Straight wire distortion removal device

Abstract

To provide a flat wire distortion removal device contributing to suppression of processing failure of the flat wire.SOLUTION: A flat wire distortion removal device (1) according to an embodiment of the disclosure has a roller leveler (3) for allowing a flat wire (5) to pass between paring rollers (31, 32), and correcting mutual parallelism between side faces arranged on both sides in the width direction of the flat wire (5). The roller leveler (3) includes a press member (33) for suppressing rotation of the flat wire (5) around a shaft extending in the long direction of the flat wire (5).SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a flat wire distortion removal device. For example, it relates to a flat wire distortion removal device having a roller leveler that passes a flat wire between paired rollers to make the sides arranged on both sides in the width direction of the flat wire parallel to each other.

Background Art

[0002] Generally, since flat wires are delivered in a state of being wound around a reel, for example, before bending the flat wire to form an edgewise coil, a process of removing the distortion of the flat wire is performed by a roller leveler. In this case, for example, as disclosed in Patent Document 1, the distortion of the flat wire is removed by passing the flat wire between the paired rollers of the roller leveler.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The applicant of the present application has found the following problems. In order to improve the output of the motor, it is necessary to increase the number of windings of the flat wire. Therefore, it is preferable to reduce the thickness of the flat wire. In this case, since an R portion is formed at the corner of the flat wire, the flat portions of the sides arranged on both sides in the width direction of the flat wire are reduced.

[0005] Therefore, as shown in FIG. 5, when performing a parallelism processing on the sides arranged on both sides in the width direction of the flat wire 5 by a roller leveler, that is, a process of removing the distortion in the width direction of the flat wire 5, the flat wire 5 may tilt between the rollers 101, resulting in defective processing of the flat wire 5.

[0006] This disclosure was made in view of these problems, and aims to realize a device for removing distortion from rectangular wires that contributes to suppressing processing defects in rectangular wires. [Means for solving the problem]

[0007] A device for removing distortion from a rectangular wire according to one aspect of the present disclosure is a device for removing distortion from a rectangular wire having a roller leveler that passes the rectangular wire between a pair of rollers to ensure parallelism between the sides of the rectangular wire arranged on both sides in the width direction, The roller leveler includes a pressing portion for suppressing the rotation of the rectangular wire about an axis extending in the longitudinal direction of the rectangular wire. [Effects of the Invention]

[0008] According to this disclosure, it is possible to realize a device for removing distortion from rectangular wires that contributes to suppressing processing defects in rectangular wires. [Brief explanation of the drawing]

[0009] [Figure 1] (a) is a diagram showing the distortion removal device for rectangular wire according to Embodiment 1, (b) is a view of the arrangement of the rollers of the first roller leveler of the distortion removal device for rectangular wire according to Embodiment 1, viewed from the X-axis + side, (c) is a view of the first roller leveler of the distortion removal device for rectangular wire according to Embodiment 1, viewed from the Y-axis - side, and (d) is a view of the second roller leveler of the distortion removal device for rectangular wire according to Embodiment 1, viewed from the Y-axis - side. [Figure 2] This is a diagram showing a typical rectangular wire. [Figure 3] This is a view of the second roller leveler of the rectangular wire distortion removal device of Embodiment 2, as seen from the Y-axis side. [Figure 4] This is a view of the second roller leveler of the rectangular wire distortion removal device of Embodiment 3, as seen from the Y-axis side. [Figure 5] This is a diagram illustrating a typical laura leveler problem. [Modes for carrying out the invention]

[0010] The following describes specific embodiments applying this disclosure in detail with reference to the drawings. However, this disclosure is not limited to the following embodiments. Also, for clarity, the explanation will be given using a three-dimensional (XYZ) coordinate system, and the following description and drawings have been simplified as appropriate.

[0011] <Embodiment 1> First, the configuration of the strain removal device for rectangular wires according to this embodiment (hereinafter sometimes simply referred to as the strain removal device) will be described. The strain removal device of this embodiment is suitable for removing strain from rectangular wires before bending them to form edgewise coils used in motors, for example.

[0012] Figure 1(a) shows the distortion removal device of this embodiment, Figure 1(b) shows the arrangement of the rollers of the first roller leveler of the distortion removal device of this embodiment as viewed from the X-axis+ side, Figure 1(c) shows the first roller leveler of the distortion removal device of this embodiment as viewed from the Y-axis- side, and Figure 1(d) shows the second roller leveler of the distortion removal device of this embodiment as viewed from the Y-axis- side. Figure 2 shows a general rectangular wire. Note that Figure 1(a) shows the distortion removal device in a simplified manner.

[0013] As shown in Figure 1(a), the distortion removal device 1 of this embodiment comprises a first roller leveler 2, a second roller leveler 3, and a feed device 4. The flat wire 5 is fed from a reel 6 on which it is wound to the first roller leveler 2 and the second roller leveler 3 by the feed device 4.

[0014] Here, the rectangular wire 5 is configured such that the conductor 51 is covered with an insulating film 52, as shown in Figure 2. For example, the rectangular wire 5 is a long member with a substantially rectangular XZ cross-section, and R-shaped portions (curved portions) 53 are formed at the corners of the rectangular wire 5. In this case, the strain removal device 1 of this embodiment is particularly suitable when the so-called aspect ratio, which is shown by the width dimension in the X-axis direction (width direction) / thickness dimension in the Z-axis direction (thickness direction) of the rectangular wire 5, is larger than that of a typical rectangular wire 5.

[0015] The first roller lever 2 adjusts the parallelism between the surface on the +Z-axis side of the flat angle line 5 and the surface on the -Z-axis side of the flat angle line 5, that is, removes the distortion in the Z-axis direction of the flat angle line 5. As shown in Fig. 1(a), the first roller lever 2 is arranged on the +Y-axis side with respect to the reel 6. As shown in Figs. 1(b) and 1(c), the first roller lever 2 includes a first roller 21 and a second roller 22.

[0016] The first roller 21 is, for example, a substantially cylindrical member made of metal extending in the X-axis direction as shown in Figs. 1(b) and 1(c), and the width dimension of the first roller 21 in the X-axis direction is not less than the width dimension of the flat angle line 5 in the X-axis direction.

[0017] As shown in Fig. 1(c), the first roller 21 is rotatably supported by a rotating shaft 24 via a bearing 23. The rotating shaft 24 extends in the X-axis direction, and the end on the -X-axis side of the rotating shaft 24 is fixed to the side wall portion 25 of the first roller lever 2. As shown in Fig. 1(b), the first rollers 21 are arranged at a predetermined interval in the Y-axis direction.

[0018] The second roller 22 is arranged, for example, on the +Z-axis side with respect to the first roller 21 as viewed from the Y-axis direction as shown in Figs. 1(b) and 1(c), and is arranged at a predetermined interval (for example, the desired thickness dimension of the flat angle line 5) from the first roller 21 in the Z-axis direction. That is, the first roller 21 and the second roller 22 form a pair as viewed from the Y-axis direction. At this time, the circumferential surfaces of the first roller 21 and the second roller 22 are arranged substantially parallel to each other and are substantially parallel to the X-axis as viewed from the Y-axis direction.

[0019] Since the second roller 22 has substantially the same configuration as the first roller 21, its description will be omitted. It is a substantially cylindrical member made of metal extending in the X-axis direction and is rotatably supported on a rotating shaft 27 via a bearing 26 as shown in Fig. 1(c). As shown in Fig. 1(b), the second roller 22 is arranged at a predetermined interval in the Y-axis direction. At this time, the second roller 22 is arranged between the first rollers 21 when viewed from the Z-axis direction.

[0020] The second roller lever 3 equalizes the parallelism between the surface on the + side of the X-axis of the flat angle line 5 and the surface on the - side of the X-axis of the flat angle line 5, that is, removes the strain in the X-axis direction of the flat angle line 5. As shown in Fig. 1(a), the second roller lever 3 is arranged on the + side of the Y-axis with respect to the first roller lever 2. As shown in Fig. 1(d), the second roller lever 3 includes a first roller 31, a second roller 32, and a pressing portion 33.

[0021] The first roller 31 is, for example, a substantially cylindrical member made of metal extending in the Z-axis direction as shown in Fig. 1(d), and the height dimension of the first roller 31 in the Z-axis direction is not less than the thickness dimension of the flat angle line 5 in the Z-axis direction.

[0022] As shown in Fig. 1(d), the first roller 31 is rotatably supported on a rotating shaft 35 via a bearing 34. The rotating shaft 35 extends in the Z-axis direction, and the end portion on the - side of the Z-axis of the rotating shaft 35 is fixed to the bottom portion 36 of the second roller lever 3. As shown in Fig. 1(a), the first roller 31 is arranged at a predetermined interval in the Y-axis direction.

[0023] The second roller 32 is arranged, for example, on the - side of the X-axis with respect to the first roller 31 when viewed from the Y-axis direction as shown in Fig. 1(d), and is arranged at a predetermined interval (for example, the desired width dimension of the flat angle line 5) in the X-axis direction from the first roller 31. That is, as shown in Fig. 1(d), the first roller 31 and the second roller 32 form a pair when viewed from the Y-axis direction. At this time, the peripheral surfaces of the first roller 31 and the second roller 32 are arranged substantially parallel to each other and are substantially parallel to the Z-axis when viewed from the Y-axis direction.

[0024] The second roller 32 has a configuration substantially the same as the first roller 31, so its description will be omitted. However, as shown in Figure 1(d), it is a substantially cylindrical metal member extending in the Z-axis direction and is rotatably supported on the rotating shaft 38 via a bearing 37. The second roller 32 is arranged at a predetermined distance in the Y-axis direction, as shown in Figure 1(a). At this time, the second roller 32 is positioned between the first rollers 31 when viewed from the X-axis direction.

[0025] The retaining portion 33 suppresses the rotation of the rectangular wire 5 around the Y axis, that is, the inclination of the rectangular wire 5. As shown in Figure 1(d), the retaining portion 33 comprises a first retaining plate 39 and a second retaining plate 40. The first retaining plate 39 is, for example, a substantially rectangular plate extending in the Y axis direction when viewed from the Z axis direction, and the Z-axis+ side of the first retaining plate 39 has a flat surface substantially parallel to the XY plane.

[0026] The width dimension of the first retaining plate 39 in the X-axis direction should be approximately equal to the width dimension of the rectangular wire 5 in the X-axis direction, as shown in Figure 1(d). Furthermore, the length of the first retaining plate 39 in the Y-axis direction should be such that, as seen from the Y-axis direction, it can cover the area where the first roller 31 and the second roller 32 of the second roller leveler 3 are positioned.

[0027] However, the width dimension of the first retaining plate 39 in the X-axis direction and the length of the first retaining plate 39 in the Y-axis direction should be set appropriately so that the retaining plate can contact the rectangular wire 5 when it attempts to tilt, thereby suppressing the tilt.

[0028] The first retaining plate 39 is preferably made of metal, for example, but any material that does not wear down when the rectangular wire 5 comes into contact with it is acceptable. The first retaining plate 39 is fixed, for example, to the bottom 36 of the second roller leveler 3.

[0029] The second retaining plate 40 is positioned on the Z-axis+ side relative to the first retaining plate 39 when viewed from the Y-axis direction, as shown in Figure 1(d), and is positioned at a predetermined distance from the first retaining plate 39 in the Z-axis direction (for example, a distance at which the rectangular wire 5 does not substantially come into contact with the first retaining plate 39 when it moves).

[0030] The second retaining plate 40 has a line-symmetric configuration with respect to the first retaining plate 39, with respect to the axis extending in the Y-axis direction as the axis of symmetry, so its explanation will be omitted. However, it is a roughly rectangular plate that extends in the Y-axis direction when viewed from the Z-axis direction, and is fixed, for example, to the ceiling portion (not shown) of the second roller leveler 3.

[0031] The feeding device 4 pulls out the rectangular wire 5 from the reel 6 and feeds it between the first roller 21 and the second roller 22 of the first roller leveler 2, and between the first roller 31 and the second roller 32 of the second roller leveler 3.

[0032] As shown in Figure 1(a), the feed device 4 is positioned on the Y-axis + side relative to the second roller leveler 3. The feed device 4 is equipped with a clamping mechanism for gripping the rectangular wire 5, and as shown by the dashed line in Figure 1(a), the feed device 4 is pulled in on the Y-axis + side, thereby pulling the rectangular wire 5 in on the Y-axis + side.

[0033] Next, the process of performing parallelization processing on the rectangular wire 5 using the distortion removal device 1 of this embodiment will be explained. First, the rectangular wire 5, which has been pulled in on the Y-axis+ side by the feed device 4, is fed between the first roller 21 and the second roller 22 of the first roller leveler 2.

[0034] The first roller 21 of the first roller leveler 2 rotates while in contact with the Z-axis-side surface of the rectangular wire 5, and the second roller 22 of the first roller leveler 2 rotates while in contact with the Z-axis-+ side surface of the rectangular wire 5. This ensures parallelism between the Z-axis-+ side surface and the Z-axis-side surface of the rectangular wire 5. In other words, distortion in the Z-axis direction of the rectangular wire 5 is eliminated.

[0035] Next, the rectangular wire 5, which has been pulled in on the Y-axis+ side by the feed device 4, is fed between the first roller 31 and the second roller 32 of the second roller leveler 3. The first roller 31 of the second roller leveler 3 rotates while in contact with the X-axis+ side surface of the rectangular wire 5, and the second roller 32 of the second roller leveler 3 rotates while in contact with the X-axis- side surface of the rectangular wire 5. This ensures parallelism between the X-axis+ side surface and the X-axis- side surface of the rectangular wire 5. In other words, distortion in the X-axis direction of the rectangular wire 5 is eliminated.

[0036] In this configuration, the first pressing plate 39 and the second pressing plate 40 of the pressing section 33 are positioned with the rectangular wire 5 in between in the Z-axis direction. As a result, when the rectangular wire 5 passes between the first roller 31 and the second roller 32, tilting of the rectangular wire 5 around the Y-axis can be suppressed. Therefore, good parallelism between the X-axis positive side and the X-axis negative side of the rectangular wire 5 can be ensured, and machining defects of the rectangular wire 5 can be suppressed.

[0037] Furthermore, the first roller leveler 2 is positioned on the Y-axis-side relative to the second roller leveler 3, and when the rectangular wire 5 is fed to the second roller leveler 3, the distortion of the rectangular wire 5 in the Z-axis direction is removed. As a result, when the rectangular wire 5 is fed to the second roller leveler 3, it is possible to suppress strong contact between the Z-axis-side and Z-axis-side surfaces of the rectangular wire 5 and the first pressing plate 39 and the second pressing plate 40 of the pressing section 33. Therefore, processing defects of the rectangular wire 5 can be further suppressed.

[0038] As described above, the distortion removal device 1 of this embodiment is configured such that when the rectangular wire 5 passes through the second roller leveler 3, the first pressing plate 39 and the second pressing plate 40 of the pressing section 33 are positioned with the rectangular wire 5 in between in the Z-axis direction.

[0039] This prevents the rectangular wire 5 from tilting around the Y-axis as it passes between the first roller 31 and the second roller 32. As a result, good parallelism between the X-axis positive side and the X-axis negative side of the rectangular wire 5 can be ensured, and processing defects of the rectangular wire 5 can be suppressed.

[0040] <Embodiment 2> Figure 3 is a view of the second roller leveler of the strain removal device of this embodiment, seen from the Y-axis side. Since the strain removal device of this embodiment has substantially the same configuration as the strain removal device 1 of Embodiment 1, redundant explanations will be omitted, and the same reference numerals will be used to describe the same components.

[0041] The distortion removal device of this embodiment differs from the distortion removal device 1 of Embodiment 1 in the configuration of the pressing section. As shown in Figure 3, the pressing section 201 comprises a pressing plate 202 and a pressing roller 203. The pressing plate 202 has substantially the same configuration as the first pressing plate 39 of Embodiment 1.

[0042] As shown in Figure 3, the pressing roller 203 clamps the rectangular wire 5, which has been fed to the second roller leveler, in the Z-axis direction between the pressing plate 202 and the pressing roller 203, thereby suppressing the tilt of the rectangular wire 5 around the Y-axis. The pressing roller 203 is positioned on the Z-axis+ side relative to the pressing plate 202 when viewed from the Y-axis direction.

[0043] The press roller 203 is a substantially cylindrical metal member extending in the X-axis direction, as shown in Figure 3, for example, and is rotatably supported on the rotating shaft 205 via a bearing 204. The rotating shaft 205 extends in the X-axis direction, and the X-axis+ end of the rotating shaft 205 is fixed to the side wall of the second roller leveler.

[0044] At this time, the circumferential surface of the pressing roller 203 is approximately parallel to the X-axis when viewed from the Y-axis direction, as shown in Figure 3. The pressing roller 203 is positioned so as to be able to press approximately the center of the rectangular wire 5 in the Y-axis direction when it is fed into the second roller leveler.

[0045] Here, the width dimension of the press roller 203 in the X-axis direction should be set appropriately so that the flat wire 5 fed to the second roller leveler is sandwiched in the Z-axis direction between the press plate 202 and the press roller 203, thereby suppressing the inclination of the flat wire 5. In this case, it is preferable that the press rollers 203 be spaced apart in the Y-axis direction.

[0046] The pressing section 201 in this configuration is designed to clamp the rectangular wire 5, which has been fed to the second roller leveler, in the Z-axis direction between the pressing plate 202 and the pressing roller 203. This prevents the rectangular wire 5 from tilting around the Y-axis as it passes between the first roller 31 and the second roller 32. Therefore, the distortion removal device of this embodiment can also ensure good parallelism between the X-axis positive side surface and the X-axis negative side surface of the rectangular wire 5, thereby suppressing processing defects in the rectangular wire 5.

[0047] In this embodiment, the pressing section 201 is equipped with a pressing plate 202, but a pressing roller may be provided instead of the pressing plate 202.

[0048] <Embodiment 3> Figure 4 is a view of the second roller leveler of the strain removal device of this embodiment, seen from the Y-axis side. Since the strain removal device of this embodiment has substantially the same configuration as the strain removal device 1 of Embodiment 1, redundant explanations will be omitted, and the same reference numerals will be used to describe the same components.

[0049] As shown in Figure 4, the distortion removal device of this embodiment omits the first pressing plate 39 and the second pressing plate 40 compared to the distortion removal device 1 of Embodiment 1, and the first groove 301 formed in the first roller 31 and the second groove 302 formed in the second roller 32 function as the pressing portion 303. In other words, the pressing portion 303 of this embodiment includes the first groove 301 and the second groove 302.

[0050] As shown in Figure 4, the first groove 301 is substantially rectangular in shape and is formed on the circumferential surface of the first roller 31. The first groove 301 is arranged in the circumferential direction of the first roller 31. The height dimension of the first groove 301 in the Z-axis direction is preferably approximately equal to the thickness dimension of the rectangular wire 5 in the Z-axis direction.

[0051] As shown in Figure 4, the second groove 302 is substantially rectangular in shape and is formed on the circumferential surface of the second roller 32. The second groove 302 is arranged in the circumferential direction of the second roller 32. The height dimension of the second groove 302 in the Z-axis direction is preferably approximately equal to the thickness dimension of the rectangular wire 5 in the Z-axis direction.

[0052] The first groove 301 and the second groove 302 are positioned at approximately equal heights in the Z-axis direction. As the rectangular wire 5 passes between the first roller 31 and the second roller 32, the X-axis positive side of the rectangular wire 5 contacts the bottom surface of the first groove 301 (i.e., the surface extending in the Z-axis direction), and the X-axis negative side of the rectangular wire 5 contacts the bottom surface of the second groove 302.

[0053] In this configuration, the pressing section 303 is set up so that the X-axis positive end of the rectangular wire 5 fed to the second roller leveler is inserted into the first groove 301, and the X-axis negative end of the rectangular wire 5 is inserted into the second groove 302.

[0054] This prevents the rectangular wire 5 from tilting around the Y-axis as it passes between the first roller 31 and the second roller 32. Therefore, the distortion removal device of this embodiment can also ensure good parallelism between the X-axis+ side surface and the X-axis- side surface of the rectangular wire 5, thereby suppressing processing defects in the rectangular wire 5.

[0055] This disclosure is not limited to the embodiments described above, and may be modified as appropriate without departing from the spirit of the invention. For example, the configuration of the pressing part in the above embodiment is illustrative, and any configuration that can suppress the tilt of the rectangular wire 5 fed to the second roller leveler around the Y axis is acceptable. For example, the arrangement and material of each roller in the first roller leveler 2 of the above embodiment are illustrative examples and can be changed as appropriate. Similarly, the arrangement and material of each roller in the second roller leveler 3 of the above embodiment are illustrative examples and can be changed as appropriate. [Explanation of Symbols]

[0056] 1. Device for removing distortion from rectangular wires 2. The First Laura Rebella 21 Laura 1 22 The Second Laura 23 Bearings 24 rotation axes 25. Side wall section of the second roller leveler 26 bearings 27 Rotation axis 3. The Second Laura Rebella 31. Laura 1 32 The Second Laura 33. Pressing part 34 Bearings 35 Rotation axis 36. Bottom of the second roller leveler 37 Bearings 38 Rotation axis 39. First retaining plate 40 Second retaining plate 4. Feed device 5. Rectangular line 51 Conductor 52 Insulating coating 53. R-shaped section of a rectangular line 6 reels 201 Pressing part 202 Retaining plate 203 Pressing roller 204 Bearing 205 Rotation axis 301 First groove 302 Second groove 303 Retaining part

Claims

[Claim 1] A device for removing distortion from a rectangular wire, having a roller leveler that passes the rectangular wire between a pair of rollers to ensure parallelism between the sides of the rectangular wire positioned on both sides in the width direction, The roller leveler includes a pressing portion for suppressing the rotation of the rectangular wire around an axis extending in the longitudinal direction of the rectangular wire, The pressing portion comprises a first pressing plate positioned to face a first surface located on one side of the thickness direction of the rectangular wire, and a second pressing plate positioned to face a second surface located on the other side of the thickness direction of the rectangular wire, wherein the first pressing plate and the second pressing plate are positioned at a distance greater than the thickness of the rectangular wire, and is characterized in that it is a device for removing distortion from a rectangular wire.

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