Manufacturing method and manufacturing system for coil member

Abstract

This manufacturing method of a coil member (C) has: a wire preparation step of preparing a metal wire (32) having a predetermined length; a dedicated wire bending step of fabricating a dedicated wire (P); a special wire bending step of fabricating a special wire (S); and a coil fabrication step of fabricating the coil member (C) by using the dedicated wire (P) and the special wire (S). In the wire preparation step, the ratio between the number of metal wires (32) allocated to the dedicated wire bending step and the number of metal wires (32) allocated to the special wire bending step is adjusted in accordance with the ratio between processing time required for the dedicated wire bending step and processing time required for the special wire bending step.

Description

[Technical field]

[0001] The present invention relates to a method and a system for manufacturing a coil member. [Background technology]

[0002] 2. Description of the Related Art Patent Document 1 and other documents disclose a manufacturing system for a rotating electric machine used for manufacturing a rotating electric machine such as a motor or a generator. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent No. 6458105 Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, the coil member to be assembled in the stator of the motor uses a U-shaped dedicated line forming the coil body and a special wire to supply power to the dedicated line. In general, the coil member to be assembled in the stator uses multiple dedicated lines of the same shape and multiple types of special wires with shapes different from the dedicated lines, and these wires are inserted into the stator core, and the ends of the wires are connected and combined to form the coil part of the stator. The number of wires required is determined according to the type of stator, and manufacturing more than the required number will result in waste. In addition, if the number of dedicated lines and special wires required for the stator are prepared and managed separately, the management and assembly work when assembling the coil member into the stator core will become complicated, and there is a risk of reducing the manufacturing efficiency of the stator. Therefore, further improvement in the manufacturing efficiency of the coil member is desired.

[0005] The present invention provides a coil member manufacturing method and manufacturing system for efficiently manufacturing coil members used in stators. [Means for solving the problem]

[0006] In order to achieve the above object, a method for manufacturing a coil member according to one aspect of the present invention includes the steps of: A method for manufacturing a coil member for use in a stator, the coil member having a U-shaped dedicated wire forming a coil body and a special wire having a different shape from the dedicated wire, comprising the steps of: a wire preparation step of preparing a wire of a predetermined length before being formed into the dedicated wire and the special wire; a dedicated line bending process for bending the wire into a U-shape to produce the dedicated line; a special wire bending process of bending the wire rod to produce the special wire; a coil manufacturing process of manufacturing the coil member using the dedicated wire and the special wire, In the wire preparation process, the ratio of the number of wires to be allocated to the dedicated wire bending process and the number of wires to be allocated to the special wire bending process is adjusted according to the ratio of the processing time required for the dedicated wire bending process to the processing time required for the special wire bending process.

[0007] Further, a method for manufacturing a coil member according to one aspect of the present invention includes the steps of: A method for manufacturing a coil member for use in a stator, the coil member having a U-shaped dedicated wire forming a coil body and a special wire having a different shape from the dedicated wire, comprising the steps of: a wire preparation step of preparing a first wire having a first predetermined length and a second wire having a second predetermined length before being formed into the dedicated wire or the special wire; a dedicated line bending process of bending the first wire into a U-shape to prepare the dedicated line; a special wire bending step of bending the second wire to produce the special wire; a coil manufacturing process of manufacturing the coil member using the dedicated wire and the special wire, the wire rod preparing step includes a sorting step of sorting the first wire rod to the dedicated wire bending step and sorting the second wire rod to the special wire bending step, In the allocation process, the ratio of the number of the first wire rods to be allocated to the dedicated wire bending process and the number of the second wire rods to be allocated to the special wire bending process is adjusted according to the ratio of the processing time required for the dedicated wire bending process to the processing time required for the special wire bending process.

[0008] In order to achieve the above object, a coil member manufacturing system according to one aspect of the present invention comprises: A manufacturing system for a coil member used for a stator, the coil member having a U-shaped dedicated wire forming a coil body and a special wire having a different shape from the dedicated wire, a wire preparation unit that prepares a wire of a predetermined length before being formed into the dedicated wire and the special wire; a dedicated line bending unit that bends the wire into a U-shape to produce the dedicated line; a special wire bending unit that bends the wire to produce the special wire; a coil manufacturing unit that manufactures the coil member using the dedicated wire and the special wire, The wire preparation unit adjusts the ratio between the number of wires to be allocated to the dedicated line bending unit and the number of wires to be allocated to the special wire bending unit depending on the ratio of the processing time required for the dedicated line bending unit to the processing time required for the special wire bending unit.

[0009] Moreover, a manufacturing system for a coil member according to one aspect of the present invention includes: A manufacturing system for a coil member used for a stator, the coil member having a U-shaped dedicated wire forming a coil body and a special wire having a different shape from the dedicated wire, a wire preparation unit that prepares a first wire having a first predetermined length and a second wire having a second predetermined length before being formed to be formed on the dedicated wire or the special wire; a dedicated line bending unit that bends the first wire into a U-shape to produce the dedicated line; a special wire bending unit that bends the second wire to produce the special wire; a coil manufacturing unit that manufactures the coil member using the dedicated wire and the special wire, the wire preparation unit has a distribution unit that distributes the first wire to the dedicated wire bending unit and distributes the second wire to the special wire bending unit, The allocation unit adjusts the ratio of the number of the first wire rods allocated to the dedicated line bending unit and the number of the second wire rods allocated to the special wire bending unit depending on the ratio of the processing time required for the dedicated line bending unit to the processing time required for the special wire bending unit. Effect of the Invention

[0010] According to the present invention, it is possible to provide a coil member manufacturing method and manufacturing system for efficiently manufacturing coil members used in stators. [Brief description of the drawings]

[0011] [Figure 1] 1 is a configuration diagram of a stator manufacturing system including a coil member manufacturing system according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a diagram illustrating an example of a stator core. [Diagram 3] FIG. 2 is a diagram showing a cutting section of a wire preparation unit in the coil member manufacturing system. [Figure 4] FIG. 2 is a diagram showing an example of a wire. [Diagram 5] FIG. 1 illustrates an example of a dedicated line. [Figure 6] FIG. 13 is a diagram showing an example of a special line. [Figure 7] 4 is a diagram showing a sorting section, a bending processing section, and a coil manufacturing section of the wire preparation unit; FIG. [Figure 8] 2 is a diagram showing a first cutting section, a first sorting section, a first pusher section, and a first wire stocker section; FIG. [Figure 9] 4 is a perspective view showing a bending processing section and a coil manufacturing section. FIG. [Figure 10] 13A and 13B are diagrams illustrating bending of a dedicated line in a first dedicated line processing unit. [Figure 11] 13A and 13B are diagrams illustrating a state of bending a special wire in a first special wire processing portion. [Figure 12] FIG. 4 is a partial enlarged view showing the conveying section of the coil manufacturing unit that conveys the dedicated wire and the special wire. [Figure 13] FIG. 2 is a diagram showing an example of a coil body. [Figure 14] 1 is a diagram showing an example of a stator constituted by a stator core and coil members; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, an embodiment of the present invention (hereinafter, referred to as the present embodiment) will be described with reference to the drawings. For the sake of convenience of explanation, the dimensions of each component shown in the drawings may differ from the actual dimensions of each component.

[0013] Fig. 1 is a configuration diagram of a stator manufacturing system 200 including a coil member manufacturing system of the present embodiment. As shown in Fig. 1, the stator manufacturing system 200 includes a manufacturing system 1 (hereinafter, referred to as coil manufacturing system 1) that manufactures a coil member C, and a coil assembling system 100 that manufactures a stator ST by assembling the manufactured coil member C to a stator core SC.

[0014] The coil manufacturing system 1 has a wire preparation unit 2 that prepares wire for producing a coil member C, a bending unit 5 that bends the wire, and a coil production unit 8 that combines the bent wires to produce a coil member C. The wire preparation unit 2 has a sorting unit 4 that outputs cut wire to the bending unit 5. The wire preparation unit 2 also has a cutting unit 3 that cuts the wire to a predetermined length.

[0015] The arrows in the figure indicate the flow until the stator ST is manufactured from the coil member C and the stator core SC. The wire cut out in the cutting section 3 of the wire preparation section 2 is transported to the sorting section 4 of the wire preparation section 2. Of the wire transported to the sorting section 4, the number of wires required for the coil member C to be manufactured is delivered to the bending section 5. The wire delivered to the bending section 5 is bent into a predetermined shape by a bending device arranged in the bending section 5, and then transported to the coil production section 8. The multiple wires transported to the coil production section 8 and bent into a predetermined shape are combined with each other to complete the coil member C. The completed coil member C is transferred from the coil production section 8 to the coil assembly system 100.

[0016] In the coil manufacturing system 1 of this embodiment, two coil members C can be produced in parallel, one each, and the wire preparation unit 2 includes a first wire preparation unit 2A and a second wire preparation unit 2B, the bending unit 5 includes a first bending unit 5A and a second bending unit 5B, and the coil production unit 8 includes a first coil production unit 8A and a second coil production unit 8B. The first wire preparation unit 2A includes a first sorting unit 4A, and the second wire preparation unit 2B includes a second sorting unit 4B. The first wire preparation unit 2A includes a first cutting unit 3A. The second wire preparation unit 2B includes a second cutting unit 3B.

[0017] The coil assembly system 100 includes a stator core preparation unit 100a that prepares the stator core SC before the coil member C is assembled, a coil assembly unit 100b that assembles the manufactured coil member C to the stator core SC, and a stator processing unit 100c that performs a predetermined process with the coil member C assembled to the stator core SC.

[0018] The stator core preparation unit 100a receives the stator core SC from the stator core supply unit 101 and performs preparation processing before the coil members C are attached. As shown in Fig. 2, the stator core SC used in this embodiment is configured in a cylindrical shape and has a plurality of grooves (or openings) formed at predetermined angular intervals and with a predetermined dimension toward the central axis. The wire of the coil members C is inserted into the plurality of grooves formed in the stator core SC.

[0019] The coil assembly unit 100b includes a positioning unit that positions the stator core SC at a predetermined position, a stator core transfer unit that transfers the stator core SC to the positioning unit, a coil transfer unit that transfers the coil member C to the positioning unit, and a stator transfer unit that transfers the stator ST in which the coil member C is incorporated into the stator core SC. The coil assembly unit 100b further includes a coil insertion unit 102 that assembles the coil member C into the stator core SC positioned in the positioning unit. The coil insertion unit 102 inserts the coil member C manufactured by the coil production unit 8 of the coil manufacturing system 1 into the stator core SC.

[0020] The stator processing section 100c includes a coil twisting section 103 that performs an operation of moving the end of the coil member C of the stator core SC into which the coil member C is inserted in the circumferential direction of the stator core SC. In the coil twisting section 103, the operation of moving the end of the coil member C is performed, so that the ends of the predetermined wire rods constituting the coil member C can be brought close to each other, and the coil member C is attached to the stator core SC. The stator processing section 100c further includes a coil welding section 104 that connects the ends of the wire rods of the coil member C attached to the stator core SC. In the coil welding section 104, the ends of the wire rods brought close to each other are subjected to an operation such as coil end welding by a welding tool, for example, to manufacture the stator ST. The stator processing section 100c further includes a final inspection section 105 that inspects the manufactured stator ST for thread binding, appearance, and the like. The manufacturing of the stator ST is completed by performing the operation in the final inspection section 105. The stator processing section 100 c further includes an unloading section 106 that unloads the completed stator ST from the coil assembly system 100 .

[0021] Next, the coil manufacturing system 1 will be described in detail. Fig. 3 is a diagram showing a first cutting section 3A of a first wire preparation section 2A in a coil manufacturing system 1. As shown in Fig. 1, two cutting sections 3 are provided, a first cutting section 3A and a second cutting section 3B, arranged in parallel. The first cutting section 3A and the second cutting section 3B have the same configuration. Therefore, only the first cutting section 3A will be described below.

[0022] 3, the first cutting unit 3A is provided with a coil delivery unit 31 that supplies a continuous metal wire G32 (e.g., a copper wire) as a base wire for producing the coil member C. The metal wire G32 delivered from the coil delivery unit 31 passes between a plurality of rollers provided in a curl straightening unit 33, whereby large distortions (curling tendencies) of the wire are straightened to form a straight metal wire G32. The straightened metal wire G32 passes through top and bottom surface peeling units 34 and side surface peeling unit 35, whereby it is processed into a metal wire G32 in which the coating of a predetermined range of a non-conductive portion has been stripped.

[0023] The stripped metal wire G32 passes through the wire cutting section 36 and is cut to a length preset according to the type of wire as a wire for producing the coil member C. Specifically, the non-conductive portion preset according to the length of the type of wire is stripped, and a predetermined position of the exposed conductive portion is cut. Also, the wire is cut into I-shaped metal wires 32 of the same length or different lengths according to the coil member C according to the type of stator. The cut I-shaped metal wire 32 is transferred from the wire cutting section 36 to the length discrimination section 38 by the wire transfer section 37. The length discrimination section 38 discriminates whether the I-shaped metal wire 32 has been cut to a set predetermined length, and sends the I-shaped metal wire 32 that has been discriminated to have been cut to the set predetermined length to the sorting section 4 (the first sorting conveyor section 41A in FIG. 2). The operation of each section of the first cutting section 3A is controlled by the first wire preparation control section 21A provided in the first wire preparation section 2A.

[0024] The I-shaped metal wire 32 cut to a predetermined length by the wire cutting section 36 is used as a U-shaped wire forming the coil body in the coil member C of the stator ST (hereinafter also referred to as "dedicated wire P"), or as a wire having a different shape from the dedicated wire P (hereinafter also referred to as "special wire S"). Examples of wires having a different shape from the dedicated wire P include multiple types of wires such as phase power lines for supplying power, jumper wires, and neutral wires. The I-shaped metal wire 32 is cut out by the wire cutting section 36 in the number of wires required to fabricate one coil member C (hereinafter also referred to as "required number of wires [pieces / unit]").

[0025] The wire used in this embodiment is a straight-line member having a rectangular cross section, as shown in FIG. 4, and is a rod-shaped member (I-shaped metal wire 32) cut to a predetermined length, which includes a conductive portion made of a conductive material and a non-conductive portion made of a non-conductive material that is in close contact with the periphery of the conductive portion and covers the conductive portion.

[0026] The dedicated line P used in this embodiment is a member obtained by bending a wire (I-shaped metal wire 32) cut to a predetermined length into a U-shape as shown in Fig. 5. The special wire S is a member obtained by bending a wire (I-shaped metal wire 32) cut to a predetermined length into a predetermined shape as shown in Fig. 6, for example.

[0027] FIG. 7 is a diagram showing the sorting section 4, bending section 5, and coil producing section 8 of the wire preparing section 2. As shown in FIG.

[0028] As shown in FIG. 7, the first sorting section 4A has a first sorting conveyor section 41A and a first pusher section 42A. The first sorting conveyor section 41A includes a conveyor that receives the I-shaped metal wires 32 sent out from the first cutting section 3A one by one, sequentially sends the received I-shaped metal wires 32 at a predetermined pitch, and moves them to the first bending section 5A. The first pusher section 42A includes a pusher that delivers the I-shaped metal wires 32 moved by the operation of the first sorting conveyor section 41A to the first bending section 5A. Specifically, the first pusher section 42A moves the I-shaped metal wires 32 moved by the operation of the first sorting conveyor section 41A to the first wire stocker section 51A of the first bending section 5A. The first pusher section 42A and the first wire stocker section 51A are disposed opposite to each other with the first sorting conveyor section 41A in between.

[0029] The second sorting section 4B has a second sorting conveyor section 41B and a second pusher section 42B. The second sorting conveyor section 41B includes a conveyor that receives the I-shaped metal wires 32 sent out from the second cutting section 3B one by one, sequentially sends the received I-shaped metal wires 32 at a predetermined pitch, and moves them to the second bending section 5B. The second pusher section 42B includes a pusher that delivers the I-shaped metal wires 32 moved by the operation of the second sorting conveyor section 41B to the second bending section 5B. Specifically, the second pusher section 42B moves the I-shaped metal wires 32 moved by the operation of the second sorting conveyor section 41B to the second wire stocker section 51B of the second bending section 5B.

[0030] FIG. 8 is a diagram relating to the first cutting section 3A, the first sorting conveyor section 41A, the first pusher section 42A, and the first wire stocker section 51A. As shown in FIG. 8, the first pusher section 42A includes a first pusher 42A1, a first second pusher 42A2, and a first third pusher 42A3 as a plurality of pushers (three in the illustrated example). The first pusher 42A1, the first second pusher 42A2, and the first third pusher 42A3 are configured to slide the moving parts (not shown) in the directions of the corresponding arrows 43a, 43b, and 43c (directions intersecting with the transport direction of the I-shaped metal wire 32 transported by the first sorting conveyor section 41A). The first pusher 42A1, the first second pusher 42A2, and the first third pusher 42A3 are, for example, servo press type pushers.

[0031] The first first pusher 42A1, the first second pusher 42A2, and the first third pusher 42A3 are configured to distribute the I-shaped metal wires 32 moved by the first distribution conveyor unit 41A to a plurality of stockers included in the first wire rod stocker unit 51A, for example, based on the number of each type of I-shaped metal wires 32 to be produced. The operation of each unit of the first distribution unit 4A and the operation of the first wire rod stocker unit 51A are controlled by a first wire rod preparation control unit 21A provided in the first wire rod preparation unit 2A.

[0032] The first bending section 5A is provided with a first wire stocker 51A for stocking the I-shaped metal wire 32 sorted from the first sorting conveyor 41A of the first sorting section 4A. The second bending section 5B is provided with a second wire stocker 51B for stocking the I-shaped metal wire 32 sorted from the second sorting conveyor 41B of the second sorting section 4B. As described above, the I-shaped metal wire 32 is used as the dedicated wire P and the special wire S. Therefore, the first wire stocker 51A and the second wire stocker 51B function as a stocker for stocking the I-shaped metal wire 32 used as the dedicated wire P, or a stocker for stocking the I-shaped metal wire 32 used as the special wire S.

[0033] In the illustrated example, in the first wire stocker section 51A, a first stocker of the first wire stocker section 51A facing the first first pusher 42A1 is provided as a first first dedicated line stocker 51A1 for stocking an I-type metal wire 32 (metal wire 32a in FIG. 8) used as a dedicated line P. A second stocker of the first wire stocker section 51A facing the first second pusher 42A2 is provided as a first second dedicated line stocker 51A2 for stocking an I-type metal wire 32 (metal wire 32a in FIG. 8) used as a dedicated line P. And a third stocker of the first wire stocker section 51A facing the first third pusher 42A3 is provided as a first special wire stocker 51A3 for stocking an I-type metal wire 32 (metal wire 32b in FIG. 8) used as a special wire S.

[0034] Similarly, in the wire stocker 51B, a stocker facing the second pusher 42B1 is provided as a first dedicated line stocker 51B1 that stocks the I-type metal wire 32 (metal wire 32a) used as the dedicated line P. A stocker facing the second pusher 42B2 is provided as a second dedicated line stocker 51B2 that stocks the I-type metal wire 32 (metal wire 32a) used as the dedicated line P. A stocker facing the second pusher 42B3 is provided as a special wire stocker 51B3 that stocks the I-type metal wire 32 (metal wire 32b) used as the special wire S.

[0035] FIG. 9 is a perspective view showing the bending section 5 and the coil manufacturing section 8. As shown in FIG. As shown in Figure 9, the bending processing section 5 has a dedicated line bending section 60 that bends the I-shaped metal wire 32 to produce a dedicated line P, and a special wire bending section 70 that bends the I-shaped metal wire 32 to produce a special wire S.

[0036] The dedicated line bending unit 60 has a first dedicated line bending unit 60A that bends the I-shaped metal wire 32 sorted from the first sorting conveyor unit 41A of the sorting unit 4 to produce the dedicated line P. The dedicated line bending unit 60 also has a second dedicated line bending unit 60B that bends the I-shaped metal wire 32 sorted from the second sorting conveyor unit 41B of the sorting unit 4 to produce the dedicated line P.

[0037] The special wire bending unit 70 has a first special wire bending unit 70A that bends the I-shaped metal wire 32 distributed from the first sorting conveyor unit 41A of the sorting unit 4 to produce the special wire S. The special wire bending unit 70 also has a second special wire bending unit 70B that bends the I-shaped metal wire 32 distributed from the second sorting conveyor unit 41B of the sorting unit 4 to produce the special wire S. The first dedicated line bending unit 60A further includes a first first dedicated line bending unit 60A1 and a first second dedicated line bending unit 60A2. The second dedicated line bending unit 60B further includes a second first dedicated line bending unit 60B1 and a second second dedicated line bending unit 60B2.

[0038] The first first dedicated line bending unit 60A1 has a first first dedicated line processing unit 61A1. The first first dedicated line bending unit 60A1 also has a first first dedicated line stocker 51A1. The first second dedicated line bending unit 60A2 has a first second dedicated line processing unit 61A2. The first second dedicated line bending unit 60A2 also has a first second dedicated line stocker 51A2.

[0039] The second first dedicated line bending section 60B1 has a second first dedicated line processing section 61B1. The second first dedicated line bending section 60B1 also has a second first dedicated line stocker 51B1. The second second dedicated line bending section 60B2 has a second second dedicated line processing section 61B2. The second second dedicated line bending section 60B2 also has a second dedicated line stocker 51B2.

[0040] The first special wire bending unit 70A has a first special wire processing unit 71A. The first special wire bending unit 70A also has a first special wire stocker 51A3. The second special wire bending unit 70B has a second special wire processing unit 71B. The second special wire bending unit 70B also has a second special wire stocker 51B3.

[0041] The first first dedicated line processing unit 61A1 is a processing unit that bends an I-shaped metal wire 32 transferred from the first first dedicated line stocker 51A1 into a U-shape to fabricate a dedicated line P. The first second dedicated line processing unit 61A2 is a processing unit that bends an I-shaped metal wire 32 transferred from the first second dedicated line stocker 51A2 into a U-shape to fabricate a dedicated line P.

[0042] The second first dedicated line processing unit 61B1 is a processing unit that bends the I-shaped metal wire 32 transferred from the second first dedicated line stocker 51B1 into a U-shape to fabricate the dedicated line P. The second second dedicated line processing unit 61B2 is a processing unit that bends the I-shaped metal wire 32 transferred from the second second dedicated line stocker 51B2 into a U-shape to fabricate the dedicated line P.

[0043] The first first dedicated line processing unit 61A1 is provided with a first first dedicated line transfer mechanism 62A1, for example, a feed roller, for transferring the I-shaped metal wire 32 from the first first dedicated line stocker 51A1 to the first first dedicated line processing unit 61A1. Similarly, the first second dedicated line processing unit 61A2 is provided with a first second dedicated line transfer mechanism 62A2 for transferring the I-shaped metal wire 32 from the first second dedicated line stocker 51A2 to the first second dedicated line processing unit 61A2. Similarly, the second first dedicated line processing unit 61B1 is provided with a second first dedicated line transfer mechanism 62B1 for transferring the I-shaped metal wire 32 from the second first dedicated line stocker 51B1 to the second first dedicated line processing unit 61B1. Similarly, the second second dedicated line processing unit 61B2 is provided with a second second dedicated line transfer mechanism 62B2 that transfers the I-shaped metal wire 32 from the second second dedicated line stocker 51B2 to the second second dedicated line processing unit 61B2.

[0044] The first special wire processing unit 71A is a processing unit that bends the I-shaped metal wire 32 stocked in the first special wire stocker 51A3 into a predetermined shape to produce the special wire S. The second special wire processing unit 71B is a processing unit that bends the I-shaped metal wire 32 stocked in the second special wire stocker 51B3 into a predetermined shape to produce the special wire S.

[0045] The first special wire processing unit 71A is provided with a first special wire transfer mechanism 72A that transfers the I-shaped metal wire 32 stocked in the first special wire stocker 51A3 to the working area of ​​the first special wire processing unit 71A. The second special wire processing unit 71B is provided with a second special wire transfer mechanism 72B (see FIG. 7) that transfers the I-shaped metal wire 32 stocked in the second special wire stocker 51B3 to the working area of ​​the second special wire processing unit 71B.

[0046] 10 is a diagram showing the configuration of the first first dedicated line processing unit 61A1 and the state of bending processing of the dedicated line P in the first first dedicated line processing unit 61A1. The first second dedicated line processing unit 61A2, the second first dedicated line processing unit 61B1, and the second second dedicated line processing unit 61B2 are also configured in the same way and are bent in the same way.

[0047] 9 and 10, the first dedicated line processing unit 61A1 has a fulcrum determining portion 611 that abuts against a bending fulcrum p1 of an I-shaped metal wire 32 to be bent into a dedicated line P, a first bending chuck 612a that holds one end of the I-shaped metal wire 32 to be bent, and a second bending chuck 612b that holds the other end opposite to the one end. Furthermore, the first dedicated line processing unit 61A1 has an alignment unit 613 for aligning the bending fulcrum p1 of the dedicated line P with the fulcrum determining portion 611 of the first dedicated line processing unit 61A1.

[0048] The first first dedicated line processing unit 61A1 aligns the bending fulcrum p1 of the dedicated line P with the fulcrum definition unit 611 by abutting the I-shaped metal wire 32 transferred from the first first dedicated line stocker 51A1 against the positioning unit 613. Next, the first bending chuck 612a and the second bending chuck 612b holding the metal wire 32 are moved in the directions of arrows 614a and 614b so as to approach each other, thereby bending the I-shaped metal wire 32 into a U-shaped dedicated line P with the fulcrum definition unit 611 with which the bending fulcrum p1 of the metal wire 32 abuts as a fulcrum.

[0049] 11 is a diagram showing the configuration of the first special wire processing unit 71A and how the special wire S is bent in the first special wire processing unit 71A. The second special wire processing unit 71B is similarly configured and is bent in the same manner.

[0050] 9 and 11, the first special wire processing unit 71A includes a first placement unit 714 where the I-shaped metal wire 32 is bent, a forming unit 710 that moves the I-shaped metal wire 32, and a first special wire transfer mechanism 72A that transfers the I-shaped metal wire 32 to a take-out position of the forming unit 710. The first placement unit 714 includes a reference abutment unit 711 that abuts against one end of the I-shaped metal wire 32 to be bent into a special wire S, and a reference holding unit 712 that holds the one end side of the I-shaped metal wire 32 abutted against the reference abutment unit 711. The forming unit 710 includes a forming mechanism unit 713 that bends the I-shaped metal wire 32 into a special wire S of a predetermined shape, and a forming and moving mechanism 7101 that moves the forming mechanism unit 713. The special wire S is bent by the forming unit 710 bending a predetermined portion on the end side opposite to one end side of the I-shaped metal wire 32 held on the first mounting part 714. Similar to the first special wire processing part 71A, the second special wire processing part 71B includes a second mounting part 724 where the bending work of the I-shaped metal wire 32 is performed, a forming unit 720 that moves the I-shaped metal wire 32, and a second special wire transfer mechanism 72B (see FIG. 7) that transfers the I-shaped metal wire 32 to the take-out position of the forming unit 720.

[0051] 11 is an enlarged view of the forming mechanism 713 in the circular region R. The forming mechanism 713 is a work tool that performs bending processing on the I-shaped metal wire 32. The forming movement mechanism 7101 moves the forming mechanism 713 to a predetermined position and posture. For example, a six-axis robot (multi-joint robot) that can freely bend arms is used as the forming movement mechanism 7101.

[0052] The first special wire processing unit 71A grips the I-shaped metal wire 32 transferred from the first special wire stocker 51A3 to the first placement unit 714 (see FIG. 7) with the gripping unit 715 of the forming mechanism unit 713, and supports the I-shaped metal wire 32 at a predetermined position by abutting one end of the I-shaped metal wire 32 against the reference abutment unit 711. The first special wire processing unit 71A also holds the one end side of the I-shaped metal wire 32 abutting against the reference abutment unit 711 with the reference holding unit 712 to fix the I-shaped metal wire 32 at a predetermined position. The first special wire processing unit 71A bends the I-shaped metal wire 32 into a predetermined shape by operating the forming unit 710, thereby producing the special wire S. The first special wire processing unit 71A inserts the special wire S, which has been bent, into a predetermined placement position on the dedicated pallet 716 by operating the forming unit 710.

[0053] The dedicated wire P bent at the first first dedicated wire processing unit 61A1 and the first second dedicated wire processing unit 61A2, and the special wire S bent at the first special wire processing unit 71A are transported to the coil production unit 8. Similarly, the dedicated wire P bent at the second first dedicated wire processing unit 61B1 and the second second dedicated wire processing unit 61B2, and the special wire S bent at the second special wire processing unit 71B are transported to the coil production unit 8.

[0054] FIG. 12 is a partial enlarged view showing a conveying section of the coil manufacturing section 8 that conveys the bent dedicated wire P and special wire S. As shown in FIG. 7, FIG. 9, and FIG. 12, the coil manufacturing unit 8 has a first manufacturing unit 80 and a second manufacturing unit 90. The coil manufacturing unit 8 also has a coil transfer unit 8H that transfers the manufactured coil member C. The first manufacturing unit 80 manufactures the coil member C using the dedicated line P bent by the first first dedicated line processing unit 61A1 and the first second dedicated line processing unit 61A2 and the special wire S bent by the first special wire processing unit 71A. The second manufacturing unit 90 manufactures the coil member C using the dedicated line P bent by the second first dedicated line processing unit 61B1 and the second second dedicated line processing unit 61B2 and the special wire S bent by the second special wire processing unit 71B. The coil transfer unit 8H transfers the coil member C manufactured by the first manufacturing unit 80 and the second manufacturing unit 90 to the next process (a process downstream of the coil manufacturing unit 8). The coil transfer unit 8H is, for example, a conveyor, and transfers the coil member C. The coil member C is transported by a transport body 8P that supports the coil member C at a predetermined position.

[0055] FIG. 13 is a diagram showing an example of a coil body. As shown in FIG. 13, the two coil members C produced in this embodiment are two-layered coil members C having a first coil member C1, the first of which is the coil member of the outer layer, and a second coil member C2, the second of which is the coil member of the inner layer. The first production unit 80 is a production unit that produces the first coil member C1, which is the coil member of the outer layer. The second production unit 90 is a production unit that produces the second coil member C2, which is the coil member of the inner layer. The first production unit 80 and the second production unit 90 are provided at predetermined positions in the coil transfer unit 8H. In this embodiment, the second production unit 90 is provided at a predetermined position in the coil transfer unit 8H upstream of the first production unit 80 (for example, the upper side in FIG. 7).

[0056] Between the first fabrication unit 80 and the first first dedicated line processing unit 61A1, a first first dedicated line conveying unit 81 is disposed to convey the dedicated line P bent in the first first dedicated line processing unit 61A1. In addition, between the first fabrication unit 80 and the first second dedicated line processing unit 61A2, a first second dedicated line conveying unit 82 is disposed to convey the dedicated line P bent in the first second dedicated line processing unit 61A2. In addition, between the first fabrication unit 80 and the first special line processing unit 71A, a first special line conveying unit 83 is disposed to convey the special line S bent in the first special line processing unit 71A. Each conveying unit 81, 82, 83 is a conveyor. In addition, between the first fabrication unit 80 and the first first dedicated line conveying unit 81, a first first dedicated line conveying chute 811 is disposed to receive the dedicated line P from the first first dedicated line conveying unit 81 and convey the dedicated line P to the first fabrication unit 80. In addition, a first second dedicated line conveying chute 821 is disposed between the first fabrication unit 80 and the first second dedicated line conveying unit 82, which receives the dedicated line P from the first second dedicated line conveying unit 82 and conveys the dedicated line P to the first fabrication unit 80.

[0057] Between the second fabrication unit 90 and the second first dedicated line processing unit 61B1, a second first dedicated line conveying unit 91 is disposed to convey the dedicated line P bent in the second first dedicated line processing unit 61B1. Between the second fabrication unit 90 and the second second dedicated line processing unit 61B2, a second second dedicated line conveying unit 92 is disposed to convey the dedicated line P bent in the second second dedicated line processing unit 61B2. Between the second fabrication unit 90 and the second special line processing unit 71B, a second special line conveying unit 93 is disposed to convey the special line S bent in the second special line processing unit 71B. Each conveying unit 91, 92, 93 is a conveyor. Between the second fabrication unit 90 and the second first dedicated line conveying unit 91, a second first dedicated line conveying chute 911 is disposed to receive the dedicated line P from the second first dedicated line conveying unit 91 and convey the dedicated line P to the second fabrication unit 90. In addition, a second second dedicated line conveying chute 921 is arranged between the second manufacturing section 90 and the second second dedicated line conveying section 92, which receives the dedicated line P from the second second dedicated line conveying section 92 and transfers the dedicated line P to the second manufacturing section 90.

[0058] The dedicated wire P bent into a U-shape by the first first dedicated wire processing unit 61A1 is transported to the first fabrication unit 80 while being hooked on the first first dedicated wire transport chute 811 provided in the first first dedicated wire transport unit 81, as shown in FIG. 12. Similarly, the dedicated wire P bent into a U-shape by the first second dedicated wire processing unit 61A2 is transported to the first fabrication unit 80 while being hooked on the first second dedicated wire transport chute 821 provided in the first second dedicated wire transport unit 82. Also, the special wire S bent by the first special wire processing unit 71A is transported to the first fabrication unit 80 while being placed on a special pallet 716 prepared in the first special wire transport unit 83 (inserted in this embodiment), as shown in FIG. 12. Although not shown, the dedicated wire P and the special wire S are transported to the second fabrication unit 90 in the same manner on the second fabrication unit 90 side.

[0059] In the second manufacturing section 90, a second coil member manufacturing unit 901 used for manufacturing the second coil member C2 is prepared. In the second manufacturing section 90, the dedicated wire P and the special wire S for manufacturing the second coil member C2 are arranged in the second coil member manufacturing unit 901, and a predetermined operation is performed to manufacture the second coil member C2 before being assembled into the stator core SC. Meanwhile, the special wire S is arranged at a predetermined arrangement position in the second coil member manufacturing unit 901 where the second coil member C2 is manufactured, and is moved together with the second coil member C2 and attached to a predetermined position of the second coil member C2 by a special wire attachment part of the special wire S provided midway on the way to the coil insertion section 102.

[0060] A first coil member manufacturing unit 801 used for manufacturing the first coil member C1 is prepared in the first manufacturing section 80. The first manufacturing section 80 manufactures the first coil member C1 in the same manner as the second manufacturing section 90. In the first manufacturing section 80, the dedicated wire P and special wire S for manufacturing the first coil member C1 are placed in the first coil member manufacturing unit 801, and a predetermined operation is performed to manufacture the first coil member C1 before it is assembled to the stator core SC. On the other hand, the special wire S is placed at a predetermined position in the first coil member manufacturing unit 801 in which the first coil member C1 is manufactured, moved together with the first coil member C1, and attached to a predetermined position of the first coil member C1 by a special wire attachment portion of the special wire S that is provided on the way to the coil insertion portion 102.

[0061] 14 is a diagram showing an example of a stator ST composed of a stator core SC and a coil member C. A special wire S is incorporated at a predetermined position into the coil member C produced as described above, which is then incorporated into the stator core SC, and the stator ST is manufactured by performing a predetermined operation in the coil assembly system 100.

[0062] Next, in the coil manufacturing system 1 configured as described above, a description will be given of the control of the adjustment of the discharge of the I-shaped metal wire 32 of a predetermined length prepared in the wire preparation unit 2 from the wire preparation unit 2 to the bending processing unit 5. As described above, the operation of the wire preparation unit 2 (the cutting unit 3 and the sorting unit 4) is controlled by the wire preparation control unit 21.

[0063] (Example of disbursement adjustment control) The first coil member C1, which is the outer layer, and the second coil member C2, which is the inner layer, constituting the multiple-layer coil member C (in this embodiment, the coil member C has two layers of coil members) are each produced by combining 42 dedicated wires P and 9 special wires S. The number of wires required for the first coil wire C1 and the second coil member C2 is 51 [wires / unit] each, and the number of wires required for the coil member C, which is the combination of the first coil member C1 and the second coil member C2, is 102 [wires / unit].

[0064] The I-shaped metal wires bent into the 42 dedicated lines P include 36 I-shaped metal wires of a first length (hereinafter referred to as the first I-shaped metal wires) and 6 I-shaped metal wires of a second length (hereinafter referred to as the second I-shaped metal wires). The I-shaped metal wires bent into the 9 special lines S include 3 I-shaped metal wires of a third length (hereinafter referred to as the third I-shaped metal wires) and 6 I-shaped metal wires of a fourth length (hereinafter referred to as the fourth I-shaped metal wires).

[0065] The first bending processing section 5A of the bending processing unit 5, which bends the I-shaped metal wire 32 delivered from the first wire preparation section 2A of the wire preparation unit 2 into a dedicated wire P and a special wire S, has a first first dedicated wire processing section 61A1 and a first second dedicated wire processing section 61A2 that bend the dedicated wire P, and a first special wire processing section 71A that bends the special wire S, as processing sections that produce the first coil member C1 that becomes the outer layer.

[0066] The first I-shaped metal wire (36 wires) is bent by the first first dedicated wire processing unit 61A1, and the second I-shaped metal wire (6 wires) is bent by the first second dedicated wire processing unit 61A2. The first special wire processing unit 71A is also bent to bend the third I-shaped metal wire (3 wires) and the fourth I-shaped metal wire (6 wires).

[0067] Also, the first processing time S1 [seconds / wire] required for the first first dedicated wire processing unit 61A1 to bend one first I-shaped metal wire, the second processing time S2 [seconds / wire] required for the first second dedicated wire processing unit 61A2 to bend one second I-shaped metal wire, the third processing time S3 [seconds / wire] required for the first special wire processing unit 71A to bend one third I-shaped metal wire, and the fourth processing time S4 ​​[seconds / wire] required for the first special wire processing unit 71A to bend one fourth I-shaped metal wire are all determined. For example, the first processing time S1 of the first I-shaped metal wire is shorter than the third processing time S3 of the third I-shaped metal wire or the fourth processing time S4 ​​of the fourth I-shaped metal wire. That is, when comparing the single processing times, the dedicated wire P can be bent faster than the special wire S.

[0068] Under such manufacturing conditions, the wire preparation control unit 21 controls the adjustment of the feeding of the I-shaped metal wire 32 from the wire preparation unit 2 to the bending unit 5 for each required number of wires in the coil members C (the required number of wires in the first coil member C1 of the outer layer, and the required number of wires in the second coil member C2 of the inner layer). In addition, the wire preparation control unit 21 controls the adjustment of the feeding of the I-shaped metal wire 32 from the wire preparation unit 2 to the bending unit 5 in accordance with, for example, the ratio of the processing time required to bend the dedicated wire P to the processing time required to bend the special wire S.

[0069] For example, the first wire preparation control unit 21A of the wire preparation control unit 21 controls the operation of the wire cutting unit 36 ​​in the first cutting unit 3A of the first wire preparation unit 2A by first controlling the cutting of 12 first I-shaped metal wires, then controlling the cutting of two second I-shaped metal wires, then controlling the cutting of one third I-shaped metal wire, and then controlling the cutting of two fourth I-shaped metal wires. The cutting of each wire in this order is considered as one cycle, and three cycles of repeated control are performed in the first wire preparation unit 2A to cut out the required number of wires (51 wires) for the first coil member C1 of the outer layer. The wires cut out by the first wire preparation control unit 21A controlling the first wire preparation unit 2A are transported from the first cutting unit 3A to the first sorting conveyor unit 41A of the first sorting unit 4A in the order in which they were cut out.

[0070] The first wire preparation control unit 21A controls the first sorting unit 4A to sort the wires moving on the first sorting conveyor unit 41A into the first first dedicated wire stocker 51A1, the first second dedicated wire stocker 51A2, and the first special wire stocker 51A3 of the first bending unit 5A according to type. Specifically, the first wire preparation control unit 21A controls the first sorting unit 4A to sort 12 first I-shaped metal wires into the first first dedicated wire stocker 51A1, 2 second I-shaped metal wires into the first second dedicated wire stocker 51A2, and 1 third I-shaped metal wire and 2 fourth I-shaped metal wires into the first special wire stocker 51A3. In other words, the first wire preparation control unit 21A controls the allocation of various wires to the first wire stocker unit 51A so that the first allocation unit 4A allocates 12 first I-type metal wires to the first first dedicated wire processing unit 61A1, 2 second I-type metal wires to the first second dedicated wire processing unit 61A2, and 1 third I-type metal wire and 2 fourth I-type metal wires to the first special wire processing unit 71A.

[0071] The first wire preparation control unit 21A controls the first sorting unit 4A to sort 36 first I-type metal wires to the first first dedicated line stocker 51A1, 6 second I-type metal wires to the first second dedicated line stocker 51A2, and 3 third I-type metal wires and 6 fourth I-type metal wires to the first special wire stocker 51A3 in the sorting control of the first sorting unit 4A performed in conjunction with the three-cycle cut-out control. In other words, the first wire preparation control unit 21A controls the first wire stocker unit 51A to sort 36 first I-type metal wires to the first first dedicated line processing unit 61A1, 6 second I-type metal wires to the first second dedicated line processing unit 61A2, and 3 third I-type metal wires and 6 fourth I-type metal wires to the first special wire processing unit 71A in the sorting control of the first sorting unit 4A performed in conjunction with the three-cycle cut-out control.

[0072] In the above control example, the first I-type metal wire is allocated to the first first dedicated line stocker 51A1 and the second I-type metal wire is allocated to the first second dedicated line stocker 51A2, but the present invention is not limited to this. For example, the second I-type metal wire may be allocated to the first first dedicated line stocker 51A1 and the first I-type metal wire may be allocated to the first second dedicated line stocker 51A2.

[0073] In the above control example, the third I-shaped metal wire and the fourth I-shaped metal wire to be bent into the special wire S are assigned to one first special wire processing unit 71A for bending, but the present invention is not limited to this. For example, two special wire processing units may be provided, and the third I-shaped metal wire and the fourth I-shaped metal wire may be assigned to one special wire processing unit each for bending.

[0074] In the above control example, the allocation control is described for the case where the I-shaped metal wires to be bent into the dedicated line P are two types of I-shaped metal wires, a first I-shaped metal wire and a second I-shaped metal wire, which are different in length, but the present invention is not limited to this. For example, the I-shaped metal wires may be I-shaped metal wires having the same length but different bending positions. In such a case, two dedicated line processing sections may be provided, and control may be performed to allocate 36 / 42 I-shaped metal wires to one dedicated line processing section and 6 / 42 I-shaped metal wires to the other dedicated line processing section, as in the above control example. Furthermore, the I-shaped metal wires to be bent into the dedicated line P may be two types of I-shaped metal wires having different lengths and bending positions.

[0075] In the above control example, the allocation control is described in the case where two dedicated line processing units are prepared and 36 first I-type metal wires are allocated to the first dedicated line processing unit 61A1 and 6 second I-type metal wires are allocated to the first second dedicated line processing unit 61A2, but the present invention is not limited to this. For example, three dedicated line processing units may be prepared. In this case, for example, the control may be performed so that 18 / 42 first I-type metal wires are allocated to the first dedicated line processing unit, 18 / 42 first I-type metal wires are allocated to the second dedicated line processing unit, and 6 / 42 second I-type metal wires are allocated to the third dedicated line processing unit.

[0076] As described above, when different types of dedicated wires P and special wires S are automatically combined on a production line to produce coil member C, the production efficiency of the coil member C may become an issue, for example, because the processing time required to process wire material into a dedicated wire P of a predetermined shape differs from the processing time required to process wire material into a special wire S of a predetermined shape.

[0077] In contrast, the coil manufacturing system 1 according to the present embodiment is configured to adjust the number of I-shaped metal wires 32 allocated to each processing unit according to the ratio between the processing time for bending the I-shaped metal wire 32 into the dedicated wire P in the first first dedicated wire processing unit 61A1 and the first second dedicated wire processing unit 61A2 and the processing time for bending the I-shaped metal wire 32 into the special wire S in the first special wire processing unit 71A. In other words, the balance of the processing load can be adjusted so that the processing load in any of the processing units is not large. Therefore, it is possible to suppress the occurrence of a period in which a processing unit performing bending processing and a processing unit not performing bending processing exist simultaneously, and the manufacturing efficiency of the coil member C can be improved.

[0078] Specifically, the number of the first I-shaped metal wire, the second I-shaped metal wire, the third I-shaped metal wire, and the fourth I-shaped metal wire cut out by the first cutting section 3A of the first wire preparation section 2A is adjusted according to the ratio of the bending time of the dedicated wire P to the bending time of the special wire S, and the cut metal wires can be distributed to each processing section of the first bending processing section 5A by the first sorting section 4A in the order of cutting. Therefore, it is possible to operate the processing device at each processing section at all times without waste so that there is no waiting time at each wire processing section. In addition, the I-shaped metal wire 32 can be stocked without interruption (empty) in the first wire stocker 51A of the first bending processing section 5A. In addition, the first wire stocker 51A of the first bending processing section 5A stocks the I-shaped metal wire 32 sorted from the first sorting section 4A, so that the sorting operation of the first sorting section 4A can be continued even if the work of the first bending processing section 5A is stopped. This improves the manufacturing efficiency of the coil member C.

[0079] Next, there will be described a method for manufacturing the coil member C using the coil manufacturing system 1. According to the coil manufacturing system 1, the following manufacturing method for the coil member C is carried out. The manufacturing method of this embodiment is as follows: A method for manufacturing a coil member C for use in a stator ST, the coil member C having a U-shaped dedicated wire P forming a coil body and a special wire S having a shape different from that of the dedicated wire P, a wire preparation process for preparing an I-shaped metal wire 32 having a predetermined length before being formed into the dedicated line P and the special line S; a dedicated line bending process for bending the I-shaped metal wire 32 into a U-shape to produce a dedicated line P; a special wire bending process for bending the I-shaped metal wire 32 to produce a special wire S; and a coil manufacturing process for manufacturing a coil member C using a dedicated wire P and a special wire S. In the wire preparation process, the ratio of the number of I-shaped metal wires 32 allocated to the dedicated wire bending process and the number of I-shaped metal wires 32 allocated to the special wire bending process is adjusted according to the ratio of the processing time required for the dedicated wire bending process to the processing time required for the special wire bending process. In this manufacturing method, the wire preparation process is performed in the wire preparation section 2 in the coil manufacturing system 1, the dedicated wire bending process is performed in the dedicated wire bending section 60 of the bending processing section 5, the special wire bending process is performed in the special wire bending section 70 of the bending processing section 5, and the coil production process is performed in the coil production section 8.

[0080] According to the manufacturing method of this embodiment, when manufacturing the coil member C having the dedicated wire P and the special wire S, the ratio of the numbers of I-shaped metal wires 32 allocated to each wire bending process is adjusted according to the processing time of each I-shaped metal wire 32. As a result, the completion timing of the dedicated wire bending process and the special wire bending process can be brought closer together, and the respective processing times can be made uniform, so that no large time difference occurs while waiting for the other wire bending process, and the coil member C can be manufactured efficiently. This makes it possible to provide a manufacturing method suitable for manufacturing the coil member C.

[0081] The manufacturing method of this embodiment is as follows: A method for manufacturing a coil member C for use in a stator ST, the coil member C having a U-shaped dedicated wire P forming a coil body and a special wire S having a shape different from that of the dedicated wire P, a wire preparation step of preparing a first wire having a first predetermined length and a second wire having a second predetermined length before being formed into a dedicated line P or a special line S; a dedicated line bending process of bending the first wire into a U-shape to prepare a dedicated line P; a special wire bending process for bending the second wire to produce a special wire S; and a coil manufacturing process for manufacturing a coil member C using a dedicated wire P and a special wire S. The wire preparation process includes a sorting process for sorting the first I wire to a dedicated wire bending process and sorting the second wire to a special wire bending process. In the allocation process, the ratio of the number of first wires to be allocated to the dedicated wire bending process and the number of second wires to be allocated to the special wire bending process is adjusted according to the ratio of the processing time required for the dedicated wire bending process to the processing time required for the special wire bending process.

[0082] According to the manufacturing method of this embodiment, the required number of dedicated wires P and special wires S used for one stator ST can be efficiently manufactured.

[0083] In the manufacturing method of this embodiment, In the sorting process, the I-shaped metal wire 32 is sorted to the dedicated bending process and the special bending process based on the type and number of the dedicated lines P and special lines S to be manufactured.

[0084] In the manufacturing method of this embodiment, The wire preparing step includes a length determining step of determining whether a first wire has a first predetermined length or a second wire has a second predetermined length based on the length of the prepared I-shaped metal wire 32 .

[0085] In the manufacturing method of this embodiment, The wire preparation step includes a wire cutting step of cutting out an I-shaped metal wire 32 from a single reel around which a continuous metal wire that will become the first wire and the second wire is wound.

[0086] In the manufacturing method of this embodiment, The dedicated line bending process is a dedicated line stocking step of stocking a first wire rod in a first dedicated line stocker 51A1 and a first dedicated line stocker 51A2; Special wire bending process: The process includes a special wire stocking step of stocking the second wire in a first special wire stocker 51A3. The dedicated line bending process includes bending the first wire rod sent out from the first dedicated line stocker 51A1 and the first dedicated line stocker 51A2 to prepare a dedicated line P; In the special wire bending process, the special wire S is produced by bending the second wire sent out from the first special wire stocker 51A3.

[0087] According to the manufacturing method of this embodiment, by stocking wires in a stocker, wires can be supplied to the dedicated wire bending process and the special wire bending process without interruption. Also, by stocking each wire, production can be continued in each bending process. Even if production work in each bending process is stalled, the sorting operation in the sorting process can be continued.

[0088] In the manufacturing method of this embodiment, The coil member C has a first dedicated line P which is a coil body and a second dedicated line P having a length different from that of the first dedicated line P, In the dedicated line bending process, a first dedicated line P and a second dedicated line P are prepared. 7 and 9, the first dedicated line P is a dedicated line P produced by bending an I-shaped metal wire 32 transferred from the first first dedicated line stocker 51A1 into a U-shape. The second dedicated line P is a dedicated line P produced by bending an I-shaped metal wire 32 transferred from the first second dedicated line stocker 51A2 into a U-shape.

[0089] In the manufacturing method of this embodiment, as shown in FIG. The dedicated line bending process is a dedicated wire forming process in which one end and the other end of the first wire are brought close to each other around a bending fulcrum portion p1 set between the one end and the other end of the first wire as a fulcrum to form the first wire into a U-shape; and a fulcrum positioning step of aligning the fulcrum portion p1 to the position of the fulcrum. In the fulcrum positioning step, the alignment is performed by adjusting the distance between either one of the one end portion or the other end portion and the fulcrum portion p1.

[0090] In the manufacturing method of this embodiment, as shown in FIG. Special wire bending process: a reference holding step of aligning one end of the second wire at a reference position serving as a reference and holding the one end side of the second wire; and a special wire forming step of moving the other end of the second wire to form the second wire into a desired shape, thereby producing a special wire S having a desired shape.

[0091] The manufacturing method of this embodiment, as shown in FIGS. 7, 9 and 12, In the coil manufacturing process, the dedicated wire P and the special wire S are combined in a designated work area. A dedicated wire P produced by the dedicated wire bending process in the number required for one coil member C and a special wire S produced by the special wire bending process in the number required for one coil member C are both supplied to the working area.

[0092] Although the embodiment of the present invention has been described above, it goes without saying that the technical scope of the present invention should not be interpreted as being limited by the description of the embodiment. The embodiment is merely an example, and it is understood by those skilled in the art that various modifications of the embodiment are possible within the scope of the invention described in the claims. The technical scope of the present invention should be determined based on the scope of the invention described in the claims and its equivalents. [Explanation of symbols]

[0093] 1: coil manufacturing system, 2: wire preparation section, 3: cutting section, 3A: first cutting section, 3B: second cutting section, 4: sorting section, 5: bending section, 8: coil production section, 21: wire preparation control section, 31: coil delivery section, 32: metal wire, 36: wire cut-out section, 37: wire transport section, 38: length discrimination section, 41A: first sorting conveyor section, 41B: second sorting conveyor section, 42A: first pusher section, 42B: second pusher section, 51A: first wire stocker section, 51B: second wire stocker section, 51A1: first first dedicated line stocker, 51A2: first second dedicated line stocker, 51A3: first special Line stocker, 51B1: second first dedicated line stocker, 51B2: second second dedicated line stocker, 51B3: second special line stocker, 60: dedicated line bending section, 60A: first dedicated line bending section, 60B: second dedicated line bending section, 61A1: first first dedicated line processing section, 61A2: first second dedicated line processing section, 61B1: second first dedicated line processing section, 61B2: second second dedicated line processing section, 62A1: first first dedicated line transfer mechanism, 62A2: first second dedicated line transfer mechanism, 62B1: second first dedicated line transfer mechanism, 62B2: second second dedicated line transfer mechanism, 70: special line bending section, 70A: first Special wire bending unit, 70B: second special wire bending unit, 71A: first special wire processing unit, 71B: second special wire processing unit, 72A: first special wire transfer mechanism, 72B: second special wire transfer mechanism, 80: first manufacturing unit, 81: first first dedicated line conveying unit, 82: first second dedicated line conveying unit, 83: first special wire conveying unit, 90: second manufacturing unit, 91: second first dedicated line conveying unit, 92: second second dedicated line conveying unit, 93: second special wire conveying unit, 100: coil assembly system, 100a: stator core preparation unit, 100b: coil assembly unit, 100c: stator processing unit, 101: stator core supply unit, 102 : coil insertion section, 106: removal section, 200: stator manufacturing system, 611: fulcrum determination section, 612a: first bending chuck, 612b: second bending chuck, 613: alignment unit, 711: reference abutment section, 712: reference holding section, 713: forming mechanism section, 714: first placement section, 801: first coil member manufacturing unit, 811: first first dedicated line conveying chute, 821: first second dedicated line conveying chute, 901: second coil member manufacturing unit, 911: second first dedicated line conveying chute, 921: second second dedicated line conveying chute, C: coil member, P: dedicated line,S: Special wire, SC: Stator core, ST: Stator,

Claims

1. A method for manufacturing a coil member for use in a stator, the coil member having a U-shaped dedicated wire forming a coil body and a special wire having a shape different from that of the dedicated wire, comprising the steps of: a wire preparation step of preparing a wire of a predetermined length before being formed into the dedicated wire and the special wire; a dedicated line bending process for bending the wire into a U-shape to produce the dedicated line; a special wire bending process of bending the wire rod to produce the special wire; a coil manufacturing process of manufacturing the coil member using the dedicated wire and the special wire, A method for manufacturing a coil member, in which, in the wire preparation process, the ratio of the number of wire rods allocated to the dedicated wire bending process and the number of wire rods allocated to the special wire bending process is adjusted according to the ratio of the processing time required for the dedicated wire bending process to the processing time required for the special wire bending process.

2. A method for manufacturing a coil member for use in a stator, the coil member having a U-shaped dedicated wire forming a coil body and a special wire having a shape different from that of the dedicated wire, comprising the steps of: a wire preparation step of preparing a first wire having a first predetermined length and a second wire having a second predetermined length before being formed into the dedicated wire or the special wire; a dedicated line bending process of bending the first wire into a U-shape to prepare the dedicated line; a special wire bending step of bending the second wire to produce the special wire; a coil manufacturing process of manufacturing the coil member using the dedicated wire and the special wire, the wire rod preparing step includes a sorting step of sorting the first wire rod to the dedicated wire bending step and sorting the second wire rod to the special wire bending step, A method for manufacturing a coil member, in which, in the allocation process, the ratio of the number of the first wire rods allocated to the dedicated wire bending process and the number of the second wire rods allocated to the special wire bending process is adjusted according to the ratio of the processing time required for the dedicated wire bending process to the processing time required for the special wire bending process.

3. 3. The method for manufacturing a coil member according to claim 2, wherein the allocation step allocates the first wire and the second wire to the dedicated wire bending step and the special wire bending step based on the types and numbers of the dedicated wires and the special wires to be produced.

4. The method for manufacturing a coil member according to claim 2, wherein the wire preparation process includes a length discrimination process for discriminating between the first wire having a first predetermined length and the second wire having a second predetermined length based on the length of the prepared metal wire.

5. 5. The method for manufacturing a coil member according to claim 4, wherein the wire preparation step includes a wire cutting step of cutting out the metal wire from a single reel around which a continuous piece of the metal wire that becomes the first wire and the second wire is wound.

6. The dedicated line bending process includes: a dedicated line stocking step of stocking the first wire rod in a dedicated line stocker; The special wire bending process includes: a special wire stocking step of stocking the second wire rod in a special wire stocker; the dedicated line bending step includes producing the dedicated line from the first wire rod sent out from the dedicated line stocker; The method for manufacturing a coil member according to claim 2 , wherein the special wire bending step produces the special wire from the second wire material fed from the special wire stocker.

7. the coil member has a first dedicated line which is the coil body and a second dedicated line having a length different from that of the first dedicated line, The method for manufacturing a coil member according to claim 2 , wherein the first dedicated line and the second dedicated line are manufactured in the dedicated line bending step.

8. The dedicated line bending process includes: a dedicated wire forming process in which one end and the other end of the first wire are brought close to each other around a bending fulcrum portion set between the one end and the other end of the first wire, thereby forming the first wire into a U-shape; a fulcrum positioning step of aligning the position of the fulcrum portion and the fulcrum, The method for manufacturing a coil member according to claim 2 , wherein the fulcrum aligning step performs alignment by adjusting a distance between the fulcrum and either one of the one end portion or the other end portion.

9. The special wire bending process includes: a reference holding step of aligning one end of the second wire at a reference position serving as a reference and holding the one end side of the second wire; The method for manufacturing a coil member according to claim 2, further comprising: a special wire forming step of moving the other end of the second wire to form the second wire into a desired shape, thereby producing the special wire having the desired shape.

10. In the coil manufacturing process, the dedicated wire and the special wire are combined in a predetermined work area, The method for manufacturing a coil member according to claim 2, wherein the dedicated wire produced in the dedicated wire bending process in the number required for one coil member and the special wire produced in the special wire bending process in the number required for one coil member are both supplied to the working area.

11. A manufacturing system for a coil member used for a stator, the coil member having a U-shaped dedicated wire forming a coil body and a special wire having a shape different from that of the dedicated wire, a wire preparation unit that prepares a wire of a predetermined length before being formed into the dedicated wire and the special wire; a dedicated line bending unit that bends the wire into a U-shape to produce the dedicated line; a special wire bending unit that bends the wire to produce the special wire; a coil manufacturing unit that manufactures the coil member using the dedicated wire and the special wire, A coil member manufacturing system in which the wire preparation unit adjusts the ratio of the number of wire rods to be allocated to the dedicated wire bending unit and the number of wire rods to be allocated to the special wire bending unit depending on the ratio of the processing time required for the dedicated wire bending unit and the processing time required for the special wire bending unit.

12. A manufacturing system for a coil member used for a stator, the coil member having a U-shaped dedicated wire forming a coil body and a special wire having a shape different from that of the dedicated wire, a wire preparation unit that prepares a first wire having a first predetermined length and a second wire having a second predetermined length before being formed to be formed on the dedicated wire or the special wire; a dedicated line bending unit that bends the first wire into a U-shape to produce the dedicated line; a special wire bending unit that bends the second wire to produce the special wire; a coil manufacturing unit that manufactures the coil member using the dedicated wire and the special wire, the wire rod preparing unit has a distribution unit that distributes the first wire rod to the dedicated wire bending unit and distributes the second wire rod to the special wire bending unit, A coil member manufacturing system, wherein the allocation unit adjusts the ratio of the number of the first wire rods allocated to the dedicated wire bending unit and the number of the second wire rods allocated to the special wire bending unit in accordance with the ratio of the processing time required for the dedicated wire bending unit to the processing time required for the special wire bending unit.

13. 13. The coil member manufacturing system according to claim 12, wherein the allocation unit allocates the first wire rod and the second wire rod to the dedicated line bending unit and the special wire bending unit based on the types and numbers of the dedicated wires and the special wires to be produced.

14. The coil member manufacturing system according to claim 12, wherein the wire preparation unit has a length discrimination unit that discriminates between the first wire having a first predetermined length and the second wire having a second predetermined length based on the length of the prepared metal wire.

15. 15. The coil member manufacturing system according to claim 14, wherein the wire preparation unit includes a wire cutting unit that cuts the metal wire from one continuous metal wire that becomes the first wire and the second wire.

16. The coil member manufacturing system according to claim 15 , wherein the wire preparation unit includes a wire transfer unit that transfers the metal wire cut out from the wire cutting unit to the length determination unit.

17. The dedicated line bending portion is a dedicated wire stocker for stocking the first wire; a dedicated line processing unit that produces the dedicated line; a dedicated line transfer mechanism that transfers the first wire from the dedicated line stocker to the dedicated line processing unit, The special wire bend portion is a special wire stocker for stocking the second wire rod; A special wire processing unit that produces the special wire; The coil member manufacturing system according to claim 12 , further comprising: a special wire transport mechanism that transports the second wire from the special wire stocker to the special wire processing section.

18. the coil member has a first dedicated line which is the coil body and a second dedicated line having a length different from that of the first dedicated line, The dedicated line bending portion is a first dedicated line creating unit that creates the first dedicated line; The coil member manufacturing system according to claim 12 , further comprising: a second dedicated line manufacturing unit that manufactures the second dedicated line having a length different from that of the first dedicated line.

19. The dedicated line bending portion is a fulcrum defining portion that comes into contact with a bending fulcrum portion that is set between one end and the other end of the first wire and serves as a fulcrum when bending the first wire; a first bending chuck for holding one end of the first wire; a second bending chuck for holding the other end of the first wire; The coil member manufacturing system according to claim 12 , further comprising: an alignment unit that aligns the fulcrum portion of the first wire with the fulcrum defining portion.

20. The special wire bend portion is a reference contact portion that contacts and supports one end of the second wire at a predetermined position serving as a reference; a reference holding portion for holding one end side of the second wire that is to be brought into contact with the reference contact portion; The system for manufacturing a coil member according to claim 12 , further comprising: a forming unit that moves the other end side of the second wire and forms it into a desired shape.

21. 13. The coil member manufacturing system of claim 12, further comprising: a dedicated line conveying unit that conveys the dedicated line manufactured in the dedicated line bending unit to the coil manufacturing unit; and a special wire conveying unit that conveys the special wire manufactured in the special wire bending unit to the coil manufacturing unit.

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