Annular alignment device

Abstract

To provide a circular alignment device capable of improving production efficiency.SOLUTION: A circular alignment device includes a coil holding portion that holds multiple coil segments in a row, a circular alignment portion that aligns the multiple coil segments in a circular shape, and a coil sending portion that sends the leading coil segment to the circular alignment portion, and the coil holding portion is linear and has a first rail along which the multiple coil segments are arranged in a row and suspended, and the coil sending portion is linear and has a second rail along which the leading coil segment received from the coil holding portion is suspended and which moves the suspended leading coil segment and sends it to the circular alignment portion, the first rail is inclined such that the side of the circular alignment portion is below in a direction of gravity and a side opposite the circular alignment portion is above in the direction of gravity, and the second rail is inclined such that the side of the circular alignment portion is below in the direction of gravity and the side of the coil holding portion is above in the direction of gravity.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to an annular alignment device.

Background Art

[0002] Hybrid vehicles equipped with motors / generators are known. The coils constituting the stator of the motor / generator are manufactured by arranging a plurality of U-shaped coil segments in an annular shape and connecting the respective tips of the plurality of annularly arranged coil segments by welding.

[0003] Patent Document 1 discloses an annular alignment device for arranging coil segments in an annular shape. The annular alignment device described in Patent Document 1 includes a feeding mechanism that performs a feeding operation for feeding out coil segments, and can supply the coil segments.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] By the way, Patent Document 1 describes a mechanism in which a plurality of coil segments are linearly aligned and held by a feeding block and a swing stopper, and the coil segments are fed one by one to the annular alignment device by a pressing unit. However, since the mechanism described in Patent Document 1 includes a feeding block and a swing stopper, the number of parts increases, and furthermore, parts for operating the feeding block and the swing stopper are also required, so the structure is complicated.

[0006] In addition, there is also a mechanism in which, from a plurality of coil segments arranged in a straight line in a row, the leading coil segment is lifted in an arc shape and cut out, and the lifted coil segment is slid by inclination and sent out to the main body of the annular alignment device. However, in such a mechanism, when cutting out, since the lifted coil segment is moved on an arc, for example, the coil segment may get caught between the guide and the cutting claw during cutting out, or two coil segments may be cut out simultaneously, or the coil segment may be dropped without being able to be cut out.

[0007] In addition, when such a mechanism lifts the last coil segment in an arc shape, the force for sending out the coil segments arranged in a row is insufficient, and the coil segment may not be able to be placed on the cutting claw, or even if the coil segment is placed, it may fall during the arc-shaped operation.

[0008] The present invention has been made in view of the above, and an object thereof is to provide an annular alignment device that can surely send out coil segments, align them in an annular shape with a simple configuration, and improve production efficiency.

Means for Solving the Problems

[0009] In order to solve the above-described problems and achieve the object, an annular alignment device according to the present invention is an annular alignment device that annularly aligns a plurality of coil segments each having a shape in which a thin wire is bent into a U shape into the shape of a coil, and includes a coil holding unit that holds the plurality of coil segments arranged in a line before annular alignment, an annular alignment unit that sequentially receives the plurality of coil segments one by one and annularly aligns the received coil segments, and a coil sending unit that takes out a leading coil segment disposed at the head of the plurality of coil segments held in a line by the coil holding unit and sends out the taken-out leading coil segment to the annular alignment unit. The coil holding unit is linear and has a first rail over which the plurality of coil segments are arranged in a line. The coil sending unit is linear and has a second rail over which the leading coil segment received from the coil holding unit is arranged and which moves the arranged leading coil segment and sends it out to the annular alignment unit. The first rail is inclined such that the side of the annular alignment unit is on the lower side in the direction of gravity and the side opposite to the annular alignment unit is on the upper side in the direction of gravity. The second rail is inclined such that the side of the annular alignment unit is on the lower side in the direction of gravity and the side of the coil holding unit is on the upper side in the direction of gravity. Due to its own weight It has a second rail over which the leading coil segment received from the coil holding unit is arranged and which moves the arranged leading coil segment and sends it out to the annular alignment unit. The first rail is inclined such that the side of the annular alignment unit is on the lower side in the direction of gravity and the side opposite to the annular alignment unit is on the upper side in the direction of gravity. The second rail is inclined such that the side of the annular alignment unit is on the lower side in the direction of gravity and the side of the coil holding unit is on the upper side in the direction of gravity.

Advantages of the Invention

[0010] According to the present invention, with a simple configuration, coil segments can be reliably sent out and annularly aligned, and production efficiency can be improved.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

[0012] Hereinafter, embodiments will be described with reference to the drawings.

[0013] FIG. 1 is a diagram showing an annular alignment device 10 according to an embodiment. The annular alignment device 10 is used, for example, in a process of manufacturing a coil that constitutes a stator of a motor / generator used in a hybrid vehicle. The annular alignment device 10 annularly aligns a plurality of coil segments 20 in the shape of a coil that constitutes a stator.

[0014] Each of the plurality of coil segments 20 has a shape in which a thin wire is bent into a U shape. Each of the plurality of coil segments 20 includes two straight legs 24 and a bent portion 26 that connects the two legs 24. The two legs 24 are formed to be parallel. The bent portion 26 connects one end of each of the two legs 24. The bent portion 26 is formed, for example, in a substantially mountain shape. The bent portion 26 may be formed in an arc shape or other shape.

[0015] Note that the direction parallel to the thin wire in each of the plurality of coil segments 20 and perpendicular to the two legs 24 is referred to as a coil conductor direction α. The direction parallel to the two legs 24, that is, the direction from the central portion of the U shape to the opening portion in each of the plurality of coil segments 20 is referred to as a coil perpendicular direction β.

[0016] The annular alignment device 10 includes a coil holding part 32, an annular alignment part 34, and a coil feeding part 36.

[0017] The coil holding part 32 holds a plurality of coil segments 20 before they are arranged in an annular shape. The coil holding part 32 holds the plurality of coil segments 20 in a line in the same posture in the direction toward the annular alignment part 34. The coil holding part 32 holds each of the plurality of coil segments 20 by overlapping them in a direction perpendicular to each of the coil conductor direction α and the coil perpendicular direction β.

[0018] The annular alignment part 34 sequentially receives the plurality of coil segments 20 one by one from the coil delivery part 36 and aligns the received plurality of coil segments 20 in an annular shape. For example, the annular alignment part 34 includes an input part 42 and a guide part 44. The input part 42 sequentially receives the coil segments 20 one by one from the coil delivery part 36. The guide part 44 moves the coil segment 20 received by the input part 42 along a substantially circular path and arranges it at a predetermined position in the annular shape. The annular alignment part 34 can form a coil in a state before being connected by welding by aligning a predetermined number of coil segments 20.

[0019] The coil delivery part 36 takes out the plurality of coil segments 20 held side by side in a line by the coil holding part 32 one by one. In this case, the coil delivery part 36 takes out from the end on the annular alignment part 34 side among the plurality of coil segments 20 arranged in a line.

[0020] Note that the coil segment 20 arranged at the head on the annular alignment part 34 side among the plurality of coil segments 20 held side by side in a line by the coil holding part 32 is called the head coil segment 20-S. The coil delivery part 36 sequentially takes out the head coil segment 20-S and, each time the taken-out head coil segment 20-S is taken out, sends the taken-out head coil segment 20-S to the input part 42 of the annular alignment part 34.

[0021] FIG. 2 is a diagram showing the manufacturing process of the coils constituting the stator of the motor / generator. A plurality of coil segments 20 are arranged in an annular shape as shown in FIG. 2 and combined to form a group 54 of coil segments aligned in an annular shape.

[0022] The coil is constituted by combining a plurality of groups 54 of coil segments having different diameters of the annulus. For example, in the example of FIG. 2, the coil is constituted by combining a first group 54-1 of coil segments having the smallest diameter of the annulus, a second group 54-2 of coil segments having the second smallest diameter of the annulus, and a third group 54-3 of coil segments having the largest diameter of the annulus.

[0023] And after a plurality of groups 54 of coil segments are combined, the tip portions of the coil segments 20 are connected by welding every two. Thereby, the coil used for the stator of the motor / generator is constituted. The annular alignment device 10 according to the present embodiment is used in the step of annularly aligning a plurality of coil segments 20 to generate a group 54 of coil segments in such a manufacturing process of the coil.

[0024] FIG. 3 is a schematic diagram of the coil holding portion 32, the coil feeding portion 36, and the input portion 42 of the annular alignment portion 34 before cutting out the coil segment 20.

[0025] The coil holding portion 32 has a first rail 62 and a stopper 64.

[0026] The first rail 62 is linear, and a plurality of coil segments 20 are bridged side by side in a row. More specifically, the first rail 62 has the bent portion 26 in the U shape on the upper side in the direction of gravity and the opening portion in the U shape on the lower side in the direction of gravity, and a plurality of coil segments 20 are bridged thereover.

[0027] The first rail 62 is inclined such that the straight portion has the side of the input portion 42 of the annular alignment portion 34 downward in the direction of gravity and the side opposite to the input portion 42 of the annular alignment portion 34 upward in the direction of gravity. Let the direction in which the first rail 62 is inclined be the first direction X. Accordingly, the plurality of coil segments 20 spanned across the first rail 62 move toward the side of the annular alignment portion 34 by their own weights, line up in the first direction X, and stack up in the same posture.

[0028] The stopper 64 regulates the position and posture of the leading coil segment 20-S among the plurality of coil segments 20 spanned across the first rail 62.

[0029] More specifically, the stopper 64 regulates the leading coil segment 20-S such that the coil vertical direction β from the central portion to the opening portion in the U shape is parallel to the second direction Y. Further, the stopper 64 regulates the leading coil segment 20-S such that the two legs 24 of the leading coil segment 20-S are at the same position in the first direction X. Note that the second direction Y is a direction perpendicular to the first direction X within the plane formed by the first direction X and the direction of gravity.

[0030] Furthermore, the stopper 64 regulates the leading coil segment 20-S in such a posture so as to be stationary at a predetermined position in the first direction X. By regulating the position and posture of the leading coil segment 20-S in this way, the plurality of coil segments 20 excluding the leading coil segment 20-S move toward the side of the annular alignment portion 34 in the first direction X due to the inclination of the first rail 62, stack up on the leading coil segment 20-S in the same posture as the leading coil segment 20-S. Thereby, the stopper 64 can hold the plurality of coil segments 20 lined up and stacked in the same posture in the first direction X.

[0031] In this embodiment, the first rail 62 includes a right first rail 72 and a left first rail 74. Each of the right first rail 72 and the left first rail 74 is rod-shaped. The right first rail 72 and the left first rail 74 are provided parallel to the first direction X. The right first rail 72 is provided on the right side when looking in the direction toward the annular alignment portion 34 in the first direction X. The left first rail 74 is provided on the left side when looking in the direction toward the annular alignment portion 34 in the first direction X.

[0032] The right first rail 72 supports the right shoulder portion at the bent portion 26 of the coil segment 20 when looking in the direction toward the annular alignment portion 34 in the first direction X. The left first rail 74 supports the left shoulder portion at the bent portion 26 of the coil segment 20 when looking in the direction toward the annular alignment portion 34 in the first direction X. Such a right first rail 72 and left first rail 74 can hold a plurality of coil segments 20 in a posture where the bent portion 26 of the U-shape is on the upper side in the gravity direction and the opening portion of the U-shape is on the lower side in the gravity direction.

[0033] Also, in this embodiment, the stopper 64 includes an upper right stopper 82, an upper left stopper 84, a lower right stopper 86, and a lower left stopper 88.

[0034] The upper right stopper 82 is a protrusion integrally formed at the end portion on the side of the annular alignment portion 34 in the right first rail 72. The upper right stopper 82 has a shape protruding upward in the right first rail 72. The upper right stopper 82 functions as a wall that restricts the upper right portion of the leading coil segment 20-S bridged over the right first rail 72 from moving to the side of the annular alignment portion 34 in the first direction X at a predetermined position.

[0035] The upper left stopper 84 is a protrusion integrally formed at the end of the annular alignment portion 34 on the left side of the first rail 74. The upper right stopper 82 has a shape protruding upward on the left side of the first rail 74. The upper left stopper 84 functions as a wall that restricts the upper left portion of the leading coil segment 20-S spanned across the left side of the first rail 74 from moving to the side of the annular alignment portion 34 in the first direction X at a predetermined position.

[0036] The lower right stopper 86 is provided near the end of the right foot portion 24 of the leading coil segment 20-S. The lower right stopper 86 restricts the end of the right foot portion 24 of the leading coil segment 20-S from moving to the side of the annular alignment portion 34 in the first direction X at a predetermined position.

[0037] The lower left stopper 88 is provided near the end of the left foot portion 24 of the leading coil segment 20-S. The lower left stopper 88 restricts the end of the left foot portion 24 of the leading coil segment 20-S from moving to the side of the annular alignment portion 34 in the first direction X at a predetermined position.

[0038] Such upper right stopper 82, upper left stopper 84, lower right stopper 86 and lower left stopper 88 can restrict the leading coil segment 20-S that has moved by its own weight to the side of the annular alignment portion 34 in the first direction X on the right side of the first rail 72 and the left side of the first rail 74 to a predetermined position.

[0039] Furthermore, such upper right stopper 82, upper left stopper 84, lower right stopper 86 and lower left stopper 88 can hold the leading coil segment 20-S in a posture where the coil vertical direction β from the central portion to the opening portion of the U-shape is parallel to the second direction Y.

[0040] In this way, the coil holding portion 32 can hold a plurality of coil segments 20 before annular alignment in a row in a predetermined posture by having the first rail 62 and the stopper 64.

[0041] FIG. 4 is a schematic diagram of the coil holding portion 32, the coil feeding portion 36, and the input portion 42 of the annular alignment portion 34 in a state where the coil segment 20 is cut out. FIG. 5 is a schematic diagram of the coil holding portion 32, the coil feeding portion 36, and the input portion 42 of the annular alignment portion 34 during the feeding of the leading coil segment 20-S.

[0042] The coil feeding portion 36 includes a second rail 92 and a dropout prevention portion 94.

[0043] The second rail 92 is disposed between the coil holding portion 32 and the input portion 42 of the annular alignment portion 34. The second rail 92 is linear and inclined such that the side of the input portion 42 of the annular alignment portion 34 is on the lower side in the direction of gravity and the side of the coil holding portion 32 is on the upper side in the direction of gravity. The direction in which the second rail 92 is inclined is defined as the third direction Z. In the present embodiment, the third direction Z is parallel to the first direction X.

[0044] The second rail 92 is movable in a direction perpendicular to the direction in which the first rail 62 is inclined. That is, the second rail 92 is movable in the second direction Y.

[0045] The second rail 92 feeds the leading coil segment 20-S from the coil holding portion 32 to the annular alignment portion 34 by moving in the second direction Y. When the second rail 92 feeds the leading coil segment 20-S from the coil holding portion 32 to the annular alignment portion 34, it operates as follows.

[0046] First, the second rail 92 is located on the lower side in the second direction Y, that is, on the open side of the U-shape in the leading coil segment 20-S. Then, the second rail 92 moves from the lower side to the upper side in the second direction Y. That is, the second rail 92 moves from the side of the open portion of the U-shape to the side of the central portion of the U-shape in the second direction Y.

[0047] The second rail 92 is arranged such that the end portion on the side of the coil holding portion 32 overlaps with the leading coil segment 20-S in the first direction X and does not overlap with the other coil segments 20 adjacent to the leading coil segment 20-S in the first direction X. Thereby, when the second rail 92 moves from the lower side to the upper side in the second direction Y, the end portion on the side of the coil holding portion 32 engages from below the bent portion 26 in the leading coil segment 20-S.

[0048] As shown in FIG. 4, with the second rail 92 engaged with the leading coil segment 20-S, the second rail 92 further moves from the lower side to the upper side in the second direction Y. Thereby, the second rail 92 cuts out only the leading coil segment 20-S from the plurality of coil segments 20 arranged in a row and lifts the leading coil segment 20-S from the lower side to the upper side in the second direction Y. As a result, the leading coil segment 20-S is bridged in a posture where the bent portion 26 in the U-shape faces the upper side in the gravity direction and the opening portion in the U-shape faces the lower side in the gravity direction.

[0049] Furthermore, as shown in FIG. 5, when the second rail 92 lifts the leading coil segment 20-S from the lower side to the upper side in the second direction Y, the regulation of the position and posture of the leading coil segment 20-S by the stopper 64 is released. The leading coil segment 20-S, whose regulation by the stopper 64 is released, moves in the direction of the input portion 42 in the annular alignment portion 34 due to its own weight because the second rail 92 is inclined. Then, the leading coil segment 20-S that has moved over the second rail 92 is supplied to the input portion 42 in the annular alignment portion 34.

[0050] In this way, by moving from the lower side to the upper side in the second direction Y, the second rail 92 receives the leading coil segment 20-S held by the first rail 62 of the coil holding portion 32, bridges the leading coil segment 20-S received from the coil holding portion 32, and moves the bridged leading coil segment 20-S and sends it out to the input portion 42 of the annular alignment portion 34.

[0051] After the second rail 92 sends out the leading coil segment 20-S to the input part 42 of the annular alignment part 34, it moves from the upper side to the lower side in the second direction Y. Then, thereafter, the second rail 92 alternately repeats the movement from the lower side to the upper side and the movement from the upper side to the lower side in the second direction Y, and takes out the plurality of coil segments 20 held by the coil holding part 32 one by one from the end and sends them out to the annular alignment part 34.

[0052] In a state where the leading coil segment 20-S is engaged with the second rail 92, the anti-drop part 94 forms a wall along the end part on the side opposite to the annular alignment part 34 of the second rail 92 so that the leading coil segment 20-S does not drop to the side opposite to the annular alignment part 34 on the second rail 92. Thereby, the anti-drop part 94 can prevent the leading coil segment 20-S from dropping while the second rail 92 is moving from the lower side to the upper side in the second direction Y.

[0053] In this way, the coil delivery part 36 has the second rail 92 and the anti-drop part 94, and can take out the leading coil segment 20-S arranged at the head of the plurality of coil segments 20 held side by side by the coil holding part 32, and send out the taken-out leading coil segment 20-S to the annular alignment part 34. Further, when sending out the leading coil segment 20-S from the coil holding part 32 to the annular alignment part 34, the coil delivery part 36 moves the second rail 92 in the direction from the opening part side to the central part side in the U shape of the leading coil segment 20-S, thereby engaging the leading coil segment 20-S with the second rail 92, releasing the regulation by the stopper 64 on the leading coil segment 20-S, and moving the leading coil segment 20-S whose regulation by the stopper 64 has been released along the second rail 92 to the annular alignment part 34 by its own weight.

[0054] As described above, in the annular alignment device 10 according to the present embodiment, the coil holding unit 32 spans the inclined first rail 62 and holds a plurality of coil segments 20 before annular alignment. Thereby, according to the annular alignment device 10, it is not necessary to provide a mechanism for sending out a plurality of coil segments 20 before annular alignment, so that the production equipment can be simplified and the production efficiency can be improved.

[0055] Further, in the annular alignment device 10 according to the present embodiment, the coil delivery unit 36 moves the leading coil segment 20-S among the plurality of coil segments 20 held in an inclined state while maintaining the held posture, that is, moves in a direction perpendicular to the inclined direction to take out the leading coil segment 20-S. Thereby, according to the annular alignment device 10, the leading coil segment 20-S can be taken out in a stable posture without colliding with other coil segments 20, and the production efficiency can be improved.

[0056] Further, in the annular alignment device 10 according to the present embodiment, the coil delivery unit 36 spans the leading coil segment 20-S on the inclined second rail 92 and sends it out to the annular alignment unit 34 by the self-weight of the leading coil segment 20-S. Thereby, according to the annular alignment device 10, it is not necessary to provide a mechanism for sending out the taken-out leading coil segment 20-S, so that the production equipment can be simplified and the production efficiency can be improved.

[0057] In addition, the annular alignment device 10 according to the present embodiment can solve problems such as biting, simultaneous extraction of two pieces, and dropping that occurred in the conventional device that lifted on the arc. Therefore, for example, the coil segment 20 is not damaged, and the coating of the coil segment 20 is not peeled off, and the production efficiency can be improved. Further, the annular alignment device 10 according to the present embodiment can extract the last coil segment 20 with the same force as the other coil segments 20 even when the last coil segment 20 is extracted. Therefore, all the plurality of coil segments 20 held by the coil holding portion 32 can be sent to the annular alignment portion 34, and the production efficiency can be improved.

[0058] As described above, the embodiments of the present invention have been described. However, these embodiments are presented as examples and are not intended to limit the scope of the invention. The embodiments can be modified in various ways.

Explanation of Reference Numerals

[0059] 10 Annular alignment device, 20 Coil segment, 20-S First coil segment, 24 Leg portion, 26 Bent portion, 32 Coil holding portion, 34 Annular alignment portion, 36 Coil sending portion, 42 Input portion, 44 Guide portion, 54 Coil segment group, 62 First rail, 64 Stopper, 72 Right first rail, 74 Left first rail, 82 Upper right stopper, 84 Upper left stopper, 86 Lower right stopper, 88 Lower left stopper, 92 Second rail, 94 Anti-drop portion, α Coil conductor direction, β Coil vertical direction, X First direction, Y Second direction, Z Third direction

Claims

1. An annular alignment device for annularly aligning a plurality of coil segments, each having a shape in which a thin wire is bent into a U shape, into the shape of a coil, comprising: a coil holding unit that holds the plurality of coil segments arranged in a line before annular alignment; an annular alignment unit that sequentially receives the plurality of coil segments one by one and annularly aligns the received coil segments; a coil sending unit that takes out a leading coil segment disposed at the head of the plurality of coil segments held in a line by the coil holding unit and sends the taken-out leading coil segment to the annular alignment unit; The annular alignment device is provided with: The coil holding unit is linear and has a first rail on which the plurality of coil segments are arranged in a line; The coil sending unit is linear and has a second rail on which the leading coil segment received from the coil holding unit is arranged, and the arranged leading coil segment is moved by its own weight and sent to the annular alignment unit; The first rail is inclined such that the side of the annular alignment unit is on the lower side in the direction of gravity and the side opposite to the annular alignment unit is on the upper side in the direction of gravity; The second rail is inclined such that the side of the annular alignment unit is on the lower side in the direction of gravity and the side of the coil holding unit is on the upper side in the direction of gravity. Annular alignment device.

2. The coil holding unit has a stopper that regulates the position and posture of the leading coil segment among the plurality of coil segments arranged on the first rail; The stopper: Regulates the leading coil segment to a predetermined position in a posture in which the coil vertical direction from the center to the opening in the U shape is perpendicular to the direction in which the first rail is inclined; By regulating the position and posture of the leading coil segment, the plurality of coil segments are stacked and held in the same posture as the leading coil segment with the leading coil segment at the head; The second rail is movable in a direction perpendicular to the direction in which the first rail is inclined. When the coil delivery unit sends out the leading coil segment from the coil holding unit to the annular alignment unit, by moving the second rail, the leading coil segment is engaged with the second rail, the regulation by the stopper on the leading coil segment is released, and the leading coil segment with the regulation by the stopper released is moved to the annular alignment unit under its own weight along the second rail. The annular alignment device according to claim 1.

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