above and below. In this embodiment, since the covering member 1a of the main surfaces 2, 2 of the rectangular wire 1 has been peeled off, the pair of holding portions 21, 21 are configured to clamp the portion of the main surfaces 2, 2 where the material is exposed. Although not shown in the figures, if necessary, a support portion can be provided to auxiliaryly support the rectangular wire 1, and the rectangular wire 1 can be supplied in a position positioned on the holding portion 21.

[0033] The pair of protrusions 25, 25 are provided on both longitudinal ends of the holding portion 21 and protrude toward the main surface 2 from the holding portion 21. That is, the pair of protrusions 25, 25 are provided on each of the pair of holding portions 21, 21, and the flat wire processing device 10 is equipped with a total of four protrusions 25. The pair of protrusions 25, 25 are formed to extend for a predetermined length along the axial direction (depth direction in the illustration) of the flat wire 1, similar to the holding portions 21, 21. The pair of protrusions 25, 25 can move up and down integrally with the holding portion 21. The pair of protrusions 25, 25 each include a first inclined portion 26 and a second inclined portion 28. The pair of protrusions 25, 25 are provided symmetrically on the left and right sides via the holding portion 21 and have the same configuration, so unless there is a particular need to distinguish them, the protrusion 25 on one side (left side) will be described.

[0034] The first inclined portion 26 has a surface that inclins inward in the longitudinal direction of the holding portion 21 from the protruding end 25a toward the holding portion 21. Figure 1(b) is an enlarged view of the left protruding portion 25 on the upper holding portion 21. As shown in Figure 1(b), the first inclined portion 26 is inclined inward in the longitudinal direction of the holding portion 21 at an inclination angle θ1 (for example, 45 degrees).

[0035] The second inclined portion 28 has a surface that faces outward in the longitudinal direction of the holding portion 21 from the protruding end 25a toward the holding portion 21. The second inclined portion 28 is inclined outward in the longitudinal direction of the holding portion 21 at an inclination angle θ2 (for example, 45 degrees). In other words, in this embodiment, the first inclined portion 26 and the second inclined portion 28 are arranged to have symmetrical inclination angles.

[0036] Here, the pair of protrusions 25, 25 provided on each of the pair of holding parts 21, 21 can move up and down integrally with the vertical movement of the pair of holding parts 21, 21. Therefore, as the pair of holding parts 21, 21 clamp the two main surfaces 2, 2 of the rectangular wire 1, the two main surfaces 2, 2 of the rectangular wire 1 are molded by the pair of protrusions 25, 25, both above and below. At this time, since the pair of protrusions 25, 25 in one side of the mold 20 are positioned opposite the pair of protrusions 25, 25 in the other side of the mold 20, the two main surfaces 2, 2 are molded symmetrically above and below. Also, as shown in Figure 1(b), the main surface 2 of the rectangular wire 1 is pressed and molded by the protruding end 25a of the protrusion 25 as part of the mold 20.

[0037] Here, the protruding end 25a of the protruding portion 25 is set to be located at a position shifted by d1 to the outside (left side in the figure) of the holding portion 21 with respect to the widthwise machining design position W of the main surface 2 (for example, 0.05 mm). Also, the protruding end 25a of the protruding portion 25 is set to be located at a position shifted by d2 to a deeper position (downward in the figure) with respect to the depthwise machining design position H of the main surface 2 (for example, 0.05 mm). As a result, the flat wire processing device 10 can process the material so that the dimensions remain within the standard range, even if there are variations in the peeling position of the coating member 1a or variations in the molding load.

[0038] The above describes the configuration of one embodiment of the flat wire processing apparatus 10 of the present invention. Next, the flat wire processing method performed in the flat wire processing apparatus 10 will be described in detail below. Note that in Figures 5 and 6, the hatched surfaces indicate the flat wire 1 in a state where the covering member 1a has been peeled off and the wire material is exposed.

[0039] As shown in Figure 2(a), a press device 50 is provided, each equipped with a press molding die 51 facing the main surfaces 2,2 and side surfaces 3,3 of the rectangular wire 1. The press device 50 can reduce the radius of curvature of the four corners 4 on the outer circumference of the rectangular wire 1 by pressing the main surfaces 2,2 and side surfaces 3,3 of the rectangular wire 1 with the press molding die 51 (radius of curvature reduction process).

[0040] Figures 2(b) and 5(b) are explanatory diagrams showing the state in which the radius of curvature of each corner 4 of the rectangular wire 1 is reduced by the press device 50. As shown in Figure 2(b), the radius of curvature of each corner 4 of the rectangular wire 1 is reduced.

[0041] As shown in Figure 2(c), a first cutting device 55 is provided, which is equipped with a pair of cutting blades 56, 56 that can move in a direction along the main surfaces 2, 2 of the rectangular wire 1. The first cutting device 55 includes the pair of cutting blades 56, 56 and a support part 57, etc. The first cutting device 55 may be included in the rectangular wire processing device 10, or it may be provided independently of the rectangular wire processing device 10.

[0042] The support portion 57 is configured to be movable in the horizontal direction by appropriate driving means (not shown) and can contact the side surface 3 of the rectangular wire 1 on the side where the cutting blades 56, 56 are advancing. By contacting the side surface 3 of the rectangular wire 1, the support portion 57 can support the rectangular wire 1 and suppress its movement.

[0043] The cutting blades 56, 56 are formed, for example, in a triangular shape, and by moving them in a direction along the main surfaces 2, 2 of the rectangular wire 1, the coating member 1a on the surface of the main surfaces 2, 2 can be peeled off (removed) (first coating member removal step).

[0044] Figure 5(c) is a perspective view of the rectangular wire 1 showing the state in which the covering member 1a on the main surfaces 2,2 has been peeled off. In the first covering member removal step, when the covering member 1a on the main surfaces 2,2 of the rectangular wire 1 is removed, the rectangular wire 1 with the wire material exposed on the main surfaces 2,2 is supplied to the rectangular wire processing apparatus 10 of the present invention. As shown in Figure 3(a), the rectangular wire 1 is positioned between a pair of molds 20,20 such that the main surfaces 2,2 of the rectangular wire 1 face each of the pair of holding parts 21,21.

[0045] Next, as shown in Figure 3(b), the two main surfaces 2,2 of the rectangular wire 1 are held between a pair of holding parts 21,21 (holding step). In this embodiment, as the holding step is performed, a pair of protrusions 25,25 on each of the pair of holding parts 21,21 are pressed against the two main surfaces 2,2, thereby forming a pair of grooves 5,5 (see Figure 3(c)) along the first inclined part 26 and the second inclined part 28 on each of the two main surfaces 2,2 (forming step). At this time, since the rectangular wire processing apparatus 10 of the present invention is equipped with a first inclined part 26 and a second inclined part 28, the material of the rectangular wire 1 can be allowed to flow out along the first inclined part 26 and the second inclined part 28, as shown by the arrows in Figure 3(b). As a result, the flow of the material of the rectangular wire 1 is distributed along the inclination of the first inclined part 26 and the second inclined part 28, so that the material of the rectangular wire 1 does not concentrate on the side of the holding part 21. In other words, the material of the rectangular wire 1 flows actively toward the longitudinal outward side of the holding portion 21 (towards the second inclined portion 28). Therefore, the rectangular wire processing apparatus 10 of the present invention can suppress the expansion of the main surfaces 2,2 of the rectangular wire 1.

[0046] As shown in Figures 3(c) and 6(a), once the holding and molding processes are complete, the rectangular wire 1 is removed from the molds 20, 20. The rectangular wire 1 has a pair of grooves 5, 5 (not shown in Figure 6(a)) formed on each of the main surfaces 2, 2 along the axial direction.

[0047] Once processing by the flat wire processing device 10 is complete, the flat wire 1 is fed to the second cutting device 60 shown in Figure 4(a). The second cutting device 60 is equipped with a pair of cutting blades 61, 61 and a support part 62, etc. The second cutting device 60 may be included in the flat wire processing device 10 or it may be provided as a separate device.

[0048] The support portion 62 abuts against the lower main surface 2 of the rectangular wire 1, thereby supporting the lower main surface 2 from below. The support portion 62 is provided with a pair of projections 63, 63 on both longitudinal sides that fit into the grooves 5, 5 of the rectangular wire 1. Each of the pair of projections 63, 63 is formed to be engageable with the pair of grooves 5, 5 (see Figure 3(c)).

[0049] The pair of cutting blades 61, 61 have a cross-section that is, for example, triangular, and by moving toward the bottom of the grooves 5, 5, they can cut the rectangular wire 1 in the shorter direction. This allows a pair of first chamfered portions 6, 6 to be formed on both sides of the rectangular wire 1 in the longitudinal direction (first chamfering step). In addition, during the first chamfering step, a second coating removal step is performed to peel off (remove) the coating material 1a from a pair of side surfaces 3, 3 of the surface of the rectangular wire 1. That is, during the first chamfering step, the rectangular wire 1 is cut in the shorter direction along the bottom of the grooves 5, 5 which are located longitudinally inward from the coating material 1a on the side surfaces 3, 3, so the coating material 1a is removed in conjunction with the first chamfering step.

[0050] Furthermore, in this embodiment, along with the execution of the first chamfering process and the second coating removal process, a pair of notches 7, 7 are formed in the short direction in the axial middle portion of the rectangular wire 1, as shown in Figure 6(b). At this time, inclined surfaces corresponding to the second chamfered portions 8a, 8a in the circumferential direction are formed in the notches 7, 7. The rectangular wire 1 on which the pair of notches 7, 7 have been formed is subjected to the deburring device 65 shown in Figure 4(b). The deburring device 65 may be included in the rectangular wire processing device 10, or it may be provided independently of the rectangular wire processing device 10.

[0051] As shown in Figure 4(b), the deburring device 65 is equipped with a pair of upper and lower deburring molds 66, 66. The pair of deburring molds 66, 66 can move closer to and further apart from each other by moving up and down. The pair of deburring molds 66, 66 can come together (for example, join) by coming closer to each other. By coming together, the deburring molds 66, 66 can clamp around the outer shape of the rectangular wire 1 on which the first chamfered portion 6 is formed (deburring process). As a result, the deburring molds 66, 66 can press against the main surfaces 2, 2 and side surfaces 3, 3 of the rectangular wire 1 on which the first chamfered portion 6 is formed at each corner. The deburring device 65 can also crush the burrs generated in the series of processes. The rectangular wire 1 on which the deburring process has been performed is fed to the third cutting device 70 shown in Figure 4(c).

[0052] As shown in Figure 4(c), the third cutting device 70 includes a cutting blade 71 and a support part 72, etc. The cutting blade 71 moves in the longitudinal direction of the flat wire 1, thereby cutting the flat wire 1 between the notches 7, 7 along the longitudinal direction (tip processing step). That is, in the tip processing step, the flat wire 1 is cut in the axial middle portion of the flat wire 1. The third cutting device 70 may be included in the flat wire processing device 10, or it may be provided independently of the flat wire processing device 10.

[0053] The support portion 72 can support the flat wire 1 by contacting the side surface 3 on one side (the side on which the cutting blade 71 is advancing). The support surface of the support portion 72 is formed in a shape that follows the outer shape of the side surface 3. That is, the support surface of the support portion 72 is formed in a shape that follows the flat portion of the side surface 3 and the inclined surfaces of the first chamfered portions 6, 6. Furthermore, the support surface of the support portion 72 is also formed in a shape that follows the inclined surface of the circumferential second chamfered portion 8a (the inclined surface of the notched portion 7: see Figure 6(b)), which will be described later.

[0054] In the tip processing step, the rectangular wire 1 is cut in the longitudinal direction, and a second chamfering step is performed to form second chamfered portions 8b, 8b (see Figures 6(c) and 7) that are inclined radially at the tip (cut surface) of the rectangular wire 1. As a result, the terminal 9 shown in Figures 6(c) and 7 is formed on the rectangular wire 1. Here, the circumferential and radial directions in the circumferential second chamfered portions 8a, 8a and the radial second chamfered portions 8b, 8b refer to the direction in which the chamfer faces relative to the circle when an annular stator coil is formed. As described above, the terminal 9 has a first chamfered portion 6, a circumferential second chamfered portion 8a, and a radial second chamfered portion 8b. In this embodiment, two rectangular wires 1 with terminals 9 formed on them are formed from one rectangular wire 1.

[0055] The above describes a method for processing flat wire according to one embodiment of the present invention. Next, the effects and advantages realized by the flat wire processing apparatus 10 and flat wire processing method of the present invention will be described below.

[0056] The flat wire processing apparatus 10 of the present invention described above has the following characteristic configurations (a) to (c). Therefore, the flat wire processing apparatus 10 of the present invention can achieve unique effects that cannot be achieved with conventional technology, as described below.

[0057] (a) The flat wire processing apparatus 10 of the present invention is a flat wire processing apparatus 10 comprising a molding die 20 for pressing and plastically deforming a flat wire 1, wherein the molding die 20 comprises a pair of holding parts 21, 21 arranged opposite to each other along the longitudinal direction of the flat wire 1 and clamping two main surfaces 2, 2 that are opposite to each other in the short direction of the flat wire 1, and a pair of protruding parts 25, 25 provided on both ends of the holding part 21 in the longitudinal direction and protruding from the holding part 21 toward the main surfaces 2, 2 of the pair of holding parts 21, wherein the pair of protruding parts 25, 25 comprises a first inclined part 26 that is inclined inward in the longitudinal direction of the holding part 21 toward the holding part 21 toward the protruding end 25a and a second inclined part 28 that has a surface that faces outward in the longitudinal direction of the holding part 21 toward the holding part 21 toward the protruding end 25a.

[0058] The flat wire processing apparatus 10 of the present invention suppresses the expansion of the two main surfaces 2,2 of the flat wire 1 by the holding part 21, and the first inclined part 26 and second inclined part 28 of the protruding part 25 can distribute the flow of the flesh (material) in the flat wire 1 to the first inclined part 26 side and the second inclined part 28 side. As a result, the flat wire processing apparatus 10 of the present invention can suppress the concentration of the flesh in the flat wire 1 on the two main surfaces 2,2 side, and thus suppress the expansion of the two main surfaces 2,2. Therefore, the flat wire processing apparatus 10 of the present invention can accurately shape the flat wire 1. Here, the flat wire 1 is assumed to have a rectangular cross-section (including those with chamfered edges).

[0059] (b) The flat wire processing apparatus 10 of the present invention described above is characterized in that the first inclined portion 26 and the second inclined portion 28 are arranged to have symmetrical inclination angles with respect to each other.

[0060] As described above, the flat wire processing apparatus 10 of the present invention, when configured as shown in (b) above, can cause the material in the flat wire 1 to flow along the first inclined portion 26 and the second inclined portion 28 in a balanced manner (for example, evenly). Therefore, the flat wire processing apparatus 10 of the present invention can perform molding with greater precision.

[0061] The above describes the configuration and effects of the flat wire processing apparatus 10 and flat wire processing method of the present invention. However, the flat wire processing apparatus 10 of the present invention is not limited to the above, and can be modified in various ways as described below.

[0062] As shown in Figure 8, the flat wire processing apparatus 10 of the present invention can be configured as a flat wire processing apparatus 100 according to a first modified example in which the shape of the pair of protrusions 25, 25 is modified. Note that the same reference numerals are used for parts similar to those in the flat wire processing apparatus 10 according to the above embodiment. Furthermore, a detailed explanation of the configuration similar to that of the flat wire processing apparatus 10 is omitted.

[0063] ≪First Variation≫ As shown in Figure 8(a), in the flat wire processing apparatus 100 according to the first modified example, the second inclined portion 28 of the pair of protrusions 25, 25 is not planar but curved in an arc shape. As shown in Figure 8(b), when the two main surfaces 2, 2 of the flat wire 1 are held by the pair of holding portions 21, 21, the flat wire 1 is shaped by the pair of protrusions 25, 25. As a result, grooves 5, 5 are formed on the surfaces of the two main surfaces 2, 2 of the flat wire 1 along the first inclined portion 26 and the second inclined portion 28. At this time, since the second inclined portion 28 is curved, the side of the grooves 5, 5 that is on the side of the second inclined portion 28 (outside the holding portion 21) is curved along the second inclined portion 28. Furthermore, in the flat wire processing apparatus 100 according to the first modified example, the thickness of the flat wire 1 is distributed along the first inclined portion 26 and the second inclined portion 28, similar to the embodiment described above, so that the expansion of the main surfaces 2, 2 is suppressed. In other words, the flat wire processing apparatus 100 according to the first modified example can be configured as shown in (c) below.

[0064] (c) The flat wire processing apparatus 100 according to the first modified example is characterized in that either one or both of the first inclined portion 26 and the second inclined portion 28 are formed in a curved shape.

[0065] The flat wire processing apparatus 100 according to the first modified example can be configured as described in (c) above, thereby allowing the material in the flat wire 1 to flow smoothly along the curvature of either or both of the first inclined portion 26 and the second inclined portion 28. Therefore, the flat wire processing apparatus 100 of the present invention can accurately form the flat wire 1 by configuring it as described in (c) above. Here, the first inclined portion 26 and the second inclined portion 28 are surfaces formed from the protruding end 25a toward the holding portion 21 by configuring them as described in (c) above, and are formed as curved surfaces. The degree of curvature of the first inclined portion 26 and the second inclined portion 28 can be set to various curvatures depending on the material and size of the flat wire 1. In addition, the first inclined portion 26 and the second inclined portion 28 can be formed in various shapes and sizes, such as having surfaces that are symmetrical to each other or surfaces that have different shapes from each other.

[0066] The above describes the configuration and operation and effects of the flat wire processing apparatus 100 according to the first modified example. Next, the details of the flat wire processing apparatus 200 according to the second modified example, in which the configuration of the holding portion 21 and the protruding portion 25 has been changed, will be described below. Note that the same reference numerals are used for parts similar to those in the flat wire processing apparatus 10 according to the above embodiment. A detailed explanation of the configuration similar to that of the flat wire processing apparatus 10 will be omitted.

[0067] ≪Second variation≫ As shown in Figure 9(a), the flat wire processing apparatus 200 according to the second modified example has a pair of protrusions 25, 25 configured to be movable relative to the holding part 21. The pair of protrusions 25, 25 are configured to move toward and toward the two main surfaces 2, 2 of the flat wire 1 along the first inclined part 26, moving toward and away from each other. Therefore, in the flat wire processing apparatus 200 according to the second modified example, the holding part 21 and the pair of protrusions 25, 25 are capable of both integrated vertical movement and independent movement. That is, although not shown in the figure, a drive source for driving the pair of protrusions 25, 25 and a drive source for driving the holding part 21, 21 are provided. Note that the drive sources may be common through an appropriate link mechanism or the like.

[0068] The holding portions 21, 21 have flat holding surfaces facing the main surfaces 2, 2 of the rectangular wire 1, and inclined surfaces 210, 210 having the same inclination angle as the first inclined portion 26 are formed on both sides of the holding portions 21, 21.

[0069] The pair of protrusions 25, 25 are configured such that the first inclined portion 26 is slidable with respect to the inclined surfaces 210, 210. Therefore, the pair of protrusions 25, 25 move along the inclined surfaces 210, 210, moving closer to and away from the main surfaces 2, 2, and also moving closer to and away from each other. In the flat wire processing apparatus 10 according to the second modified example, the second inclined portion 28 of the pair of protrusions 25, 25 is not inclined (inclination angle θ2 is 0 degrees). That is, the outer surfaces of the pair of protrusions 25, 25 (corresponding to the second inclined portions 28, 28) are set to intersect (orthogonal in this embodiment) with respect to the main surfaces 2, 2.

[0070] As shown in Figure 9(b), first, the pair of holding parts 21, 21 approach the main surfaces 2, 2 of the rectangular wire 1 integrally with the pair of protruding parts 25, 25, and clamp the main surfaces 2, 2 of the rectangular wire 1.

[0071] Next, as shown in Figure 9(c), with the rectangular wire 1 held between the holding parts 21, 21, the pair of protrusions 25, 25 move along the inclined surfaces 210, 210 of the holding part 21, thereby molding the main surfaces 2, 2 of the rectangular wire 1.

[0072] As described above, the flat wire processing apparatus 200 according to the second modified example can be configured as shown in (d) below.

[0073] (d) In the flat wire processing apparatus 200 according to the second modified example, the pair of protrusions 25, 25 are able to move toward and away from the two main surfaces 2, 2 along the first inclined portions 26, 26 while moving toward and away from each other.

[0074] The flat wire processing apparatus 200 according to the second modified example of the present invention described above can be configured as shown in (d) above, so that the two main surfaces 2,2 of the flat wire 1 are held in place by the holding parts 21,21 beforehand, and the protruding parts 25,25 are applied to perform the molding process. As a result, the flat wire processing apparatus 200 of the present invention can suppress the expansion of the two main surfaces 2,2 of the flat wire 1. Furthermore, as shown in (d) above, the flat wire processing apparatus 200 of the present invention can have the pair of protruding parts 25,25 applied along the inclination of the first inclined parts 26,26, so that the fleshy part of the flat wire 1 can be actively made to flow outward in the longitudinal direction (outward in the longitudinal direction relative to the main surface 2). As a result, the flat wire processing apparatus 200 of the present invention can efficiently suppress the expansion of the two main surfaces 2,2 of the flat wire 1.

[0075] The above describes the configuration and operation and effects of the flat wire processing apparatus 200 according to the second modified example. Next, the details of the flat wire processing apparatus 300 according to the third modified example, in which the configuration of the holding part 21 is changed, will be described below. Note that the same reference numerals are used for parts similar to those in the flat wire processing apparatus 10 according to the above embodiment. A detailed explanation of the configuration similar to that of the flat wire processing apparatus 10 will be omitted.

[0076] ≪Third Variation≫ As shown in Figure 10, the flat wire processing apparatus 300 according to the third modified example has a holding portion 21 formed to extend along the axial direction of the flat wire 1, on which a plurality of protrusions 301 (also referred to as ribs 301) are provided. Although not shown in the figure, the plurality of protrusions 301 are also provided symmetrically on the upper holding portion 21. The plurality of protrusions 301 are formed along a direction that intersects (for example, perpendicular to) the axial direction of the flat wire 1 (in the third modified example, the longitudinal direction of the main surfaces 2,2). The plurality of protrusions 301 can suppress the displacement of the flat wire 1 in the axial direction due to frictional force when the main surfaces 2,2 of the flat wire 1 are clamped by the holding portions 21,21. The number of plurality of protrusions 301, as well as the shape, size, and material of the protrusions 301, can be changed in various ways.

[0077] As described above, the flat wire processing apparatus 300 according to the third modified example can be configured as shown in (e) below.

[0078] (e) In a flat wire processing apparatus 300 according to a third modified example of the present invention, the mold 20 is formed to extend in the axial direction of the flat wire 1, and a plurality of protrusions 301 are formed along a direction intersecting the axial direction at predetermined intervals in the axial direction.

[0079] The flat wire processing apparatus 300 according to the third modified example of the present invention described above can suppress the displacement of the flat wire 1 in the axial direction when forming the flat wire 1 that extends in the axial direction due to friction by the plurality of protrusions 301. Therefore, the flat wire processing apparatus 300 according to the third modified example of the present invention can form the flat wire 1 with high precision.

[0080] The above describes the configuration and effects of the flat wire processing apparatus 10, 100, 200, 300 of the present invention. However, the flat wire processing apparatus 10, 100, 200, 300 of the present invention is not limited to the embodiments and modifications described above, and various modifications can be made within the scope of the present invention. For example, the flat wire processing apparatus 10, 100, 200, 300 can be as described in (a) above, and can be used to form wires of various shapes and sizes. Furthermore, the flat wire processing apparatus 10 of the present invention may, for example, not have some or all of the configurations described in (b) to (e) above, or may have some or all of the configurations described in (b) to (e) above, and may have other configurations.

[0081] Next, the effects and benefits realized by the flat wire processing method of the present invention will be described below. The flat wire processing method of the present invention described above has the following characteristic configurations (f) to (h). Therefore, the flat wire processing method of the present invention can produce unique effects that cannot be achieved by the prior art, as described below.

[0082] (f) The flat wire processing method of the present invention described above is a flat wire processing method using a molding die 20 that presses and plastically deforms a flat wire 1, wherein the molding die 20 is provided with a pair of holding parts 21, 21 that are arranged opposite to each other along the longitudinal direction of the flat wire 1 and clamp two main surfaces 2, 2 that are opposite to each other in the short direction of the flat wire 1, and a pair of protruding parts 25, 25 that are provided on both ends of the holding part 21, 21 in the longitudinal direction and protrude from the holding part 21, 21 toward the main surfaces 2, 2, and a first inclined part 26 that is inclined toward the holding part 21 in the longitudinal direction toward the holding part 21 from the protruding end 25a, and The present invention is characterized by the following steps: first, a second inclined portion 28 having a surface facing outward in the longitudinal direction of the holding portion 21 toward the portion 21; a holding step in which the pair of holding portions 21, 21 clamp the two main surfaces 2, 2; a molding step in which, as the holding step is performed, a pair of protrusions 25, 25 on each of the pair of holding portions 21, 21 are pressed against the two main surfaces 2, 2 to form a pair of grooves 5, 5 along the first inclined portion 26 and the second inclined portion 28 on each of the two main surfaces 2, 2; and a first chamfering step in which a flat rectangular wire 1 is cut in the short direction along the bottom of the grooves 5, 5 to form a first chamfered portion 6.

[0083] The flat wire processing method of the present invention, as described above, can be configured as shown in (f) above, so that a molding process can be performed to form a pair of grooves 5,5 while holding the two main surfaces 2,2 during the holding process. In other words, since the flat wire processing method of the present invention can perform the molding process together with the holding process, the flat wire 1 can be molded efficiently. Furthermore, since the pair of protrusions 25,25 of the flat wire processing method of the present invention have a first inclined portion 26 and a second inclined portion 28, respectively, the flesh portion of the flat wire 1 can be distributed to the first inclined portion 26 side and the second inclined portion 28 side during the molding process. Therefore, the flat wire processing method of the present invention can suppress the concentration of the flesh portion of the flat wire 1 inward in the longitudinal direction of the two main surfaces 2,2, thus suppressing the expansion of the two main surfaces 2,2. In addition, since the first chamfered portion 6,6 can be formed by cutting the grooves 5,5 formed in the molding process along the bottom in the short direction, the cutting process can be performed while utilizing the grooves 5,5 for positioning. Therefore, the flat wire processing method of the present invention can process flat wires 1 with high precision.

[0084] (g) The flat wire processing method of the present invention described above is characterized in that the surface of the flat wire 1 is covered with a covering member 1a, and prior to the holding step, a first covering member removal step is performed to remove the covering member 1a from at least two main surfaces 2,2 that are to be held by the holding portions 21,21 of the surface of the flat wire 1, and the first chamfering step includes a second covering member removal step to remove the covering member 1a from a pair of side surfaces 3,3 of the surface of the flat wire 1.

[0085] The flat wire processing method of the present invention described above includes a first chamfering step that includes a second coating member removal step in which a pair of coating members 1a are removed from the surface of the flat wire 1, thus shortening the processing steps. Therefore, cost reduction can be expected with the flat wire processing method of the present invention. Hereinafter, the flat wire processing method of the present invention can also be modified by reversing the execution order of the first coating member removal step and the second coating member removal step. That is, the flat wire processing method of the present invention can also be modified by reversing the processing order of the main surfaces 2,2 in the longitudinal direction and the side surfaces 3,3 in the short direction.

[0086] (h) The flat wire processing method of the present invention described above is characterized in that a burr-crushing mold 66 is provided which, when joined together, clamps the outer shape of the flat wire 1 on which the first chamfered portion is formed, and after the execution of the first chamfering step, a burr-crushing step is performed in which the flat wire 1 is clamped by the burr-crushing mold 66 to crush the burrs, and a tip processing step is performed in which the axial tip side of the flat wire 1 is cut, and the tip processing step includes a second chamfering step in which a second chamfered portion 8b that is inclined in the radial direction is formed at the tip of the flat wire 1.

[0087] The flat wire processing method of the present invention described above, when configured as shown in (h) above, enables high-precision molding without burrs, and also enables the precise formation of terminals 9 of the flat wire 1 (for example, terminals of a stator coil).

[0088] The above describes the configuration and effects of the flat wire processing method of the present invention. However, the flat wire processing method of the present invention is not limited to the embodiments and modifications described above, and various modifications can be made within the scope of the present invention. For example, the flat wire processing method may be as described in (f) above, and may, for example, not include some or all of the configurations related to (g) and (h) above, or may include some or all of (g) and (h) above, and other configurations. Furthermore, the flat wire processing method of the present invention can be carried out using any of the flat wire processing devices 10, 100, 200, 300, etc., which include any of the above-described (a) and (b) to (e).

[0089] As described above, the flat wire processing apparatus 10, 100, 200, 300 and the flat wire processing method of the present invention can be modified in various ways, not just according to the embodiments and modifications described above.

[0090] In this embodiment, the flat wire 1 with a rectangular cross-section is used as the target for processing, but the flat wire 1 may also have a square cross-section. Also, in this embodiment, the two main surfaces 2,2 which are arranged opposite each other along the longitudinal direction of the flat wire 1 are held by a pair of holding parts 21,21, but the pair of holding parts 21,21 may be configured to hold the side surfaces 3,3 in the short direction.

[0091] In this embodiment, the surface of the rectangular wire 1 is covered with a covering member 1a, and the processing target is a rectangular wire 1 from which the covering member 1a has been peeled off from two main surfaces 2,2, excluding a pair of side surfaces 3,3. However, the covering member 1a can be provided as needed, and the rectangular wire processing apparatus 10 of the present invention can also be used for rectangular wires 1 that do not have a covering member 1a. Furthermore, when processing a rectangular wire 1 covered with a covering member 1a, the locations where the covering member 1a is peeled off and the locations where it is maintained can be set in various places within the scope that the invention can be achieved. For example, in the rectangular wire processing apparatus 10 of the present invention described above, the rectangular wire 1 can be configured such that its surface is covered with a covering member 1a, the covering member 1a is peeled off from the two main surfaces 2,2 that are clamped by a pair of holding parts 21,21, and the covering member 1a is maintained on the pair of side surfaces 3,3 located between the two main surfaces 2,2 on the surface of the rectangular wire 1. Furthermore, although this embodiment illustrates a case where the covering member 1a of the rectangular wire 1 is formed of an insulator, the covering member 1a of the rectangular wire 1 is not limited to this and various types can be used.

[0092] In this embodiment, the first inclined portion 26 and the second inclined portion 28 of the protruding portion 25 are arranged to have symmetrical inclination angles, but the flat wire processing apparatus 10 of the present invention is not limited to this. For example, the first inclined portion 26 and the second inclined portion 28 may be arranged to have asymmetrical inclination angles. Furthermore, the inclination angles of the first inclined portion 26 and the second inclined portion 28 can be set to various angles, not just 45 degrees, depending on the material of the flat wire 1, etc. For example, as in the flat wire processing apparatus 300 according to the third modified example, the surface corresponding to the second inclined portion 28 may be non-inclined (inclination angle 0 degrees). Also, in this embodiment, the pair of left and right protruding portions 25, 25 are formed to be symmetrical, but the pair of protruding portions 25, 25 can also be asymmetrical.

[0093] Furthermore, in this embodiment, the first inclined portion 26 and the second inclined portion 28 are formed as flat surfaces, but the first inclined portion 26 and the second inclined portion 28 can be modified in various ways, such as being curved in some parts or bent in some parts, as long as the objective of the invention can be achieved.

[0094] In this embodiment, the first chamfered portion 6 is formed in the first chamfering step by cutting the rectangular wire 1 in the short direction along the bottom of the groove 5. However, the rectangular wire processing method of the present invention is not limited to this, and the first chamfered portion 6 can be formed by various methods. For example, in the rectangular wire processing method of the present invention, the first chamfered portion 6 can also be formed in the first chamfering step by polishing or the like instead of cutting.

[0095] Furthermore, in this embodiment, the coating member 1a of the rectangular wire 1 is removed by cutting in the first coating member removal step and the second coating member removal step. However, the rectangular wire processing method of the present invention is not limited to this, and the coating member 1a can be removed by various methods. For example, the rectangular wire processing method of the present invention may involve pulling the peeled end of the coating member 1a to peel it off from the main surface 2,2 and the side surface 3,3.

[0096] Furthermore, in this embodiment, the deburring process is performed by clamping the outer shape of the rectangular wire 1 with deburring molds 66, 66, but the deburring process is not limited to this, and deburring (including deburring) can be performed by various methods. For example, the deburring process may be performed by polishing, etc. Also, in this embodiment, in the tip processing process, a cutting process is performed to cut the axial tip side of the rectangular wire 1, and a second chamfering process is performed to form a second chamfered portion 8b that is inclined in the radial direction, but the second chamfering process can be performed as needed, and the second chamfering process can be omitted. In addition, the cutting of the axial tip side of the rectangular wire 1 in the tip processing process can be performed by various methods and means.

[0097] The above describes various embodiments and modifications of the flat wire processing apparatus and flat wire processing method according to the present invention. However, the present invention is not limited to those exemplified in the above embodiments and modifications, and it will be readily apparent to those skilled in the art that other embodiments may exist in the spirit and nature of the teachings, without departing from the scope of the claims. [Industrial applicability]

[0098] The present invention can be suitably used in forming coil terminals of stators in various types of electric motors, such as motors and generators. Furthermore, the present invention can be suitably used in the manufacture of electric motors used in various vehicles, such as electric vehicles and hybrid vehicles. Additionally, the present invention can be used in the processing of various wire materials utilizing flat rectangular wire. [Explanation of symbols]

[0099] 1: Flat rectangular line 1a: Covering member 2: Main surface 3: Side view 5: Groove 6: First chamfered section 8a: Second chamfered section (circumferential direction) 8b: Second chamfered section (radial direction) 10:Flat wire processing equipment 20: Molding mold 21: Holding part 25:Protrusion 25a:Protruding end 26: 1st slope 25a:Protruding end 28:Second slope part 63: Protrusion 66: Deburring mold 100:Flat wire processing equipment 200:Flat wire processing equipment 300:Flat wire processing equipment 301: Protrusion (rib) 500: Flat rectangular line 550: Molding mold H: Depth direction machining design position W: Width direction machining design position

Claims

1. A flat wire processing apparatus equipped with a molding die that presses and plastically deforms a flat wire, The aforementioned mold is A pair of holding parts are arranged opposite to each other along the longitudinal direction of the rectangular wire and clamp two main surfaces that face each other in the short direction of the rectangular wire, Each of the pair of holding portions is provided with a pair of protrusions on both longitudinal ends of the holding portion and projecting from the holding portion toward the main surface, Equipped with, The pair of protrusions are, A first inclined portion that slopes inward in the longitudinal direction of the holding portion toward the holding portion side from the protruding end, A second inclined portion having a surface that faces outward in the longitudinal direction of the holding portion toward the holding portion from the protruding end, A flat wire processing apparatus characterized by having [a certain feature].

2. The flat wire processing apparatus according to claim 1, characterized in that the first inclined portion and the second inclined portion are arranged such that they have symmetrical inclination angles.

3. The pair of protrusions are, The flat wire processing apparatus according to claim 1 or 2, characterized in that it is able to approach and move away from the two main surfaces along the first inclined portion while moving away from each other.

4. A method for processing rectangular wire using a molding die that presses and plastically deforms rectangular wire, In the aforementioned mold, A pair of holding parts are arranged opposite to each other along the longitudinal direction of the rectangular wire and clamp two main surfaces that face each other in the short direction of the rectangular wire, Each of the pair of holding portions is provided with a pair of protrusions on both longitudinal ends of the holding portion and projecting from the holding portion toward the main surface, In addition to providing, A first inclined portion that slopes inward in the longitudinal direction of the holding portion toward the holding portion side from the protruding end, A second inclined portion having a surface that faces outward in the longitudinal direction of the holding portion toward the holding portion side from the protruding end, Form it, A holding step in which the two main surfaces are held between the pair of holding parts, A molding step in which, as the holding step is performed, the pair of protrusions on each of the pair of holding parts are pressed against the two main surfaces, thereby forming a pair of grooves along the first inclined portion and the second inclined portion on each of the two main surfaces, A first chamfering step is to form a first chamfered portion by cutting the rectangular wire in the shorter direction along the bottom of the groove, A method for processing rectangular wire, characterized by performing the following steps.

5. The surface of the aforementioned rectangular wire is covered with a covering member. Prior to the holding step, a first covering member removal step is performed, in which the covering member is removed from at least the two main surfaces of the flat wire that are to be held by the holding portion. The method for processing a rectangular wire according to claim 4, characterized in that the first chamfering step includes a second coating member removal step of removing the coating member from the pair of side surfaces of the rectangular wire.

6. A deburring mold is provided that, when joined together, clamps the outer shape of the flat wire on which the first chamfered portion is formed, thereby surrounding it. After the first chamfering step is performed, The deburring process involves deburring the flat wire by clamping it with the deburring die, A tip processing step in which the axial end of the aforementioned rectangular wire is cut, This is what is executed, The method for processing a rectangular wire according to claim 4 or 5, characterized in that the tip processing step includes a second chamfering step of forming a second chamfered portion that is inclined radially at the tip of the rectangular wire.

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