Coil forming device and coil forming method

Abstract

To provide a coil molding device capable of molding a belt-like coil without blocking maintenance of defined outside diameter dimension when the belt-like coil is wound around a coil winding jig.SOLUTION: A coil molding device comprises: a coil transportation mechanism 4 for transporting a belt-like coil 2 having plural linear parts 6 and side ends 7 respectively connected to both ends of the plural linear parts 6 by guiding the side ends by a guide member 17 to draw a turning trajectory; a coil winding jig 3 rotating to wind the belt-like coil transported in a turning transportation zone by the coil transportation mechanism by inserting the plural linear parts in plural comb tooth-like grooves 15; and a correction member 18 arranged in slide contact with its own correction face 25 from an outer peripheral side relating to rotation on the side end of the belt-like coil to be rotated, and correcting a posture of the slide-contact side end is made not to enter an area nearer an outer peripheral side than a virtual extension line of the corresponding linear part, while the correction face has width for housing the side ends in a width direction orthogonal to the transportation direction.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a coil forming apparatus and a coil forming method. [Background technology]

[0002] The stator of a rotating electric machine has a wound strip-shaped coil. The strip-shaped coil is formed in advance into a substantially cylindrical wound state with a diameter smaller than the inner diameter of the stator core, and is inserted into the inside of the stator core. The wound strip-shaped coil is expanded inside the stator core, and is attached by inserting the straight portions of the strip-shaped coil into the slots of the stator core.

[0003] It is known in the past to form a strip-shaped coil into a substantially cylindrical wound state by feeding the coil into a cylindrical coil winding jig one pitch at a time and winding it around the coil winding jig (see, for example, Patent Document 1). When winding the coil around the coil winding jig to form the wound state, it is important to wind the coil accurately so that the multiple straight portions do not become misaligned. In the above-mentioned prior art, a pre-alignment member is inserted between adjacent straight portions at a position immediately before the coil winding jig on the transport path of the strip-shaped coil, thereby aligning the overlap of the straight portions immediately before being wound around the coil winding jig.

[0004] However, the above-mentioned prior art does not specifically disclose how to transport the strip coil to the coil winding jig and wind it up. In particular, it does not provide any particular perspective on how to shape the strip coil into an arc shape that fits the outer periphery of the coil winding jig when winding it onto the coil winding jig. If this shape is not properly formed, the strip coil may not be wound according to specifications, resulting in quality defects. The occurrence of quality defects leads to increased material consumption and wasteful consumption of resources. Furthermore, the operating time of the manufacturing equipment required to achieve the planned production volume is extended, resulting in increased power consumption. This ultimately has a negative impact on the global environment.

[0005] In view of the above circumstances, the present applicant developed a technology that can easily form a strip coil into a predetermined winding state by accurately forming the strip coil into an arc shape so that it fits along the outer periphery of the coil winding jig when winding the strip coil onto the coil winding jig, and has obtained a patent for this technology in Japan (Patent Document 2).When a strip coil that has been sufficiently formed into an arc shape is inserted into a slot in a stator core of a rotating electrical machine, its own springback keeps the multiple linear conductors of the strip coil aligned within the slot without separating. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent No. 4953032 [Patent Document 2] Patent No. 7222007 Summary of the Invention [Problem to be solved by the invention]

[0007] However, the inventors have found that the coil conductors overlap at the side ends of the arc-shaped strip coil, causing the coil to bend in the direction of extension of the straight portion. If this occurs, the strip coil may not satisfy the outer diameter specification when inserted into the slot of the stator core of a rotating electrical machine.

[0008] The present invention has been made in consideration of the above circumstances, and aims to provide a coil forming device and a coil forming method that can form a strip-shaped coil without hindering the maintenance of a predetermined outer diameter dimension when winding the strip-shaped coil onto a coil winding jig. If it is possible to process a strip-shaped coil into a predetermined wound state with a high yield without producing defective products, it will be possible to reduce the wasteful consumption of resources, reduce the operating time of the manufacturing device, and save electric energy, thereby contributing to the conservation of the global environment. [Means for solving the problem]

[0009] (1) A coil forming apparatus (for example, a coil forming apparatus 1 described later) according to the present disclosure includes a coil conveying mechanism (for example, a coil conveying mechanism 4 described later) that conveys a strip-shaped coil (for example, a strip-shaped coil 2 described later) having a plurality of straight portions (for example, a straight portion 6 described later) and side ends (for example, side ends 7 described later) connected to both ends of the plurality of straight portions in a predetermined turning conveying section (for example, a section including a turning conveying section S2 described later) by guiding the side ends using guide members (for example, guide members 17 described later), so as to draw a turning locus, and a coil conveying mechanism that guides the strip-shaped coil conveyed in the turning conveying section by the coil conveying mechanism, and guides the plurality of straight portions through a plurality of comb-like grooves (for example, a and a correcting member (for example, correcting member 18 described later) that is arranged so as to slide with its own correcting surface (for example, correcting surface 25 described later) against the side end of the strip-shaped coil that is rotated after being wound around the coil winding jig from the outer periphery of the rotation, the correcting surface having a width that can accommodate the end of the side end in the width direction perpendicular to the conveying direction, and that corrects the posture of the sliding side end so that it does not enter into the area on the outer periphery of a virtual extension line (for example, virtual extension line Lv described later) of the corresponding straight portion.

[0010] (2) The coil forming method according to the present invention includes a coil transport step of transporting a strip-shaped coil (e.g., strip-shaped coil 2 described later) having a plurality of straight portions (e.g., straight portion 6 described later) and side ends (e.g., side end 7 described later) connected to both ends of the plurality of straight portions, in a predetermined turning transport section (e.g., a section including turning transport section S2 described later) by guiding the side ends with guide members (e.g., guide member 17 described later), so as to draw a turning locus; and a coil transport step of transporting the strip-shaped coil transported in the turning transport section by the coil transport step by winding the plurality of straight portions with a plurality of rotating coil winding jigs (e.g., coil winding jig 3 described later). and a straightening step of sliding a straightening surface (e.g., straightening surface 25 described later) of a straightening member (e.g., straightening member 18 described later) against the side end of the strip-shaped coil that has been wound around the coil winding jig in the coil winding step and is rotating, from the outer periphery of the rotation, so as to accommodate the end of the side end in the width direction perpendicular to the conveying direction of the side end, thereby correcting the posture of the sliding side end so that it does not bend outward from an imaginary extension line (e.g., imaginary extension line Lv described later) of the corresponding straight portion. [Effects of the Invention]

[0011] According to the coil forming device described in (1) above, the side end of the strip-shaped coil is pressed by sliding contact with the correction surface of the correction member, thereby correcting the orientation of the strip-shaped coil so that it does not enter the area on the outer periphery of the imaginary extension line of the corresponding straight portion. This makes it possible to prevent the side end of the strip-shaped coil from interfering with other components when inserting and assembling the strip-shaped coil formed into a roughly cylindrical shape into the stator of a rotating electric machine, and makes it possible to provide a high-quality stator coil.

[0012] According to the coil forming method described in (2) above, the side end of the strip-shaped coil is pressed by sliding contact with the correcting surface of the correcting member, thereby correcting the orientation of the strip-shaped coil so that it does not enter the area on the outer periphery of the imaginary extension line of the corresponding straight portion. This makes it possible to prevent the side end of the strip-shaped coil from interfering with other components when inserting and assembling the strip-shaped coil formed into a roughly cylindrical shape into the stator of a rotating electric machine, and makes it possible to provide a high-quality stator coil. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a side view showing a coil forming apparatus according to the present disclosure. [Figure 2] 2 is a diagram showing a strip-shaped coil formed by the coil forming device of FIG. 1. FIG. [Figure 3] 2 is a schematic diagram showing a coil winding jig in the coil forming apparatus of FIG. 1. FIG. [Figure 4] 4 is a schematic diagram showing a state in which a strip-shaped coil is wound around the coil winding jig of FIG. 3. FIG. [Figure 5] 2 is a diagram showing a configuration around a correcting member in the coil forming apparatus of FIG. 1. FIG. [Figure 6] 2 is a diagram showing the coil forming device portion of FIG. 1 as viewed from the left side in front. [Figure 7] 2 is a diagram showing the coil forming device portion of FIG. 1 as viewed from the front from the right side. [Figure 8] 2 is a schematic diagram illustrating the function of a correcting member in the coil forming apparatus of FIG. 1. FIG. [Figure 9] FIG. 9 is a partially enlarged view of FIG. 8. [Figure 10] 2 is a schematic diagram illustrating the function of a correcting member in the coil forming apparatus of FIG. 1. FIG. [Figure 11] 6 is a diagram showing a state in which a portion of the strip-shaped coil whose posture has been corrected by the correcting member in FIG. 5 is viewed from the front from the right side. FIG. [Figure 12] 6 is a diagram showing the state of the strip-shaped coil whose posture has been corrected by the correcting member of FIG. 5, as viewed from the left side. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0014] The coil forming apparatus of the present disclosure will be described below with reference to the drawings. FIG. 1 is a side view of the coil forming apparatus 1 of the present disclosure. FIG. 2 is a diagram showing a strip-shaped coil 2 formed by the coil forming apparatus 1. FIG. 1 shows the coil forming apparatus 1 without the strip-shaped coil 2. When forming the strip-shaped coil 2 by the coil forming apparatus 1, as shown in FIG. 2, the strip-shaped coil 2 is gripped by a conveying body 5 of a coil conveying mechanism 4 of the coil forming apparatus 1, and the strip-shaped coil 2 is conveyed from a linear conveying section S1 of the coil conveying mechanism 4 to a rotating conveying section S2 following this section. In this process, the strip-shaped coil 2 is formed into an arc shape and wound around a coil winding jig 3. FIG. 3 is a schematic perspective view of the coil winding jig 3, and FIG. 4 is a schematic perspective view of the strip-shaped coil 2 wound around the coil winding jig 3.

[0015] FIG. 2 shows a state in which the strip-shaped coil 2 is held in the linear transport section S1 of the coil transport mechanism 4. The strip-shaped coil 2 is composed of a coil conductor 2a, which is a conductor wire having a substantially rectangular cross-section and an insulating layer on its outer surface. The strip-shaped coil 2 is formed into a long, corrugated strip shape by a predetermined die-wound coil forming process. The strip-shaped coil 2 has multiple parallel straight portions 6 and side end portions 7 connected to both ends of the multiple straight portions 6, and extends in a strip-like shape in a direction perpendicular to the straight portions 6. The straight portions 6 are inserted into slots formed on the inner periphery of a stator core of a rotating electrical machine (not shown). The straight portions 6 are linearly oriented in the same direction and extend parallel to each other at regular intervals. The side end portions 7 are connected to both ends of the straight portions 6 in the extension direction.

[0016] Each of the side end portions 7 is configured to alternately connect one end and the other end of adjacent straight portions 6 in a mountain-like shape in the loop formed by the two straight portions 6 and the two side end portions 7, and overlap with a shift at the pitch of the straight portions 6. When the strip coil 2 is fitted into the slot of the stator core of a rotating electrical machine, the side end portions 7 form coil end portions that respectively protrude from the slot in the axial direction of the stator core.

[0017] The coil transport mechanism 4 transports the strip coil 2 by moving the transport body 5. The transport body 5 is configured by connecting a plurality of roughly rectangular plate-shaped piece members 8 having the same structure and stacked along their thickness direction. Each of the piece members 8 is guided by a pair of parallel transport rails 9 and moves aligned in a stacked manner. The pair of transport rails 9 is installed from the linear transport section S1 of the coil transport mechanism 4 through the turning transport section S2 to the linear reverse transport section S3, and is configured by plate-shaped members with a fixed width.

[0018] 1, the conveying rail 9 forms a horizontally U-shaped conveying path that extends from the linear conveying section S1 through the turning conveying section S2 to the linear reverse conveying section S3. Each of the plurality of piece members 8 has a first gripping claw 10 and a second gripping claw 11 that protrude from its upper end surface and are spaced apart in the thickness direction. In the conveying body 5, between adjacent piece members 8 aligned in a stacked configuration, a gripping groove 12 that grips the straight portion 6 of the strip coil 2 is formed between the first gripping claw 10 of one piece member 8 and the second gripping claw 11 of the other piece member 8.

[0019] The coil transport mechanism 4 grips the straight portion 6 in the gripping groove 12 of the transport body 5 and transports the strip coil 2 from the linear transport section S1 to the turning transport section S2. Each of the multiple piece members 8 has a guide protrusion (not shown) protruding from both sides in the width direction, which is the extension direction of the gripping groove 12, near its lower end surface. Each piece member 8 has its guide protrusion slidably received and guided in a guide groove (not shown) provided on the opposing surface of each of a pair of transport rails 9 along the extension direction of the transport rails 9. Note that while FIG. 2 only partially illustrates the strip coil 2, the strip coil 2 of the present disclosure has a length that allows it to be wound multiple times around the coil winding jig 3.

[0020] The above-described linear conveyance section S1, turning conveyance section S2, and linear reverse conveyance section S3 are sections of conveyance sections for conveying the piece members 8, while the linear conveyance section S1 and turning conveyance section S2 directly correspond to sections of the conveyance path for the strip-shaped coil 2. In the linear conveyance section S1, the series of piece members 8 holding the strip-shaped coil 2 are conveyed linearly toward the coil winding jig 3. In the turning conveyance section S2 following the linear conveyance section S1, as the series of piece members 8 are turned and conveyed in an arc, the strip-shaped coil 2 held by the piece members 8 are sequentially transferred to the coil winding jig 3 by a guide member 17, which will be described later, and wound up. In the linear reverse conveyance section S3 following the turning conveyance section S2, the series of piece members 8, after releasing the strip-shaped coil 2, are conveyed linearly in the opposite direction to the linear conveyance section S1.

[0021] The coil winding jig 3 of the coil transport mechanism 4 is shown in FIGS. 3 and 4. The coil winding jig 3 has a substantially cylindrical jig body 13, a plurality of comb-tooth portions 14 protruding radially from the outer periphery of the jig body 13, a plurality of comb-tooth grooves 15 provided between adjacent comb-tooth portions 14 in the circumferential direction, and an axial hole 16 opening at the center of the jig body 13. The comb-tooth portions 14 and the comb-tooth grooves 15 are provided at both axial ends of the jig body 13, respectively. The circumferential phases of the comb-tooth portions 14 and the comb-tooth grooves 15 at one end of the jig body 13 are aligned with those of the comb-tooth portions 14 and the comb-tooth grooves 15 at the other end. The coil winding jig 3 of the present disclosure has 72 comb-tooth grooves 15 at each axial end of the jig body 13. The number of comb-tooth grooves 15 corresponds to the number of slots in a stator core of a rotating electric machine to which the strip coil 2 is attached.

[0022] The distance between the comb teeth 14 and comb tooth-shaped grooves 15 at one end of the jig body 13 and the comb teeth 14 and comb tooth-shaped grooves 15 at the other end is approximately equal to the length in the extension direction of the straight portion 6 of the strip coil 2. Therefore, the straight portion 6 of the strip coil 2 can be accommodated across the comb tooth-shaped grooves 15 at one end of the jig body 13 and the comb tooth-shaped grooves 15 at the other end.

[0023] The coil winding jig 3 is formed so that the outer diameter of the coil winding jig 3, determined by the radial length of the comb-tooth portion 14, is equal to or smaller than the inner diameter of the stator core so that it can be inserted inside the stator core of a rotating electric machine. The coil winding jig 3 is disposed at a predetermined location on the coil forming apparatus 1 and is driven by a motor (not shown) so that it can rotate clockwise around the axial hole 16 as viewed from the side in FIG. 1 . As shown in FIG. 4 , the strip coil 2 is formed into a substantially cylindrical wound state. In the wound state, the coil conductors 2 a at the side ends 7 of the strip coil 2 protrude from the comb-tooth grooves 15 in the extension direction, while the coil conductors 2 a at the straight portions 6 are housed within the comb-tooth grooves 15, preventing misalignment. Therefore, the strip coil 2 can stably maintain its substantially cylindrical wound state. The strip coil 2 of the present disclosure is wound around the coil winding jig 3 in multiple layers by rotating the coil winding jig 3 multiple times.

[0024] 1, 5, 6, and 7, the following describes the configuration of a guide member 17 that guides the side end portion 7 of the strip coil 2 in the coil transport mechanism 4 and a correction member 18 that corrects the posture of the side end portion 7 of the strip coil 2 when it is wound around the coil winding jig 3. FIG. 5 is an enlarged view of the configuration of the correction member 18 and its surroundings in the coil forming apparatus 1 of FIG. 1. FIG. 6 is a front view of the coil forming apparatus 1 of FIG. 1 from the left. FIG. 7 is a front view of the coil forming apparatus 1 of FIG. 1 from the right. In FIGS. 5, 6, and 7, parts corresponding to those in FIG. 1 are denoted by the same reference numerals. The guide member 17 is a member that guides and transports the strip coil 2 so that it follows a turning trajectory that gradually moves inward in the turning radius direction from a turning start position P1 where the strip coil 2 transitions from the linear transport section S1 to the turning transport section S2. The correction member 18 is a member that uses a sliding surface 23, which is a part of its lower surface, to give the strip coil 2 an arc-like shape when viewed from the side, and uses a correction surface 25, which is a part of its upper surface, to correct the posture of the side end portion 7 of the strip coil 2.

[0025] The guide members 17 are a pair of plate-like members provided on both outer sides of the pair of conveyor rails 9 in Fig. 2, and the guide member 17 on the front side is shown in Fig. 1, which is a side view of the coil forming apparatus 1. The guide member 17 on the back side in the side view in Fig. 1 has the same shape and dimensions as the guide member 17 on the front side and is arranged plane-symmetrically. Therefore, hereinafter, with regard to the guide members 17, the guide member 17 on the front side shown in Fig. 1 will be representatively described.

[0026] The guide member 17 in the coil forming apparatus 1 of the present disclosure includes a portion of the first guide member 19 arranged in an area corresponding to the turning conveying section S2 and a portion of the second guide member 20 arranged in an area continuing clockwise from the turning conveying section S2. The first guide member 19 corresponds to the entire turning conveying section S2 and is arranged in a semicircular arc area on the left side near the outer periphery of the coil winding jig 3 in the side view of FIG.

[0027] The first guide member 19 has a first guide surface 21 that is curved clockwise in a side view and gradually turns inward in the direction of the turning radius in the section from the turning start position P1 to the turning end position P2 of the turning conveyance section S2. The first guide surface 21 guides the strip coil 2 in a part or all of its area so that it traces a turning trajectory that gradually turns inward in the direction of the turning radius. The first guide surface 21 slides and presses the strip coil 2 as it is turned and conveyed through the turning conveyance section S2, moving it from the conveyor body 5 side to the coil winding jig 3 side.

[0028] Specifically, the first guide member 19 acts on the strip coil 2 during rotation and transport while the straight portions 6 are gripped by the conveyance body 5 and held by the conveyance body 5, with the straight portions 6 gripped in the gripping grooves 12 formed between the plurality of piece members 8 in the conveyance body 5, as follows: The first guide surface portions 21 of the first guide member 19, which are curved clockwise in a side view and gradually inward in the direction of the turning radius, slide against and press the coil conductor 2a at the side end portion 7. This sliding contact and pressure by the first guide surface portions 21 causes the coil conductors 2a at the straight portions 6 to be released from the gripping grooves 12 and transferred one after another to the comb-tooth-shaped grooves 15 on the coil winding jig 3 side. In this way, the strip coil 2 is released from the piece members 8 of the conveyance body 5 and wound on the coil winding jig 3 side.

[0029] 1, the second guide member 20 is a member arranged so that its second guide surface portion 22 is located over the entire semicircular arc region from the terminal position P2 of the turning conveying section S2 to the vicinity of the outer periphery on the right side of the coil winding jig 3. The second guide member 20 is a plate-like member having the right semicircular arc-shaped second guide surface portion 22 as its left end and a right end portion 20a that extends rearward from the second guide surface portion 22, i.e., to the right side in FIG. 1, and having a linear portion perpendicular to the linear conveying section S1 and the linear reverse conveying section S3. The upper and lower ends of the second guide member 20 are located in the region of the conveying rail 9 between the linear reverse conveying section S3 and the linear conveying section S1.

[0030] The second guide surface portion 22 acts to slide against and press the coil conductor 2a at the side end portion 7 of the strip-shaped coil 2 that has been released from the bridge member 8 of the conveying body 5 and wound around the coil winding jig 3 by the first guide surface portion 21 of the first guide member 19. That is, the second guide surface portion 22 of the second guide member 20 has a curved shape that gradually turns inward in the turning radius direction clockwise in a side view of the second guide member 20, and slides against and presses the coil conductor 2a at the side end portion 7 as the coil winding jig 3 rotates. As a result, the coil conductor 2a of the successive straight portions 6 that have been moved from the conveying body 5 side to the outermost position in the comb-tooth-shaped grooves 15 of the coil winding jig 3 by the first guide surface portion 21 is pressed toward the second outermost outer position via the coil conductor 2a that is overlapped in the next turn, and enters the comb-tooth-shaped grooves 15 to a predetermined depth. As a result, the strip-shaped coil 2 is wound around the coil winding jig 3 in a normal state in which the coil conductors 2a of the straight portions 6 are pressed into the comb-tooth grooves 15 in a multi-layered manner (FIG. 4).

[0031] A straightening member 18 is provided near the lower end of the second guide member 20. The straightening member 18 is a plate-like member that is rectangular in plan view and extends from the right end 20a of the second guide member 20 in the direction of extension of the linear conveying section S1, with its width direction aligned with the thickness direction of the second guide member 20 (i.e., the direction perpendicular to the plane of FIG. 1). The straightening member 18 has a sliding surface 23 that faces and makes sliding contact with the conveyed strip coil 2 in a region spanning the linear conveying section S1 including the turning start position P1 and the turning conveying section S2. In FIG. 1, the sliding surface 23 is the lower surface of the straightening member 18. As shown in FIG. 6, the strip coil 2 moves sandwiched between the sliding surface 23 and the first guide surface 21 in a state in which the pair of parallel straight portions 6, 6 and the coil conductor 2a of the side end 7 that is connected to the straight portions 6, 6 overlap and intersect with the coil conductor 2a located directly below it. The sliding surface 23 is in sliding contact with the coil conductor 2a at the side end 7 at its end 24 in the transport direction of the strip coil 2, and this sliding contact point is used as a force point to apply bending stress to the coil conductor 2a, causing the side end 7 to bend into an arc shape and form a shape.

[0032] The correcting member 18 has an upper surface opposite to the sliding contact surface 23, on which a correcting surface 25 is formed, which is a concave surface that is arc-shaped in side view and whose thickness decreases partially toward the end 24. The concave curvature of the correcting surface 25 corresponds to the curvature of the circumferential envelope of the side end 7 of the strip-shaped coil 2 in a properly wound state. The width and position of the correcting surface 25 are selected so as to accommodate the end of the side end 7 of the strip-shaped coil 2 in the width direction perpendicular to the conveyance direction. The correcting surface 25 comes into sliding contact with the coil conductor 2a of the side end 7 of the strip-shaped coil 2 that is wound around the coil winding jig 3 and rotates, from the outer periphery of the rotation, and corrects the posture of the coil conductor 2a of the side end 7 so that it does not enter the outer periphery from the extension direction of the coil conductor 2a of the corresponding straight portion 6.

[0033] Referring to Figure 6, the coil conductor 2a at the side end 7 of the strip-shaped coil 2 is guided toward the back of the paper in Figure 6 by the first guide member 19, and each straight portion 6 of the strip-shaped coil 2 is moved between the comb tooth portions 14 during the first rotation of the coil winding jig 3 and wound once, and then wound multiple times during further rotations.

[0034] 7, with the first turn of the coil winding jig 3, the straight portion 6 that was wound in a single layer at the outermost position of the coil winding jig 3 is pushed into the second position from the outermost position via the straight portion 6 located at the outermost periphery in the next turn, resulting in a state of multiple windings around the coil winding jig 3. This pushing is performed by guiding the coil conductor 2a at the side end portion 7 of the strip-shaped coil 2 to the far side of the page in FIG. 7 by the second guide member 20. In FIGS. 6 and 7, a plurality of lead wires 7a extend from the strip-shaped coil 2 wound around the coil winding jig 3 in the same direction as the extension direction of the coil conductor 2a of the straight portion 6.

[0035] 1 and 5, the strip-shaped coil 2 is formed into an arc shape and then wound in multiple layers near the outer periphery of the coil winding jig 3. During this multiple winding, the coil conductors 2a overlap at the side end 7 of the strip-shaped coil 2, resulting in a bent posture with some portions protruding outward from the imaginary extension line Lv of the straight portion 6. In the coil forming device 1 of the present disclosure, the portions of the coil conductors 2a at the side end 7 of the strip-shaped coil 2 that tend to protrude outward from the imaginary extension line Lv of the straight portion 6 are pressed by sliding contact with the correcting surface 25 of the correcting member 18, thereby correcting the posture.

[0036] As described above, the width and position of the correction surface 25 are selected so as to accommodate the end of the side end 7 of the strip-shaped coil 2 in the width direction perpendicular to the conveying direction. Therefore, the correction surface 25 slides and presses the coil conductor 2a of the side end 7, including the end in the width direction perpendicular to the conveying direction. This allows the posture of the side end 7 to be fully corrected.

[0037] Next, the operation of the correcting member 18 will be described with reference to Figures 8, 9, and 10. Figure 8 is a schematic diagram illustrating the operation of the correcting member 18 in the same side view as Figure 1. Figure 9 is a partial enlarged view corresponding to the circled portion C1 in Figure 8. Figure 10 is a schematic diagram illustrating the operation of the correcting member 18 in a front view from the right side. In Figures 8, 9, and 10, parts corresponding to those in Figure 1 are assigned the same reference numerals.

[0038] As the coil conductor 2a of the strip-shaped coil 2 is guided by the first guide surface portion 21 of the first guide member 19 and turned and transported, it is formed into an arc shape by the sliding surface 23 on the lower surface of the corrector 18. The formed coil conductor 2a is guided by the first guide surface portion 21 as the coil winding jig 3 rotates clockwise, and gradually enters the comb-tooth-shaped grooves 15. The coil conductor 2a in the comb-tooth-shaped grooves 15 is brought into an area where it is guided by the second guide member 20 as the coil winding jig 3 rotates clockwise.

[0039] The second guide surface portion 22 of the second guide member 20 gradually guides the coil conductor 2a in the comb-tooth groove 15 inward in the direction of the turning radius as the coil conductor 2a turns clockwise, causing it to penetrate deeper into the comb-tooth groove 15. Strictly speaking, in the phase in which the coil conductor 2a is guided by the second guide surface portion 22, the coil conductor 2a is guided in a state in which it is overlapped in multiple layers in the depth direction of the comb-tooth groove 15, as shown in Fig. 10, but this is depicted in a simplified manner in the schematic diagrams of Figs.

[0040] If no measures are taken at the overlapping portion of the side end portion 7, the coil conductor 2a shown by the imaginary line on the left side of Fig. 10 will assume a posture in which it is bent downward, i.e., toward the outer periphery of the coil winding jig 3. In the case of the coil forming device 1 of the present disclosure, the coil conductor 2a shown by the solid line on the right side of Fig. 10 is pressed by sliding contact with the correction surface 25 of the correction member 18, so that the posture is corrected in advance to prevent the above-mentioned bending.

[0041] As a result, the coil conductor 2a at the side end 7 assumes a position that does not extend beyond the region outer circumferentially of the imaginary extension line Lv of the corresponding straight portion 6. Due to the action of the correcting member 18 as described above, the coil conductor 2a of the strip-shaped coil 2 wound in multiple layers around the coil winding jig 3 is positioned such that the side end 7 does not extend beyond the region outer circumferentially of the imaginary extension line Lv of the corresponding straight portion 6, conforming to a shape that satisfies the regular specifications, as shown in Figures 11 and 12 .

[0042] Fig. 11 is a diagram showing a portion of the strip coil 2 whose posture has been corrected by the correcting member 18, as viewed from the front, from the right side. Fig. 12 is a diagram showing a portion of the strip coil 2 whose posture has been corrected by the correcting member 18, as viewed from the front, from the left side. In Figs. 11 and 12, parts corresponding to those in Figs. 1 and 5 are given the same reference numerals. As shown in Figs. 11 and 12, the strip coil 2 wound in multiple layers around the coil winding jig 3 has an outer circumferential profile in the posture of the side end portion 7 that is substantially aligned with the imaginary extension line Lv of the corresponding straight portion 6, and does not extend beyond the region outer circumferential side of the imaginary extension line Lv.

[0043] 11 and 12, the side end 7 satisfies the outer diameter requirement for this type of stator coil specification. This prevents the side end 7 of the strip-shaped coil 2 from interfering with other components when the strip-shaped coil 2, which is formed into a roughly cylindrical shape, is inserted into the stator core of a rotating electrical machine for assembly, making it possible to provide a high-quality stator coil.

[0044] Next, we will explain a coil forming method that uses this coil forming device 1 to correct the posture of the side end 7 of the strip-shaped coil 2 so that it satisfies the outer diameter requirement for this type of stator coil. The coil forming method includes a coil transporting step, a coil winding step, and a correcting step.

[0045] In the coil transport process, a strip-shaped coil 2 having a plurality of straight portions 6 and side end portions 7 connected to both ends of the plurality of straight portions 6 is transported in a predetermined rotating transport section S2 so as to trace a rotating trajectory, with the side end portions 7 guided by a guide member 17.

[0046] In the coil winding process, the strip coil 2 transported through the rotating transport section S2 in the coil transport process is wound by inserting the multiple straight portions 6 into the multiple comb-tooth grooves 15 of the rotating coil winding jig 3.

[0047] In the straightening process, the straightening surface 25 of the straightening member 18 is brought into sliding contact with the side end 7 of the strip-shaped coil 2, which is wound around the coil winding jig 3 and rotated in the coil winding process, from the outer periphery of the rotation so as to accommodate the widthwise end of the side end 7 perpendicular to the conveying direction, and the posture of the sliding contacting side end 7 is corrected so that it does not bend outward beyond the imaginary extension line Lv of the corresponding straight portion 6.

[0048] According to the coil forming method of the present disclosure, the side end portion 7 of the strip-shaped coil 2 is pressed by sliding contact with the correcting surface 25 of the correcting member 18, thereby correcting the position of the side end portion 7 so that it does not enter the area on the outer periphery of the imaginary extension line Lv of the corresponding straight portion 6. This prevents the side end portion 7 of the strip-shaped coil 2 from interfering with other components when the strip-shaped coil 2 formed into a roughly cylindrical shape is inserted and assembled into the stator of a rotating electric machine, making it possible to provide a high-quality stator coil.

[0049] While one embodiment of the coil forming apparatus of the present disclosure has been described above, the technical concept of the present disclosure is not limited thereto. The detailed configuration may be modified as appropriate within the spirit and scope of the technical concept of the present disclosure. For example, in the above example, the straightening surface 25 is provided on the upper surface of the same straightening member 18, and the sliding surface 23 having the end portion 24 that acts to form the straightening wire is provided on the lower surface. However, instead of this, the member having the straightening surface 25 and the member having the sliding surface 23 may be configured as separate members. [Explanation of symbols]

[0050] Lv...Virtual extension line P1: Turning start position P2…Terminal position S1: Straight conveying section S2: Rotating transport section S3: Straight reverse conveyance section 1... Coil forming device 2...Strip coil 2a...Coil conductor 3...Coil winding jig 4... Coil transport mechanism 5...Transport body 6...Straight section 7... Side end 7a... Outlet line 8... Piece member 9... Conveyor rail 10... First gripping claw 11... Second gripping claw 12... Gripping groove 13... Fixture body 14... Comb tooth part 15... Comb tooth-shaped groove 16... Shaft hole 17... Guide member 18... Correction member 19... First guide member 20... Second guide member 20a... Right end 21... First guide surface 22... Second guide surface 23... Folding joint surface 24... End 25... Correction surface

Claims

1. a coil transport mechanism that transports a strip-shaped coil having a plurality of straight portions and side ends connected to both ends of the plurality of straight portions in a predetermined rotating transport section, while guiding the side ends using a guide member, so as to draw a rotating trajectory; a coil winding jig that rotates to wind the strip-shaped coil transported through the turning transport section by the coil transport mechanism by inserting the plurality of straight portions into the plurality of comb-tooth grooves, respectively; a coil forming device provided with a correction member arranged so that the correction member has a correcting surface on its upper surface sliding against the side end of the strip-shaped coil that is wound around the coil winding jig and rotates from the outer periphery of the rotation, the correction surface having a width that can accommodate the end of the side end in the width direction perpendicular to the conveying direction, correcting the posture of the slidingly contacting side end so that it does not enter the area outer periphery of the imaginary extension line of the corresponding straight portion, and forming the coil conductor of the strip-shaped coil into an arc shape with the sliding surface on its lower surface as the strip-shaped coil is conveyed in a rotating manner.

2. a coil transport step of transporting a strip-shaped coil having a plurality of straight portions and side ends connected to both ends of the plurality of straight portions in a predetermined rotating transport section, with the side ends being guided by a guide member so as to trace a rotating trajectory; a coil winding step of winding the strip-shaped coil transported through the turning transport section by the coil transport step by inserting the plurality of straight portions into a plurality of comb-tooth grooves of a rotating coil winding jig, a correction step in which a correction surface on the upper surface of a correction member is brought into sliding contact with the side end of the strip-shaped coil that is wound around the coil winding jig and rotated in the coil winding step, from the outer peripheral side relative to the rotation, so as to accommodate the end of the side end in the width direction perpendicular to the conveying direction of the side end, thereby correcting the posture of the sliding contacting side end so that it does not enter an area outer than an imaginary extension line of the corresponding straight portion, and a correction step in which the sliding contact surface on the lower surface of the correction member is used to shape the coil conductor of the strip-shaped coil into an arc shape as the strip-shaped coil is conveyed in a rotating manner.

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