Coil forming device and coil manufacturing method

Abstract

To provide a coil forming device that achieves a configuration capable of forming a coil in which wires are aligned and bulge and irregular winding are suppressed, and a method of manufacturing a coil.SOLUTION: Provided is a coil forming device 100 obtaining a coil 300 by winding wires 200 supplied from a wire supply part 10. The coil forming device includes: a wire guide part 1 which contacts the wires supplied from the wire supply part 10 to change the supply direction of the wires; a wire feeding part 2 to which the wires passing through the wire guide part are supplied; and a winding core 6 around which the wires supplied from the wire feeding part are wound. The wire guide part contacts the wires at a position different from a position where the wires are supplied to the wire feeding part, in viewing the wires in a first supply direction that is a supply direction of wires from the wire supply part to the wire guide part.SELECTED DRAWING: Figure 1

Description

[Technical Field]

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

[0002] Winding devices that wind wire to obtain a coil are known. Such a winding device is disclosed, for example, in Patent Document 1. Specifically, Patent Document 1 discloses a winding device that winds wire around a winding core that is rotated by a rotating means, where the winding core has an inner winding core that is rotated by the rotating means and an outer winding core that surrounds the inner winding core and rotates together with the inner winding core. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-064404 Summary of the Invention [Problem to be solved by the invention]

[0004] While a wire is being wound around a bobbin for supplying wire, the wire may be given a non-uniform curl in direction and strength. When a wire is supplied to a winding core in a direction perpendicular to the rotation axis and wound around the winding core to obtain a coil, as in the winding device described in Patent Document 1, the non-uniform curl of the wire may cause the wire to swell and become misaligned, resulting in irregular winding.

[0005] As described above, a coil in which the wire is not aligned and bulges and winds irregularly, may not be able to be smoothly inserted into a slot of a stator. For this reason, there is a demand for a coil forming device that can form a coil in which the wire is aligned and bulges and winding irregularities are suppressed.

[0006] The object of the present invention is to realize a configuration in a coil forming device capable of forming a coil by winding wire around a winding core, in which the wire is aligned and swelling and winding irregularities are suppressed. [Means for solving the problem]

[0007] A coil forming apparatus according to an exemplary embodiment of the present invention obtains a coil by winding a wire rod supplied from a wire rod supply unit. The coil forming apparatus includes a wire rod guide unit that contacts the wire rod supplied from the wire rod supply unit and changes the supply direction of the wire rod, a wire rod payout unit to which the wire rod that has passed through the wire rod guide unit is supplied, and a winding core around which the wire rod supplied from the wire rod payout unit is wound. When viewing the wire rod in a first supply direction, which is the supply direction of the wire rod from the wire rod supply unit to the wire rod guide unit, the wire rod guide unit contacts the wire rod at a position different from the position at which the wire rod is supplied to the wire rod payout unit.

[0008] Furthermore, a coil manufacturing method according to an exemplary embodiment of the present invention is a method for manufacturing a coil configured by winding a wire rod around a winding core. The method includes a wire rod supplying step of supplying the wire rod from a wire rod supply unit to a wire rod payout unit, and a wire rod winding step of winding the wire rod supplied from the wire rod payout unit around the winding core. In the wire rod supplying step, the wire rod guide unit contacts the wire rod at a position different from a position where the wire rod is supplied to the wire rod payout unit, as viewed in a first supply direction that is a supply direction of the wire rod from the wire rod supply unit to the wire rod guide unit, thereby changing the supply direction of the wire rod. [Effects of the Invention]

[0009] According to the coil forming device and the coil manufacturing method according to an exemplary embodiment of the present invention, it is possible to form a coil in which the wires are aligned and swelling and winding irregularities are suppressed. [Brief explanation of the drawings]

[0010] [Figure 1]FIG. 1 is a diagram showing an example of the overall configuration of a coil forming apparatus according to an embodiment. [Figure 2] FIG. 2 is a perspective view showing a contact surface of the wire guide portion according to the embodiment with the wire. [Figure 3] FIG. 3 is a diagram showing an example of a wire rod feeding section according to the embodiment. [Figure 4] FIG. 4 is a diagram showing an example of a wire rod feeding section according to the embodiment. [Figure 5] FIG. 5 is a diagram illustrating an example of the overall configuration of a coil forming device according to an embodiment. [Figure 6] FIG. 6 is a diagram showing an example of the overall configuration of a coil forming device according to a first modified example. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the drawings. The same or corresponding parts in the drawings are designated by the same reference numerals, and their description will not be repeated. Furthermore, the dimensions of the components in each drawing do not faithfully represent the actual dimensions of the components and the dimensional ratios of the components.

[0012] In the following description of the coil forming apparatus 100, the direction parallel to the central axis R of the winding core 6 will be referred to as the "axial direction." The axial direction is also the direction in which the wire 200 wound around the winding core 6, which will be described later, is aligned. In the following description, an example will be described in which the axial direction is parallel to the vertical direction when the coil forming apparatus 100 is installed. However, this definition does not intend to limit the orientation of the coil forming apparatus 100 during use or the direction of the central axis R of the winding core 6 to the vertical direction. The direction of the central axis R of the winding core 6 does not have to be parallel to the vertical direction.

[0013] Furthermore, in the following description, the expressions "fix," "connect," and "attach" (hereinafter referred to as "fixing") include not only cases where members are directly fixed to each other, but also cases where members are fixed via other members. In other words, in the following description, the expression "fixing" includes both direct and indirect fixing of members to each other.

[0014] (Embodiment) An example of a coil forming apparatus 100 according to an embodiment will be described with reference to FIGS. 1 to 5. In each drawing, the supply direction of the wire material 200 is indicated by an outlined arrow. The coil forming apparatus 100 is an apparatus that supplies the wire material 200 and winds the supplied wire material 200 to obtain a coil 300. For example, the coil forming apparatus 100 obtains a coil to be inserted into a slot of a motor stator. Note that the coil obtained by the coil forming apparatus 100 is not limited to a coil to be inserted into a slot of a stator. The wire material 200 is, for example, a copper wire having an insulating coating. However, the wire material 200 is not limited to a copper wire, and the coil forming apparatus 100 can wind a wire material made of a conductive material.

[0015] (Overall composition) Fig. 1 is a diagram showing an example of the overall configuration of a coil forming apparatus 100 according to an embodiment. As shown in Fig. 1, the coil forming apparatus 100 includes a wire supply unit 10, a wire guide unit 1, a wire feed unit 2, a wire winding unit 3, and a winding control unit 7. In the coil forming apparatus 100, the wire supply unit 10, the wire guide unit 1, the wire feed unit 2, and the wire winding unit 3 are arranged in this order from upstream to downstream in the supply direction of the wire 200. Furthermore, the coil forming apparatus 100 includes a guide support unit 4 that supports the wire guide unit 1, and a feed unit support unit 5 that supports the wire feed unit 2.

[0016] (Wire supply section) The wire rod supply unit 10 has a plurality of bobbins 10a, a wire rod gathering unit 10b, and a gathering unit support unit 10c. One wire rod 200 is wound around the bobbin 10a. The wire rod 200 is unwound from each bobbin 10a. As a result, a plurality of wire rods 200 are simultaneously supplied to the wire rod guide unit 1, the wire rod unwinding unit 2, and the wire rod winding unit 3.

[0017] The wire rod gathering portion 10b is located between the bobbin 10a and the wire rod guide portion 1 in the supply direction of the wire rod 200. For example, the wire rod gathering portion 10b is a tubular member and has a gathering through-hole (not shown). The plurality of wire rods 200 unwound from the bobbin 10a pass through the gathering through-hole of the wire rod gathering portion 10b.

[0018] The assembly support portion 10c is located between the bobbin 10a and the wire guide portion 1, and supports the wire assembly portion 10b.

[0019] (Wire guide section) FIG. 2 is a perspective view showing an example of the wire guide section 1 that comes into contact with the wire 200. The wire guide section 1 is located between the wire gathering section 10b and the wire feeding section 2 in the supply direction of the wire 200. As shown in FIG. 2, the wire guide section 1 has a guide main body section 11 and an elastic deformation section 12. In the following description, the supply direction of the wire 200 from the wire supply section 10 to the wire guide section 1 is referred to as a first supply direction D1. Specifically, the wire 200 is supplied in the wire guide section 1 from one side to the other side of the first supply direction D1.

[0020] The guide body 11 is plate-shaped. The guide body 11 may be columnar or cylindrical, and is not limited to a plate-shaped body. In this embodiment, the guide body 11 is a metal plate. The guide body 11 may be made of a material other than metal.

[0021] The elastic deformation portion 12 is, for example, sheet-shaped or plate-shaped. The elastic deformation portion 12 is attached to one surface of the guide body 11. The elastic deformation portion 12 is located at a position where it comes into contact with the plurality of wire rods 200 being fed. The elastic deformation portion 12 is located at least at the other end of the wire rod guide 1 in the first feed direction D1. As shown in FIG. 2 , the plurality of wire rods 200 parallel to the first feed direction D1 come into contact with the elastic deformation portion 12 of the wire rod guide 1 in a lined-up state.

[0022] The elastic deformation portion 12 is elastically deformed by contact with the wire rod 200. The elastic deformation portion 12 is recessed when the wire rod guide portion 1 comes into contact with the wire rod 200. The elastic deformation portion 12 is, for example, felt. When the wire rod 200 comes into contact with the wire rod guide portion 1, the supply direction of the wire rod 200 changes to a direction different from the direction in which the wire rod 200 is supplied from the wire rod assembly portion 10b to the wire rod guide portion 1.

[0023] 1, the guide support part 4 is located between the wire gathering part 10b and the wire feeding part 2 in the supply direction of the wire 200. The guide support part 4 supports the wire guide part 1.

[0024] (Wire rod feeding section) 3 and 4 are diagrams showing an example of the wire rod feeding section 2 according to the embodiment. The wire rod feeding section 2 supplies the wire rod 200 that has passed through the wire rod guide section 1 to the wire rod winding section 3. In the following description, the feeding direction of the wire rod 200 between the wire rod guide section 1 and the wire rod feeding section 2 is referred to as a second feeding direction D2.

[0025] As shown in Fig. 1, the wire rod unwinding section 2 is located between the wire rod guide section 1 and the wire rod winding section 3 in the supply direction of the wire rod 200. In the axial direction of a winding core 6 described later, a position P2 where the wire rod 200 is supplied to the wire rod unwinding section 2 is different from a position P1 where the wire rod guide section 1 and the wire rod 200 come into contact with each other. Specifically, in the example of Fig. 1, when the wire rod 200 is viewed in a first supply direction D1, the positions of the wire rod guide section 1 and the wire rod unwinding section 2 are different in the axial direction.

[0026] As shown in FIG. 3, the wire rod feeding section 2 has a feeding main body 21. For example, the feeding main body 21 is columnar. The feeding main body 21 has a plurality of alignment through holes 22. The alignment through holes 22 are located at the center of the short side of the end face of the feeding main body 21 where the alignment through holes 22 open, and are lined up in the longitudinal direction. The alignment through holes 22 are lined up in the axial direction. One wire rod 200 passes through one alignment through hole 22. As a result, the plurality of wire rods 200 are lined up in the axial direction with respect to the wire rod feeding section 2. Note that the alignment direction of the alignment through holes 22 does not have to be the axial direction.

[0027] The directions in which the multiple alignment through holes 22 penetrate the feed-out main body 21 are the same or the same except for errors due to processing during manufacturing of the wire rod feed-out portion 2. The wire rod 200 supplied from the wire rod guide portion 1 to the wire rod feed-out portion 2 passes through the alignment through holes 22 of the wire rod feed-out portion 2.

[0028] FIG. 4 is a cross-sectional view taken along the arrow XX in FIG. 3 and includes a cross-section of the alignment through hole 22. As shown in FIG. 4, the alignment through hole 22 has a central portion 23, an entrance opening 24, and an exit opening 25. The central portion 23 extends in the direction of penetration of the alignment through hole 22 and has a constant inner diameter. One end of the entrance opening 24 opens to one side of the dispensing main body 21, and the other end of the entrance opening 24 is connected to the central portion 23. The inner diameter of the entrance opening 24 increases toward the opening located on one side of the dispensing main body 21. Meanwhile, one end of the exit opening 25 is connected to the central portion 23, and the other end of the exit opening 25 opens to the other side of the dispensing main body 21. The inner diameter of the exit opening 25 increases toward the opening located on the other side of the dispensing main body 21.

[0029] 1, the feeding section support section 5 is located between the wire guide section 1 and the wire winding section 3 in the supply direction of the wire 200. The feeding section support section 5 supports the wire feeding section 2.

[0030] Specifically, the feed-out portion support portion 5 supports the wire rod feed-out portion 2 at a position where the penetration direction of the alignment through-hole 22 of the wire rod feed-out portion 2 is perpendicular to the axial direction and the opening on the other side of the penetration direction of the alignment through-hole 22 faces the winding core 6, which will be described later. As a result, the wire rod feed-out portion 2 supplies the wire rod 200 to the winding core 6 in a direction different from the second supply direction D2. As described above, the inner diameter of the entrance-side opening 24 of the alignment through-hole 22 increases toward one side of the feed-out main body portion 21, i.e., the upstream side in the supply direction of the wire rod 200.

[0031] As shown in FIG. 1, the feed-out unit support unit 5 includes a feed-out unit moving unit 51. For example, the feed-out unit moving unit 51 has a moving motor 52, a ball screw 53, and a slide table 54. The ball screw 53 extends in the axial direction. The moving motor 52 rotates the ball screw 53. The wire rod feed-out unit 2 is fixed to one flat surface of the slide table 54. The slide table 54 has a nut (not shown) on the surface opposite to the surface to which the wire rod feed-out unit 2 is fixed. The ball screw 53 is inserted into a hole in the nut.

[0032] The movement motor 52 can rotate in both the forward and reverse directions. When the movement motor 52 rotates, the slide table 54 moves in the axial direction. This allows the wire rod feeding unit 2 fixed to the slide table 54 to move.

[0033] (Wire winding section) The wire winding unit 3 is located on the most downstream side in the supply direction of the wire 200 in the coil forming apparatus 100. The wire winding unit 3 has a winding core 6 and a winding motor 31.

[0034] The winding core 6 has a base portion 61, a pair of core rods 62, and a rotating shaft portion 63. The base portion 61 is a plate-like or rod-like member. The base portion 61 extends in a direction perpendicular to the axial direction. The ends of each core rod 62 are attached to the base portion 61. There may be three or more core rods 62. The core rods 62 extend in the axial direction. The core rods 62 may extend in the axial direction with the same shape. The core rod 62 may have one or more tapered portions whose diameter decreases or increases toward one axial side. The core rod 62 may have one or more tapered portions whose diameter decreases or increases toward the other axial side. An end of the wire 200 is fixed to one of the core rods 62.

[0035] The rotating shaft 63 extends in the axial direction. One axial end of the rotating shaft 63 is connected to the base 61 of the winding core 6. The other axial end of the rotating shaft 63 is connected to the winding motor 31. When the winding motor 31 rotates, the rotating shaft 63 of the winding core 6 rotates about the central axis R. This causes the winding core 6 to rotate, and the wire 200 is wound onto the core rod 62.

[0036] (winding control section) The winding control unit 7 controls the operation of the moving motor 52 and the winding motor 31. Specifically, when winding the coil 300, the winding control unit 7 rotates the moving motor 52 to reciprocate the slide table 54. The winding control unit 7 also rotates the winding motor 31, rotates the moving motor 52, and rotates the winding core 6. The winding control unit 7 is, for example, a board having a control circuit and a memory.

[0037] (Coil manufacturing) Next, an example of a manufacturing process of the coil 300 using the coil forming apparatus 100 according to the embodiment will be described with reference to Figures 1 and 5. In the manufacturing process of the coil 300, a wire winding process and a wire feeding process are performed using the coil forming apparatus 100.

[0038] First, as a pretreatment for the wire winding step and the wire supplying step, the wire rods 200 are drawn out from the plurality of bobbins 10a. The drawn out plurality of wire rods 200 are passed through the gathering through-holes of the wire rod gathering section 10b. Next, while the gathered wire rods 200 are brought into contact with the wire rod guide section 1, the wire rods 200 are passed through each of the alignment through-holes 22 of the wire rod feeding section 2. The ends of the plurality of wire rods 200 that have passed through the wire rod feeding section 2 are attached to the winding core 6. Note that each of the wire rods 200 drawn out from the plurality of bobbins 10a has a curl that was imparted while being wound around the bobbin 10a.

[0039] In the wire winding step, the winding control unit 7 rotates the winding motor 31. This rotates the winding core 6 and the rotating shaft unit 63, and the wire 200 is wound around the winding core 6. The winding control unit 7 rotates the winding core 6 a predetermined number of times. When the required number of turns of the coil 300 have been formed, the winding control unit 7 stops the winding motor 31. A cutting device (not shown) cuts the plurality of wire rods 200 at a position between the wire rod unwinding unit 2 and the winding core 6. The coil 300 is removed from the winding core 6. When a coil 300 is subsequently manufactured, ends of the cut plurality of wire rods 200 are attached to the winding core 6.

[0040] As the winding core 6 takes up the wire rod 200, the wire rod 200 is transported toward the winding core 6. While the wire rod 200 is being wound around the winding core 6, a plurality of wire rods 200 are continuously supplied from the wire rod supply unit 10 to the wire rod guide unit 1, the wire rod unwinding unit 2, and the winding core 6.

[0041] Specifically, a plurality of wire rods 200 fed from a plurality of bobbins 10a of the wire rod supply unit 10 penetrate the wire rod gathering unit 10b. The plurality of wire rods 200 passing through the wire rod gathering unit 10b are fed in a first feeding direction D1 from the wire rod gathering unit 10b toward the wire rod guide unit 1. The wire rod guide unit 1 feeds the plurality of wire rods 200 fed from the wire rod supply unit 10 to the wire rod feeding unit 2. When the wire rod 200 comes into contact with the wire rod guide unit 1, the feeding direction of the wire rod 200 changes from the first feeding direction D1 to a second feeding direction D2.

[0042] The wire rod 200 passes through the alignment through-hole 22 of the wire rod unwinding unit 2 and is supplied to the winding core 6. In the wire rod unwinding unit 2, the supply direction of the wire rod 200 changes from the second supply direction D2 to a direction toward the winding core. The wire rod 200 is supplied to the winding core 6 in a direction parallel to the passing direction of the alignment through-hole 22 in the wire rod unwinding unit 2. The wire rod unwinding unit 2 supplies the plurality of wire rods 200 supplied from the wire rod supply unit 10 to the winding core 63. In this way, in the coil forming apparatus 100, a wire rod supplying process is carried out in parallel with the wire rod winding process.

[0043] 1 and 5 show an example in which a position P1 where the wire guide unit 1 contacts the wire rod 200 and a position P2 where the wire rod 200 is supplied to the wire rod feeding unit 2 are different in the axial direction. Since the positions P1 and P2 are different in the axial direction, the supply direction of the wire rod 200 changes from a first supply direction D1 to a second supply direction D2. In the example of FIGS. 1 and 5, the first supply direction D1 is, for example, parallel to the horizontal direction. The second supply direction D2 is a direction toward one side in the axial direction as it moves toward the downstream side of the supply direction of the wire rod 200. In the example of FIGS. 1 and 5, the one side in the axial direction is upward in the vertical direction.

[0044] The wire rod guide section 1 is positioned to apply tension to the wire rod 200. As a result, the wire rod 200 is pressed against the elastic deformation section 12 of the wire rod guide section 1. The wire rod 200 is fed while being pressed against the wire rod guide section 1. When the wire rod 200 passes through the end of the wire rod guide section 1 on the other side of the first feeding direction D1, the wire rod 200 is curved in a predetermined direction. The predetermined direction is a direction in which the feeding direction of the wire rod 200 changes when viewed from the first feeding direction D1, i.e., a direction in which the feeding direction changes from the first feeding direction D1 to the second feeding direction D2. For example, when a position P1 where the wire rod guide section 1 contacts the wire rod 200 and a position P2 where the wire rod 200 is fed to the wire rod unwinding section 2 are different in the axial direction, the wire rod 200 is curved in the predetermined direction. As a result, the curve of the wire rod 200 that was imparted while being wound around the bobbin 10a is removed. Here, "removing the curl" means that the curl has been weakened. Some of the curl imparted to the wire 200 while it was being wound around the bobbin 10a may remain, or the curl may be completely removed. Furthermore, since the warping direction and the strength of the curl imparted to the wire 200 are uniform, when the wire 200 is wound, the wire 200 is aligned in parallel. A coil 300 in which swelling and winding irregularities are suppressed is obtained.

[0045] In the wire rod supplying step, the winding control unit 7 controls the rotation of the movement motor 52 of the feed-out unit support unit 5. Specifically, the winding control unit 7 moves the wire rod feed-out unit 2 in the axial direction of the winding core 6. As shown in Figs. 1 and 5 , when winding the wire rod 200 around the winding core 6, the winding control unit 7 changes the position of the wire rod feed-out unit 2.

[0046] For example, from the start to the end of the wire rod winding process, the winding control unit 7 moves the wire rod feeding unit 2 back and forth in the axial direction. For example, every time the wire rod 200 is wound around the winding core 6 for one turn, the winding control unit 7 moves the wire rod feeding unit 2 in the axial direction by a predetermined amount.

[0047] Here, in the axial direction of the winding core 6, a distance L1 between a position P1 where the wire guide part 1 and the wire rod 200 come into contact with each other and a position P2 where the wire rod 200 is supplied to the wire rod supplying part 2 is larger than an axial width W1 of the coil 300 wound around the winding core 6. In other words, the distance L1 between the position P1 where the wire guide part 1 and the wire rod 200 come into contact with each other and a position P2 where the wire rod 200 is supplied to the wire rod supplying part 2 is larger than the axial movement width of the wire rod supplying part 2.

[0048] 5 shows an example of a state in which, when the wire 200 is viewed in the first supply direction D1, the moved wire rod unwinding unit 2 is located at a position closest to the wire rod guide unit 1. As shown in Fig. 5, even when the wire 200 is closest in the axial direction, when the wire 200 is viewed in the first supply direction D1, a distance L1 between a position P1 where the wire rod guide unit 1 and the wire rod 200 come into contact with each other and a position P2 where the wire rod 200 is supplied to the wire rod unwinding unit 2 is larger than the axial width W1 of the coil 300.

[0049] The first supply direction D1 and the second supply direction D2 intersect because the position P1 where the wire guide unit 1 contacts the wire rod 200 is different from the position P2 where the wire rod 200 is supplied to the wire rod feeding unit 2. The angle formed between the first supply direction D1 and the second supply direction D2 may be 10 degrees or more, or may be 12 degrees or more. By setting the angle formed between the first supply direction D1 and the second supply direction D2 to a certain angle or more, the wire rod 200 can be efficiently curled.

[0050] In addition, in the wire feeding process, the tension of the wire 200 from the wire feeding unit 10 to the wire guide unit 1 is smaller than the tension of the wire 200 from the wire guide unit 1 to the wire feed unit 2. In the coil forming device 100, the tension of the wire 200 from the wire feeding unit 10 to the wire guide unit 1 is suppressed. That is, the wire 200 is prevented from being strongly curled in the section from the wire feeding unit 10 to the wire guide unit 1. Therefore, the bulging and irregular winding of the coil 300 due to the curl imparted in the section from the wire feeding unit 10 to the wire guide unit 1 is suppressed.

[0051] As described above, the coil forming apparatus 100 according to the embodiment obtains the coil 300 by winding the wire rod 200 supplied from the wire rod supply unit 10. The coil forming apparatus 100 includes a wire rod guide unit 1 that comes into contact with the wire rod 200 supplied from the wire rod supply unit 10 to change the supply direction of the wire rod 200, a wire rod unwinding unit 2 to which the wire rod 200 that has passed through the wire rod guide unit 1 is supplied, and a winding core 6 around which the wire rod 200 supplied from the wire rod unwinding unit 2 is wound. When viewing the wire rod 200 in a first supply direction D1, which is the supply direction of the wire rod 200 from the wire rod supply unit 10 to the wire rod guide unit 1, the wire rod guide unit 1 comes into contact with the wire rod 200 at a position different from the position at which the wire rod 200 is supplied to the wire rod unwinding unit 2.

[0052] Moreover, the manufacturing method of the coil 300 according to the embodiment is a manufacturing method of the coil 300 configured by winding the wire rod 200 around the winding core 6. The manufacturing method of the coil 300 includes a wire rod supplying step of supplying the wire rod 200 from the wire rod supply unit 10 to the wire rod unwinding unit 2, and a wire rod winding step of winding the wire rod 200 supplied from the wire rod unwinding unit 2 around the winding core 6. In the wire rod supplying step, when the wire rod 200 is viewed in a first supplying direction D1, which is the supplying direction of the wire rod 200 from the wire rod supply unit 10 to the wire rod guide unit 1, the wire rod guide unit 1 is brought into contact with the wire rod 200 at a position different from the position where the wire rod 200 is supplied to the wire rod unwinding unit 2, to change the supplying direction of the wire rod 200.

[0053] According to the coil forming device 100 and the manufacturing method of the coil 300 described above, the wire rod guide section 1 comes into contact with the wire rod 200, thereby changing the supply direction of the wire rod 200 from the wire rod guide section 1 to the wire rod feeding section 2 to a direction different from the first supply direction D1. At this time, the wire rod 200 is pressed against the wire rod guide section 1. By pressing the wire rod 200 against the wire rod guide section 1, the wire rod 200 is given a tendency to bend in a predetermined direction. As a result, when the wire rod feeding section 10 is a bobbin 10a, the tendency of the wire rod 200 given while being wound around the bobbin 10a is removed.

[0054] Furthermore, because the wire rod 200 is given a tendency to be warped in a predetermined direction before being wound around the winding core 6, the wire rods 200 are aligned in parallel in the coil 300 obtained by winding the wire rod 200 around the winding core 6. This makes it possible to obtain a coil 300 in which swelling and winding irregularities are suppressed. As a result, when the coil 300 is inserted into a stator, the wire rods 200 in the obtained coil 300 are aligned, making it easy to insert the coil 300 into the slots of the stator.

[0055] The wire rod 200 is wound around the winding core 6 while being aligned in the axial direction. In the axial direction of the winding core 6, a position P2 at which the wire rod 200 is supplied to the wire rod feeding section 2 is different from a position P1 at which the wire rod guide section 1 and the wire rod 200 come into contact with each other.

[0056] In the axial direction of the winding core 6, the position of the wire rod guide section 1 and the position of the wire rod unwinding section 2 are different, so the supply direction of the wire rod 200 changes in the axial direction of the winding core 6 between the wire rod guide section 1 and the wire rod unwinding section 2. The wire rod 200 is given a tendency to warp in the axial direction of the winding core 6. As a result, the position of the wire rod 200 is aligned in the axial direction of the winding core 6, and a coil 300 in which swelling and winding irregularities are suppressed can be obtained.

[0057] The wire 200 is supplied from one side to the other side in a first supply direction D1. The wire guide unit 1 has an elastic deformation part 12 that comes into contact with the wire 200 and elastically deforms at the end on the other side of the wire guide unit 1 in the first supply direction D1.

[0058] The elastic deformation portion 12 elastically deforms when the wire rod 200 comes into contact with it. The wire rod 200 is supplied to the wire rod feeding portion 2 while contacting the elastic deformation portion 12. The end portion of the wire rod guide portion 1 on the other side in the first supply direction D1 imparts a curve to the wire rod 200 so that the wire rod 200 is warped in a predetermined direction. By winding the wire rod 200 thus warped, the wire rod 200 is aligned, and a coil 300 in which swelling and winding irregularities are suppressed can be obtained. Furthermore, the elastic deformation portion 12 is recessed in response to the wire rod 200 that comes into contact with it. If a corner is located at the end portion on the other side in the first supply direction D1 of the member guiding the wire rod, the wire rod 200 is strongly rubbed against the corner, but since the elastic deformation portion 12 is recessed, damage to the wire rod 200 is suppressed. Therefore, a coil 300 in which damage to the wire rod 200 is reduced can be efficiently produced.

[0059] The wire rod unwinding section 2 supplies the wire rod 200 in a direction different from a second supply direction D2, which is the supply direction of the wire rod 200 from the wire rod guide section 1 to the wire rod unwinding section 2. The wire rod unwinding section 2 changes the supply direction of the wire rod 200 from the wire rod unwinding section 2 to the winding core 6 with respect to the second supply direction D2, which is the supply direction of the wire rod 200 from the wire rod guide section 1 to the wire rod unwinding section 2. The wire rod 200 is supplied to the winding core 6 while contacting the wire rod unwinding section 2, so that the wire rod 200 can be adjusted in the wire rod unwinding section 2 before being wound around the winding core 6. Therefore, it is possible to obtain a coil 300 in which the wire rod 200 is aligned and swelling and winding irregularities are suppressed.

[0060] The wire rod feeding section 2 has an alignment through-hole 22 through which the wire rod 200 supplied from the wire rod guide section 1 passes. The alignment through-hole 22 has an inlet side opening 24 whose inner diameter increases toward the upstream side in the supply direction of the wire rod 200.

[0061] The wire rod 200 passes through the alignment through-hole 22 of the wire rod feed-out unit 2 and is supplied to the winding core 6 while contacting the inner surface of the alignment through-hole 22. This imparts a tendency for the wire rod 200 to be warped in a predetermined direction. By winding this wire rod 200 around the winding core 6, it is possible to obtain a coil 300 in which swelling and winding irregularities are suppressed. Furthermore, if a corner is located at the position where the wire rod 200 enters the wire rod feed-out unit 2, the wire rod 200 is strongly rubbed by the corner, but since the wire rod 200 is supplied along the inner surface of the entrance-side opening 24 of the alignment through-hole 22, damage to the wire rod 200 is suppressed. Therefore, it is possible to efficiently produce the coil 300 in which the wire rod 200 is not damaged.

[0062] The wire rod 200 is wound around the winding core 6 while being aligned in the axial direction. In the axial direction of the winding core 6, a distance L1 between a position P1 where the wire rod guide unit 1 and the wire rod 200 come into contact with each other and a position P2 where the wire rod 200 is supplied to the wire rod unwinding unit 2 is greater than a width W1 in the axial direction of the winding core 6 of the coil 300 obtained by winding the wire rod 200 around the winding core 6.

[0063] If the difference in position between the wire guide section 1 and the wire feed section 2 is small, the wire 200 may not be sufficiently curled. Since the distance between the wire guide section 1 and the wire feed section 2 is greater than the axial width of the winding core 6 of the coil 300, the wire 200 can be curled to align itself. This makes it possible to obtain a coil 300 in which swelling and irregular winding are suppressed.

[0064] The wire rod supply unit 10 supplies a plurality of wire rods 200 to the wire rod guide unit 1. The wire rod guide unit 1 supplies the plurality of wire rods 200 supplied from the wire rod supply unit 10 to the wire rod unwinding unit 2. The wire rod unwinding unit 2 supplies the plurality of wire rods 200 supplied from the wire rod guide unit 1 to the winding core 6. The plurality of wire rods 200 supplied from the wire rod unwinding unit 2 are wound around the winding core 6. The plurality of wire rods 200 are wound around the winding core 6 at the same time. This allows a plurality of coils 300 to be obtained efficiently.

[0065] The tension of the wire rod 200 between the wire rod supply unit 10 and the wire rod guide unit 1 is smaller than the tension of the wire rod 200 between the wire rod guide unit 1 and the wire rod unwinding unit 2. Since the tension generated in the wire rod 200 between the wire rod supply unit 10 and the wire rod guide unit 1 is suppressed, the wire rod 200 is not strongly curled in the section from the wire rod supply unit 10 to the wire rod guide unit 1. Swelling and irregular winding of the coil 300 due to the curling in the section from the wire rod supply unit 10 to the wire rod guide unit 1 is suppressed. It is possible to obtain a coil 300 in which the wire rod 200 is aligned and swelling and irregular winding are suppressed.

[0066] (First Modification) 6 is a diagram showing an example of a coil forming apparatus 100A according to a first modified example of the embodiment. The coil forming apparatus 100A according to the first modified example has the same configuration as the coil forming apparatus 100 according to the embodiment, except for the wire guide unit 1. The same components as those in the embodiment are denoted by the same reference numerals, and the description thereof will be omitted.

[0067] The wire rod guide portion 1A of the first modified example has a cylindrical or columnar shape. The wire rod guide portion 1A is, for example, a pulley. The wire rod guide portion 1A is located between the wire rod gathering portion 10b and the wire rod feeding portion 2 in the feeding direction of the wire rod 200. When the wire rod 200 is viewed in the first feeding direction D1, a position P1 where the wire rod guide portion 1A and the wire rod 200 come into contact with each other is different from a position P2 where the wire rod 200 is fed to the wire rod feeding portion 2. The peripheral surface of the wire rod guide portion 1A may be made of an elastic material or may be made of a material other than an elastic material.

[0068] The wire rod guide part 1A of the first modified example has a curved surface at the other end part of the wire rod guide part 1 in the first supply direction D1 and at a part that comes into contact with the wire rod 200. In other words, the peripheral surface of the cylinder or column of the wire rod guide part 1A comes into contact with the wire rod 200.

[0069] (Second Modification) An example of a coil forming apparatus 100 according to a second modified example of the embodiment will be described with reference to Fig. 3. The coil forming apparatus 100 according to the second modified example has the same configuration as the coil forming apparatus 100 according to the embodiment except for the wire guide unit 1B. Description of the same configuration as the coil forming apparatus 100 according to the embodiment will be omitted.

[0070] The wire guide section 1B of the coil forming device 100 according to the second modified example is the same member as the wire feed-out section 2. The wire guide section 1B of the second modified example has a plurality of alignment through holes 22. The outlet-side opening 25 of the wire guide section 1B has an inner diameter that increases toward the other side in the first supply direction D1 of the wire 200. When passing through the wire guide section 1B, the wire 200 comes into contact with the curved surface of the outlet-side opening 25.

[0071] According to the first and second modifications, the wire guide portions 1A, 1B have curved surfaces at the other end portions of the wire guide portions 1A, 1B in the first supply direction D1 and at the portions that come into contact with the wire rod 200. Since the wire rod 200 is supplied while being pressed against the curved surfaces of the wire guide portions 1A, 1B, the wire rod 200 is given a tendency to bend in a predetermined direction. By winding this wire rod 200 around the winding core 6, it is possible to obtain a coil 300 in which the wire rod 200 is aligned and in which swelling and winding irregularities are suppressed. Furthermore, if a corner is located at the other end portion of the member that guides the wire rod in the first supply direction D1, the wire rod 200 is strongly rubbed against the corner, but since the wire rod 200 is supplied along the curved surfaces, damage to the wire rod 200 is suppressed. Therefore, it is possible to efficiently produce a coil 300 in which the wire rod 200 is less damaged.

[0072] <Other embodiments> Although the embodiments of the present invention have been described above, the above-described embodiments are merely examples for carrying out the present invention. Therefore, the present invention is not limited to the above-described embodiments, and it is possible to appropriately modify the above-described embodiments within the scope of the spirit of the present invention.

[0073] In the embodiment, when the wire rod 200 is viewed in the first supply direction D1, a position P2 where the wire rod 200 is supplied to the wire rod unwinding portion 2 is different in the axial direction from a position P1 where the wire rod 200 comes into contact with the wire rod guide portion 1. However, when the wire rod is viewed in the first supply direction, the position where the wire rod is supplied to the wire rod unwinding portion may be different in the axial direction from the position where the wire rod guide portion comes into contact with the wire rod, or may be different in the left-right direction, upper-left direction, lower-left direction, upper-right direction, or lower-right direction. In other words, the position where the wire rod is supplied to the wire rod unwinding portion and the position where the wire rod guide portion comes into contact with the wire rod may be different in a direction other than the axial direction.

[0074] In the embodiment, contact between the wire guide unit 1 and the wire 200 changes the supply direction of the wire 200 to an upward vertical direction. However, contact between the wire guide unit and the wire may also change the supply direction of the wire to a downward vertical direction. Furthermore, contact between the wire guide unit and the wire may also change the supply direction of the wire to the left or right, or to the upper left, lower left, upper right, or lower right when viewed from the first supply direction.

[0075] In the embodiment, the wire guide portion 1 has an elastic deformation portion 12 that comes into contact with the wire 200 and elastically deforms. However, the wire guide portion does not necessarily have to have the elastic deformation portion 12.

[0076] In the first and second modified examples, the wire rod guide part 1 has a curved surface at the end part on the other side in the first supply direction D1 of the wire rod guide part 1 and at the portion in contact with the wire rod 200. However, the wire rod guide part does not have to have a curved surface at the end part on the other side in the first supply direction of the wire rod guide part and at the portion in contact with the wire rod.

[0077] In the embodiment, the wire rod feeding section 2 feeds the wire rod 200 in a direction different from the second feeding direction D2. However, the wire rod feeding section may feed the wire rod in the second feeding direction.

[0078] In the embodiment, the alignment through-hole 22 of the wire rod feeding unit 2 has an inlet-side opening 24 whose inner diameter increases toward the upstream side in the supply direction of the wire rod 200. However, the alignment through-hole of the wire rod feeding unit does not have to have an inner diameter that increases toward the upstream side in the supply direction of the wire rod.

[0079] In the embodiment, a distance L1 in the axial direction between a position P1 where the wire guide part 1 contacts the wire 200 and a position P2 where the wire 200 is supplied to the wire feed part 2 is larger than the axial width W1 of the coil 300. However, the distance between the position where the wire guide part contacts the wire and the position where the wire is supplied to the wire feed part may be smaller than the axial width of the coil.

[0080] In the embodiment, the wire rod supply unit 10 supplies a plurality of wire rods 200, and the winding core 6 simultaneously winds the plurality of wire rods 200. However, the wire rod supply unit may supply only one wire rod, and only one wire rod may be wound around the winding core.

[0081] In the embodiment, the tension of the wire 200 from the wire supply unit 10 to the wire guide unit 1 is smaller than the tension of the wire 200 from the wire guide unit 1 to the wire feed unit 2. However, the tension of the wire from the wire supply unit to the wire guide unit may be equal to or greater than the tension of the wire from the wire guide unit to the wire feed unit.

[0082] In the embodiment, the elastically deformable portion 12 is made of, for example, felt. However, the elastically deformable portion may be made of cloth other than felt. The elastically deformable portion may also be made of sponge or rubber, and is not limited to cloth as long as it is made of an elastically deformable material.

[0083] The position of the wire guide unit 1 may be adjustable. For example, the guide support unit may have a guide position adjustment unit. The guide position adjustment unit has a slide unit, a slide guide unit, and a lock unit. The wire guide unit is fixed to the slide unit. The slide guide unit slidably supports the slide unit. The lock unit has a locking mechanism that fixes the position of the slide unit. The locking mechanism may be, for example, a screw fastening, but it does not have to be a screw fastening and is not particularly limited. With these configurations, the position at which the wire guide unit is fixed can be adjusted according to the type and thickness of the wire. Note that the position of the wire guide unit may be adjustable by configurations other than the slide unit, slide guide unit, and lock unit.

[0084] In the above embodiment, the feed-out unit support unit 5 has a movement motor 52, a ball screw 53, and a slide table 54. However, the configuration for moving the wire rod feed-out unit may be, for example, a robot arm. Any configuration other than a movement motor, a ball screw, and a slide table may be used as long as it is capable of moving the wire rod feed-out unit.

[0085] In the embodiment, the winding core 6 rotates around the central axis R. However, the winding core may not rotate around the central axis, and the wire rod unwinding unit may rotate around the winding core. Alternatively, the winding core may rotate, and the wire rod unwinding unit may rotate around the winding core. When the wire rod unwinding unit rotates around the winding core, the axial direction is parallel to the rotation axis of the wire rod unwinding unit.

[0086] In the embodiment, the wire rod unwinding section 2 moves in the axial direction. However, the winding core may move in the axial direction without moving the wire rod unwinding section. In this case, the distance in the axial direction of the winding core between the position where the wire rod guide section and the wire rod come into contact and the position where the wire rod is supplied to the wire rod unwinding section is greater than the movement width of the winding core. [Industrial Applicability]

[0087] The present invention can be used in a coil forming apparatus that winds a wire to obtain a coil. [Explanation of symbols]

[0088] 100, 100A coil forming device 200 wire rod 300 coils 1, 1A, 1B Wire guide section 11 Guide body 12 Elastic deformation part 2 Wire rod feeding section 21 Payout main body 22 Alignment through-hole 23 Central part 24 Entrance opening 25 Outlet side opening 3 Wire winding section 31 Winding motor 4 Guide support part 5 Feeding part support part 51 Payout moving part 52 Travel motor 53 Ball screw 54 Sliding Table 6 Roll core 61 Base 62 Core rod 63 Rotating shaft 7 Winding control section 10 Wire supply section 10a bobbin 10b Wire gathering part 10c Collecting part support part D1 1st supply direction D2 2nd supply direction P1 position P2 position R center axis

Claims

1. A coil forming apparatus for obtaining a coil by winding a wire rod supplied from a wire rod supply unit, a wire guide portion that comes into contact with the wire supplied from the wire supply portion to change the supply direction of the wire; a wire rod feeding section to which the wire rod that has passed through the wire rod guide section is supplied; a winding core around which the wire rod supplied from the wire rod feeding section is wound, the wire rod guide portion contacts the wire rod at a position different from a position at which the wire rod is supplied to the wire rod feeding portion when viewing the wire rod in a first supply direction which is a supply direction of the wire rod from the wire rod supply portion to the wire rod guide portion, the wire supply unit supplies a plurality of the wires to the wire guide unit; the wire rod guide unit supplies the plurality of wire rods supplied from the wire rod supply unit to the wire rod feeding unit, the wire rod feeding unit supplies the plurality of wire rods supplied from the wire rod guide unit to the winding core, the plurality of wire rods supplied from the wire rod feeding section are wound around the winding core, a position at which the plurality of wire rods are supplied to the wire rod feeding portion in the axial direction of the winding core is different from a position at which the plurality of wire rods contact with the wire rod guide portion, The plurality of wire rods are aligned in the axial direction in the wire rod feeding section, and are wound around the winding core in the axially aligned state.

2. The coil forming apparatus according to claim 1, The plurality of wire rods are supplied from one side to the other side in the first supply direction in the wire rod guide portion, The wire guide portion has an elastic deformation portion at the other end of the wire guide portion in the first supply direction, the elastic deformation portion contacting the plurality of wires and elastically deforming.

3. The coil forming apparatus according to claim 1, The plurality of wire rods are supplied from one side to the other side in the first supply direction in the wire rod guide portion, The wire guide portion has a curved surface at an end portion on the other side in the first supply direction of the wire guide portion and at a portion that comes into contact with the plurality of wires.

4. The coil forming apparatus according to any one of claims 1 to 3, The wire rod feeding section feeds the plurality of wire rods in a direction different from a second feeding direction, which is a feeding direction of the wire rods from the wire rod guide section to the wire rod feeding section.

5. The coil forming apparatus according to claim 4, the wire rod feeding section has a plurality of through holes through which the plurality of wire rods supplied from the wire rod guide section pass, respectively; The through hole has an inlet opening whose inner diameter increases toward the upstream side in the wire feeding direction.

6. The coil forming apparatus according to any one of claims 1 to 5, a distance in the axial direction between a position where the wire guide portion and the wire material contact each other and a position where the wire material is supplied to the wire material unwinding portion is greater than a width in the axial direction of the coil obtained by winding the plurality of wire materials around the winding core.

7. The coil forming apparatus according to any one of claims 1 to 6, A coil forming device, wherein a tension of the wire between the wire supply section and the wire guide section is smaller than a tension of the wire between the wire guide section and the wire feed section.

8. A method for manufacturing a coil formed by winding a wire around a winding core, a wire rod supplying step of supplying a plurality of wire rods from a wire rod supply unit to a wire rod unwinding unit; a wire rod winding step of winding the plurality of wire rods supplied from the wire rod feeding section around the winding core, In the wire rod supplying step, when the plurality of wire rods are viewed in a first supply direction, which is a supply direction of the wire rods from the wire rod supply unit to the wire rod guide unit, the wire rod guide unit is brought into contact with the plurality of wire rods at a position in the axial direction of the winding core that is different from a position where the plurality of wire rods are supplied to the wire rod unwinding unit, to change the supply direction of the plurality of wire rods; and The plurality of wire rods are arranged in the axial direction in the wire rod feeding section, In the wire winding step, the plurality of wires are wound around the winding core while being aligned in the axial direction.

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