Method and apparatus for manufacturing conductive wires

Abstract

To provide a conductor wire manufacturing method which contributes to improvement of yield.SOLUTION: A conductor wire manufacturing method according to one embodiment of the present disclosure is a method for manufacturing a conductor wire used in a motor, the method comprising the steps of: forming slits (2) in a strip-shaped conductive member (1); cutting out a pine-needle-shaped wire (3) having the slits (2) from the conductive member (1); and expanding the slits (2) of the wire (3). The method may further comprise the step of covering the wire (3) having the expanded slits (2) with an insulation coating (17).SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to a method and an apparatus for manufacturing a conductive wire used in a motor.

Background Art

[0002] It is desired to efficiently manufacture a conductive wire used in a motor. For example, in Patent Document 1, a coil wire continuous in a U-shaped zigzag is punched out from a winding material, and the coil wire is folded into a coil shape to form a winding subassembly.

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. The technique of Patent Document 1 has a problem of poor yield because a coil wire continuous in a U-shaped zigzag is punched out from a winding material.

[0005] The present disclosure has been made in view of such problems, and realizes a conductive wire manufacturing method and a conductive wire manufacturing apparatus that contribute to an improvement in yield.

Means for Solving the Problems

[0006] A conductive wire manufacturing method according to an aspect of the present disclosure is a method for manufacturing a conductive wire used in a motor, a step of forming a slit in a strip-shaped conductive member; a step of cutting out a pine-leaf-shaped wire having the slit from the conductive member; a step of widening the slit of the wire; and includes.

[0007] The above-described method for manufacturing a conductor preferably includes a step of covering the wire material with the widened slit with an insulating coating.

[0008] In the above-described wire manufacturing method, it is preferable to overlap multiple wires and simultaneously widen the slits in the multiple wires.

[0009] In the above-described wire manufacturing method, it is preferable to form alternating slits in the conductive member, and cut the wire material by cutting between adjacent slits having an open portion on one side, so as to reach the slit having an open portion on the other side.

[0010] A wire manufacturing apparatus according to one aspect of this disclosure is a wire manufacturing apparatus used for motors, A cutting section for cutting out a pine needle-shaped wire having the slit from a strip-shaped conductive member having the slit formed therein, A first holding part that holds the end of the wire on the connecting part side, A second holding portion that holds one end of the wire on the open side, A third holding portion that holds the other end of the wire on the open side, A drive unit moves the second holding part and the third holding part so as to widen the slit in the wire, It is equipped with. [Effects of the Invention]

[0011] According to this disclosure, a wire manufacturing method and wire manufacturing apparatus that contribute to improving yield can be realized. [Brief explanation of the drawing]

[0012] [Figure 1] This diagram illustrates the process of cutting and stacking wires from a conductive material in the wire manufacturing method of the embodiment. [Figure 2] This diagram illustrates the process of cutting wire material from a conductive member in the wire manufacturing method of the embodiment. [Figure 3]This is a diagram for explaining the step of widening the slit of the stacked wire rods in the wire manufacturing method of the embodiment. [Figure 4] This is a diagram for explaining the step of covering the wire rod with a widened slit with an insulating coating in the wire manufacturing method of the embodiment. [Figure 5] This is a diagram for explaining how to cut out a wire rod from a conductive member in another embodiment.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, specific embodiments to which the present disclosure is applied will be described in detail with reference to the drawings. However, the present disclosure is not limited to the following embodiments. Also, for clarity of explanation, the following description and drawings are appropriately simplified. Here, in the following explanation, for clarity of explanation, a three-dimensional (XYZ) coordinate system is used.

[0014] FIG. 1 is a diagram for explaining the step of cutting out and stacking wire rods from a conductive member in the wire manufacturing method of the present embodiment. FIG. 2 is a diagram for explaining how to cut out a wire rod from a conductive member in the wire manufacturing method of the present embodiment.

[0015] FIG. 3 is a diagram for explaining the step of widening the slit of the stacked wire rods in the wire manufacturing method of the present embodiment. FIG. 4 is a diagram for explaining the step of covering the wire rod with a widened slit with an insulating coating in the wire manufacturing method of the present embodiment.

[0016] The wire manufacturing method and wire manufacturing apparatus of the present embodiment are suitable, for example, when manufacturing a wire such as a U-shaped or V-shaped segment coil wound around a stator core or rotor core of a motor. In the wire manufacturing method of the present embodiment, first, a conductive member 1 such as a wound strip-shaped copper plate as shown in FIG. 1(a) is prepared.

[0017] Next, as shown in FIGS. 1(b) and 1(c), the conductive member 1 is sent out to the + side of the Y-axis and passed through the roller leveler 11 of the wire manufacturing apparatus 10 to check the parallelism between the + side surface and the - side surface of the Z-axis of the conductive member 1. The conductive member 1 with the parallelism checked is passed through the cutting portion 12 of the wire manufacturing apparatus 10 to form the slit 2 while cutting out the wire 3 from the conductive member 1.

[0018] Specifically, the cutting portion 12 of the wire manufacturing apparatus 10 includes, for example, a press machine. As shown in FIG. 2, the conductive member 1 is sequentially provided with, as the slit 2, a first slit 4 having an opening portion on the + side of the X-axis and having a substantially isosceles triangular shape when viewed from the Z-axis direction, and a second slit 5 having an opening portion on the - side of the X-axis and having a substantially isosceles triangular shape when viewed from the Z-axis direction, alternately formed.

[0019] At this time, as shown in FIG. 2, the first slit 4 is disposed between the hypotenuses of the second slits 5 adjacent in the Y-axis direction. Incidentally, the length of the second slit 5 in the X-axis direction may be longer than the length of the first slit 4 in the X-axis direction.

[0020] Then, as shown in FIG. 2, the cutting portion 12 of the wire manufacturing apparatus 10 cuts between the second slits 5 adjacent in the Y-axis direction in order from the + side of the Y-axis of the conductive member 1 so as to reach the - side end portion of the X-axis of the first slit 4, and cuts out the wire 3 as shown in FIG. 1(c).

[0021] In FIG. 2, the cutting portion of the conductive member 1 is indicated by a broken line. For example, the cutting portion is substantially parallel to the XZ plane and extends substantially in the X-axis direction. Further, in FIG. 1(c), an upper view of the wire 3 as viewed from the + side of the Z-axis and a lower view of the wire 3 as viewed from the + side of the X-axis are shown.

[0022] As shown in FIG. 1(c), the wire 3 is, for example, formed into a flat-leaf-shaped flat wire having the second slit 5 (i.e., the slit 2), having a connecting portion on the + side of the X-axis, and having an opening portion on the - side of the X-axis.

[0023] Next, as shown in Figure 1(d), the wires 3 are stacked in the Z-axis direction in equal positions relative to each other. Here, Figure 1(d) shows the upper stacked wire 3 as viewed from the Z-axis+ side, and the lower stacked wire 3 as viewed from the X-axis+ side.

[0024] Next, as shown in Figure 3(a), the first holding part 13 of the wire manufacturing apparatus 10 holds the end of the overlapping wires 3 on the connecting side, the second holding part 14 of the wire manufacturing apparatus 10 holds the end of the overlapping wires 3 on the open side of the Y-axis+, and the third holding part 15 of the wire manufacturing apparatus 10 holds the end of the overlapping wires 3 on the open side of the Y-axis-.

[0025] The first holding part 13, the second holding part 14, and the third holding part 15 of the wire manufacturing apparatus 10 are configured to hold the ends of stacked wires 3, such as a collet chuck, and the second holding part 14 and the third holding part 15 can be moved closer together and further apart in the Y-axis direction by a drive unit (not shown).

[0026] Next, as shown in Figure 3(b), the drive unit of the wire manufacturing apparatus 10 separates the second holding part 14 in the Y-axis direction, thereby widening the slit 2 of the stacked wires 3 to the desired size.

[0027] Then, as shown in Figure 3(c), the first holding part 13, the second holding part 14, and the third holding part 15 of the wire manufacturing apparatus 10 release the holding of the end of the wire 3. After that, for example, a crank portion, which is formed in a typical segment coil, may be formed on the wire 3.

[0028] Next, the wire 3 with the widened slit 2 is covered with an insulator. Specifically, as shown in Figures 4(a) to 4(c), for example, an insulating film 17 with high self-adhesion properties, such as polyimide, is floated in the hydraulic fluid (such as ATF) 16, and the wire 3 with the widened slit 2 is moved to the side of the hydraulic fluid 16 and inserted into the hydraulic fluid 16 so that the wire 3 is covered with the insulating film 17.

[0029] This allows us to obtain a wire 3 covered with an insulating coating 17 for use as a motor conductor. At this time, the wire 3 can be covered with the insulating coating 17 while pushing out the air with hydraulic pressure. Alternatively, the end of the wire 3 on the open side may be masked so that the end of the wire 3 on the open side is not covered with the insulating coating 17.

[0030] As described above, the wire manufacturing method and wire manufacturing apparatus 10 of this embodiment cut out a pine needle-shaped wire 3 having a slit 2 from the conductive member 1, and then widens the slit 2 of the wire 3. Compared to the method described in Patent Document 1, which punches out a continuous U-shaped zigzag coil wire from a winding material, the wire 3 can be obtained more efficiently from the conductive member 1, contributing to an improvement in yield.

[0031] Furthermore, when the wire 3 is covered with an insulating coating 17 and then the slit 2 of the wire 3 is widened, the area of ​​the insulating coating 17 that covers the bendable portion of the wire 3 becomes thinner. However, in this embodiment, the slit 2 of the wire 3 is widened before the wire 3 is covered with the insulating coating 17, thus preventing the insulating coating 17 from becoming thinner. Furthermore, by cutting the wire 3 from the conductive member 1, a flat rectangular wire can be easily obtained.

[0032] In this embodiment, one wire 3 is cut out sequentially from the Y-axis + side of the conductive member 1. However, as shown in Figure 5, for example, two wires 3 may be cut out from a conductive member 1 in which the first slit 4 and the second slit 5 are arranged symmetrically with respect to the axis AX, which extends in the Y-axis direction when viewed from the Z-axis direction. The number of wires 3 to be cut out is not limited.

[0033] Furthermore, in this embodiment, the wire 3 is cut from the conductive member 1 by a progressive press, but for example, the wire 3 may be cut from the conductive member 1 by a transfer press or a tandem press. Alternatively, the wire 3 may be cut from the conductive member 1 using an NC lathe, a CO2 laser, or metal shears, in short, the means for cutting the wire 3 from the conductive member 1 are not limited.

[0034] In this embodiment, the wires 3 were stacked in the Z-axis direction to widen the slits 2 of the wires 3, but the slits 2 may be widened for each individual wire 3.

[0035] In this embodiment, the wire 3 is covered with an insulating coating 17 by liquid transfer, but the wire 3 may also be covered with an insulating coating 17 by UV curing, injection molding, transfer molding, vacuum forming, or casting. Furthermore, the material of the insulating coating 17 is not limited to thermoplastic resin or thermosetting resin, but may also be an insulating ceramic such as glass or enamel.

[0036] In this case, the wire manufacturing method of this embodiment can prevent the thinning of the insulating coating 17, as described above, so an inexpensive ceramic coating can be used as the insulating coating 17.

[0037] Furthermore, in this embodiment, a first slit 4 and a second slit 5 are formed in the conductive member 1, but it is sufficient if at least one of them is formed.

[0038] This disclosure is not limited to the embodiments described above, and may be modified as appropriate without departing from the spirit of the invention. [Explanation of Symbols]

[0039] 1. Conductive member 2 Slits, 4 First Slit, 5 Second Slit 3 wire rod 10 Wire manufacturing apparatus, 11 Roller leveler, 12 Cutting section, 13 First holding section, 14 Second holding section, 15 Third holding section 16. Hydraulic oil 17 Insulating coating

Claims

1. A method for manufacturing conductors used in motors, A step of forming a first slit and a second slit in a strip-shaped conductive member, A step of cutting out a pine needle-shaped wire having the second slit from the conductive member, The process of widening the second slit in the wire, Equipped with, The conductive member is formed with alternating first and second slits, and the portion of the conductive member between the second slits, which have an open portion on one side, is cut so as to reach the first slit, which has an open portion on the other side, thereby cutting out the wire. A method for manufacturing a conductor, comprising stacking a plurality of the aforementioned wires in the thickness direction of the wires and simultaneously widening the second slits of the plurality of wires in a first direction perpendicular to the thickness direction of the wires.

2. The method for manufacturing a conductor according to claim 1, further comprising the step of covering the wire with the widened second slit with an insulating coating.

3. The wire manufacturing method according to claim 1, wherein the length of the second slit in the thickness direction of the wire and the length of the second direction perpendicular to the first direction is longer than the length of the first slit in the thickness direction of the wire and the length of the second direction perpendicular to the first direction.

4. The method for manufacturing a conductive wire according to claim 3, wherein the first slit and the second slit are isosceles triangular in shape when viewed from the thickness direction of the conductive member.

5. A wire manufacturing apparatus used in the wire manufacturing method according to any one of Claims 1 to 4, A cutting section is provided for cutting out a pine needle-shaped wire having the second slits, by cutting the portion between the second slits, which have an open portion on one side of an adjacent band-shaped conductive member, so as to reach the first slit, which has an open portion on the other side of the band, and having the first slits formed alternately on the band-shaped conductive member. A first holding part that holds the ends of the multiple wires on the connecting part side when the multiple wires are stacked in the thickness direction of the wires, A second holding part that holds one end of the open portion side of the plurality of wires, A third holding part that holds the other end of the open portion side of the plurality of wires, A drive unit moves the second holding unit and the third holding unit so as to simultaneously widen the second slits of the plurality of wires in a direction perpendicular to the thickness direction of the wires, A wire manufacturing apparatus equipped with the following features.

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