Molding system and molding method

Abstract

This molding system comprises: a first molding device for molding a linear conductive wire piece into a U-shaped conductive wire piece having a pair of leg parts and an intermediate part between the pair of leg parts at a first molding position; a second molding device for molding the intermediate part into a prescribed shape at a second molding position; a first storage means for storing the U-shaped conductive wire piece discharged from the first molding device; and a first supply means for supplying the U-shaped conductive wire piece stored in the first storage means to the second molding device. The first storage means is disposed below the first molding position, and the first supply means is disposed below the second molding position.

Description

Molding system and molding method

[0001] The present invention relates to a technique for forming a conductive piece.

[0002] A known method for manufacturing conductor components, such as coil segments used in the stator coils of electric motors, involves first forming a piece of conductor into a U-shape and then bending the middle portion of the conductor piece through secondary forming (see, for example, Patent Document 1).

[0003] Patent No. 4327486

[0004] If the device for performing primary molding and the device for performing secondary molding are configured as separate devices, this may lead to an increase in size and complexity of the molding system.

[0005] An object of the present invention is to provide a molding system that is relatively small and can be simply configured.

[0006] According to the present invention, there is provided a molding system comprising: a first molding device that molds a straight wire piece into a U-shaped wire piece having a pair of legs and an intermediate portion between the pair of legs at a first molding position; a second molding device that molds the intermediate portion into a predetermined shape at a second molding position; a first storage means that stores the U-shaped wire pieces discharged from the first molding device; and a first supply means that supplies the U-shaped wire pieces stored in the first storage means to the second molding device, wherein the first storage means is positioned below the first molding position, and the first supply means is positioned below the second molding position.

[0007] According to the present invention, it is possible to provide a molding system that is relatively small and can be simply configured.

[0008] 9 is a schematic diagram of a molding system according to one embodiment of the present invention. An explanatory diagram of a control circuit and a molding method. A side view of a storage device and a supply device. A plan view of a storage device and a supply device. An explanatory diagram of the operation of the supply device of FIGS. 3 and 4. An explanatory diagram of the operation of the supply device of FIGS. 3 and 4. A front view of a molding device. A cross-sectional view of the molding device taken along line A-A in FIG. 7. A cross-sectional view of the molding device taken along line B-B in FIG. 7. A diagram in which the moving mechanism and a contact member are omitted from FIG. 9. A perspective view of an abutting member. An explanatory diagram of the operation of the molding device. An explanatory diagram of the operation of the molding device. An explanatory diagram showing the fulcrum position of the abutting member and the dimensional relationship between the fulcrum positions. A perspective view of a discharge member and a storage device. An explanatory diagram of a storage mode of conductor pieces that fall naturally from the molding device. A front view of a supply device. An explanatory diagram of the operation of the supply device. An explanatory diagram of the operation of the supply device. An explanatory diagram of the operation of the supply device. An explanatory diagram of the operation of the supply device. A view of the molding device seen from above. A view of the molding device seen from below. A cross-sectional view taken along line CC in FIG. 22 (with some components omitted). 22 (some components are omitted). A perspective view of the abutting member, etc. An explanatory diagram showing the positional relationship of the abutting member with respect to the forming position. An explanatory diagram of the operation of the forming device. An explanatory diagram of the operation of the forming device. A perspective view of the storage device. A front view of the lead wire component. A plan view of the lead wire component of FIG. 31. A diagram showing another example of the configuration of the fulcrum unit.

[0009] Hereinafter, the embodiments will be described in detail with reference to the accompanying drawings. Note that the following embodiments do not limit the scope of the invention as claimed, and not all combinations of features described in the embodiments are necessarily essential to the invention. Two or more of the features described in the embodiments may be arbitrarily combined. Furthermore, the same reference numerals are used for the same or similar components, and redundant explanations will be omitted.

[0010] <First embodiment> <Overview of molding system> Fig. 1 is a schematic diagram of a molding system 100 according to one embodiment of the present invention. In the figure, arrows X and Y indicate horizontal directions that are orthogonal to each other, and arrow Z indicates the up-down direction. When distinguishing between one direction of the X direction and the opposite direction, they may be written as +X direction and -X direction. The same applies to the Y direction and Z direction.

[0011] Forming system 100 is a system that performs two-stage bending on conductor pieces. Forming system 100 includes storage device 110 for storing conductor pieces to be bent, supply device 200 for supplying conductor pieces from storage device 110 to forming device 300, forming device 300 for performing a first bending process on the conductor pieces supplied from supply device 200, storage device 140A for storing the conductor pieces that have been bent the first time by forming device 300, supply device 400 for supplying conductor pieces from storage device 140A to forming device 500, forming device 500 for performing a second bending process on the conductor pieces supplied from supply device 400, and storage device 140B for storing the conductor pieces (conductor parts 63) that have been bent the second time by forming device 500.

[0012] In this embodiment, the molding system 100 forms a conveying path including the storage device 110, the supply device 200, the storage device 140A, the supply device 400, and the storage device 140B along which the conductive wire pieces to be molded are conveyed. The molding device 300 and the molding device 500 are disposed at a predetermined height position above the conveying path.

[0013] The molding device 300 is supported by a stand 150. The storage device 110 and the supply device 200 are disposed on the sides of the molding device 300 in the Y direction. The stand 150 includes a plate-shaped base member 151 and a plurality of support columns 152, and the molding device 300 is supported by the plurality of support columns 152 at a predetermined height position (first height position).

[0014] The conductor wire pieces formed by the forming device 300 are discharged by gravity via the discharge member 130 into the storage device 140A, where they are temporarily stored. The discharge member 130 is supported by the frame 153 of the stand 150, and extends from below the forming device 300 at an angle in the X direction. The conductor wire pieces stored in the storage device 140A are supplied to the forming device 500 by the supply device 400. The forming device 500 performs a second bending process on the conductor wire pieces supplied from the supply device 400.

[0015] The molding device 500 is supported by a stand 160. The stand 160 includes a plate-shaped base member 161 and a plurality of support columns 162, and the molding device 500 is supported at a predetermined height position (second height position) by the plurality of support columns 162. The storage device 140A and the supply device 400 are supported by a frame 163 of the stand 160, and the supply device 400 is supported at a lower position than the molding device 500.

[0016] The conductor pieces (conductor parts 63) formed by the forming device 500 are discharged by gravity into the storage device 140B and stored therein. The storage device 140B is supported by the frame 164 of the stand 160. The conductor parts 63 stored in the storage device 140B are transported to the next process by a transport device (not shown) or by an operator.

[0017] In this embodiment, the molding devices 300 and 500 are supported by the stands 150 and 160, respectively, but both the molding devices 300 and 500 may be supported by a single stand.

[0018] Here, in this embodiment, the molding device 300 and the molding device 500 are supported so that the first height position is higher than the second height position, but the first height position and the second height position may be the same height, or the first height position may be lower than the second height position.

[0019] <Forming Flow> The flow of forming a conductor piece by the forming system 100 will be described with reference to FIG. 2 in addition to FIG. 1 . The forming system 100 operates under the control of a control circuit 600. The control circuit 600 is an electronic circuit that controls the forming system 100. The control circuit 600 includes, for example, a processor represented by a CPU, a storage device, an input / output interface that relays between an external device and the processor, a communication interface that communicates with a higher-level controller, a drive circuit that drives an actuator, and a signal processing circuit that processes detection signals from sensors. The storage device is a semiconductor memory such as a ROM or RAM, a hard disk, or the like. The processor controls the forming system 100 by executing a control program stored in the storage device.

[0020] The actuators to be controlled include various motors, described below, that exert driving force to move the components of the molding system 100. The sensors include a rotary encoder that detects the amount of rotation of the motor and a position sensor that detects the position of the component. The positions of the component can be controlled by driving the motor based on the detection results of these sensors.

[0021] The molding system 100 is a system for molding a linear conductor piece 62 to manufacture a conductor component 63. The conductor piece 62 has a linear conductor 61a and an insulating coating (insulating film) 61b that covers the periphery of the conductor 61a. At both ends of the conductor piece 62, the conductor 61a is exposed from the insulating coating 61b. A plurality of conductor pieces 62 are stored in a storage device 110, and are supplied one by one from the storage device 110 to a molding device 300 by a supply device 200.

[0022] In the forming device 300, the conductor piece 62 is bent into a U-shape to produce a conductor piece 63', which is an intermediate part. The conductor piece 63' has a pair of straight-extending leg portions 64 and a middle portion 65 between the pair of legs 64. The pair of legs 64 extend parallel to each other. The middle portion 65 is curved in a V-shape. The conductor piece 63' is discharged to the storage device 140A via the discharge member 130. The conductor piece 63' is stored in the storage device 140A in an inverted U-shaped position. The conductor pieces 63' stored in the storage device 140A are supplied one by one to the forming device 500 by the supply device 400 while still in the inverted U-shaped position.

[0023] In the forming device 500, the intermediate portion 65 of the conductor piece 63' is twisted to produce the conductor component 63. This twisting forms the intermediate portion 65 into a three-dimensional curved shape that is also curved in the thickness direction. The conductor component 63 is discharged and stored in the storage device 140B while still in the inverted U-shape.

[0024] Fig. 31 shows a front view of the conductor component 63, and Fig. 32 shows a plan view of the conductor component 63. The conductor component 63 of this embodiment is a coil segment that constitutes a stator coil of a three-phase AC motor. The conductor component 63 has a pair of linearly extending leg portions 64 and an intermediate portion 65 between the pair of leg portions 64. The intermediate portion 65 is curved in a V-shape and has a three-dimensional curved shape that is also curved in the thickness direction.

[0025] <Storage Device 110 and Supply Device 200> The configurations of the storage device 110 and supply device 200 will be described with reference to Figures 3 and 4. Figure 3 is a side view of the storage device 110 and supply device 200, and Figure 4 is a plan view of the storage device 110 and supply device 200. The storage device 110 includes a pair of trays 111 spaced apart in the Y direction. The pair of trays 111 are supported in an inclined position by support columns 112. Each tray 111 has a mounting surface 111a on which the conductor pieces 62 are placed, and the mounting surface 111a has a downward slope that slopes in the -Z direction toward the +X direction. Wall portions 111b protruding from the mounting surface 111a are provided at the end on the +X side of the mounting surface 111a and at the outer end in the Y direction.

[0026] The conductor pieces 62 are placed on the placement surface 111a in a position oriented in the Y direction, straddling the pair of trays 111. The conductor pieces 62 are placed on the placement surface 111a in a form arranged in the X direction, and the conductor pieces 62 on the placement surface 111a are encouraged to move toward the end of the placement surface 111a in the +X direction due to their own weight and the inclination of the placement surface 111a.

[0027] The supply device 200 includes a pickup mechanism 210 and a transport mechanism 220. The pickup mechanism 210 includes a holding member 211 and an elevating unit 212 that raises and lowers the holding member 211. The holding member 211 is disposed between the pair of trays 111 in the Y direction and is located at the +X-direction end of the pair of trays 111 in the X direction. The holding member 211 has a recess (holding portion) that holds one conductor piece 62. The elevating unit 212 is, for example, an electric cylinder or an air cylinder, and moves the holding member 211 between a position lower than the pair of trays 111 and a position higher than the pair of trays 111 in the Z direction.

[0028] The conveying mechanism 220 includes a rail member 222 extending in the Y direction. The rail member 222 is supported by a plurality of support columns 221. A holding unit 223 is provided on the rail member 222 so as to be movable in the Y direction. The holding unit 223 includes a moving section 223a and a gripping section 223b that grips the conductor piece 62. The moving section 223a can reciprocate in the Y direction by being guided by the rail member 222. Examples of the movement mechanism of the moving section 223a include a ball screw mechanism, a rack-and-pinion mechanism, and a linear motor mechanism. The gripping section 223b has a pair of claws that can be opened and closed in the Z direction and a drive mechanism for the claws. The drive mechanism is, for example, an electric chuck or an air chuck. The gripping section 223b is located at the same height in the Z direction as the molding position 305 of the molding device 300, and at the same position in the X direction as the molding position 305. The storage device 110 is located below the molding position 305.

[0029] 5 and 6 are explanatory diagrams of the operation of the supply device 200, showing a series of operations for supplying the conductor pieces 62 from the storage device 110 to the molding device 300.

[0030] 5 shows a standby state before supply. The holding member 211 is located at a position lower than the pair of trays 111. The holding unit 223 is located at the position shown in FIG. 4 (the end position of the rail member 222 in the -Y direction).

[0031] As shown in state ST1052 in Fig. 5 and state ST1061 in Fig. 6 , by raising the holding member 211 by the lifting unit 212, one conductor piece 62 is removed from the pair of trays 111. As shown in state ST1053 in Fig. 5 , by further raising the holding member 211 by the lifting unit 212, the conductor piece 62 held by the holding member 211 is positioned to the side in the Y direction at the same height as the holding unit 223.

[0032] Here, the width of the groove in the X direction of the recess of the holding member 211 is narrower than the width of one conductor piece and narrower than the width of two conductor pieces, so that the pickup mechanism 210 can lift up one conductor piece even when multiple conductor pieces are stored in the storage device 110.

[0033] As shown in state ST1062 in Figure 6, the holding unit 223 moves in the +Y direction and further grips the -Y direction end of the conductor piece 62. The holding member 211 is lowered by the lifting unit 212. As shown in state ST1063 in Figure 6, the holding unit 223 moves in the Y direction to the +Y direction end of the rail member 222, and the conductor piece 62 is transported to the forming position 305. After the conductor piece 62 is held by the forming device 300, the holding unit 223 releases its grip on the conductor piece 62 and returns in the -Y direction to the position of state ST1061. By repeating the above operations, the conductor piece 62 is sequentially supplied from the storage device 110 to the forming device 300.

[0034] <Molding Apparatus 300> The molding apparatus 300 will be described with reference to Figures 7 to 9. Figure 7 is a front view of the molding apparatus 300, Figure 8 is a cross-sectional view of the molding apparatus 300 taken along line A-A in Figure 7, and Figure 9 is a cross-sectional view of the molding apparatus 300 taken along line B-B in Figure 7.

[0035] The molding device 300 includes a base member BM as a structure that supports each component of the molding device 300. The base member BM includes an upper plate member 301, a lower plate member 302, and a central wall portion 303 and left and right wall portions 304 that connect these. The upper plate member 301 is a rectangular member, and its top portion is provided with multiple reinforcing ribs arranged in a grid pattern. The lower surface 301a of the upper plate member 301 forms mounting portions for multiple fulcrum units 310A-310C and a pressing unit 320A.

[0036] The lower plate member 302 is a rectangular member, and its bottom is provided with a plurality of reinforcing ribs arranged in a grid pattern. The upper surface 302a of the lower plate member 302 forms mounting portions for a plurality of pressing units 320B and 320C. The lower plate member 302 is a member that is shorter in the X direction than the upper plate member 301, and the forming position 305 is located at a position offset in the +X direction from the lower plate member 302. Therefore, the forming position 305 is a position exposed below the forming device 300.

[0037] The wall portion 303 extends in the X direction and connects the upper plate member 301 and the lower plate member 302 near their centers in the Y direction. The left and right wall portions 304 extend in the X direction and connect the upper plate member 301 and the lower plate member 302 at their respective ends in the Y direction.

[0038] <Supporting point units 310A to 310C> The supporting point units 310A to 310C are mechanisms that form supporting points for bending the conductor piece 62. The supporting point units 310A to 310C basically have the same configuration. Each of the supporting point units 310A to 310C includes a position changing mechanism 311 and a contact member 317.

[0039] The position change mechanism 311 is a mechanism that changes the position of the abutment member 317. The position change mechanism 311 includes a plate-shaped base member 311a. The base member 311a is a support member that supports the other components of the position change mechanism 311, and is fixed to the upper plate member 301. The position change mechanism 311 includes a movable member 314 that supports the abutment member 317. A plurality of sliders 316 are provided on the surface of the movable member 314 that faces the base member 311a. Each slider 316 engages with a rail member 315 that extends on the base member 311a, and is movable along the rail member 315. The rail member 315 of the fulcrum unit 310A extends in the X direction, and therefore the movable member 314 and the abutment member 317 are able to reciprocate freely in the X direction. The rail members 315 of the fulcrum units 310B and 310C extend in the Y direction, and therefore the movable member 314 and the abutting member 317 can freely reciprocate in the Y direction.

[0040] The position changing mechanism 311 includes a motor 312 as a drive source. The motor 312 is fixed to a base member 311a via a bracket 312a. The position changing mechanism 311 includes a drive mechanism 313 that converts the rotation of the motor 312 into translational motion of the movable member 314. In this embodiment, the drive mechanism 313 is a ball screw mechanism. However, the drive mechanism 313 may be another mechanism such as a belt transmission mechanism. The drive mechanism 313 includes a ball screw shaft 313a, a ball nut 313b, and a plurality of bearings 313c that rotatably support the ball screw shaft 313a.

[0041] The ball screw shaft 313a extends parallel to the rail member 315. The ball nut 313b is threadedly engaged with the ball screw shaft 313a and is fixed to the movable member 314. The ball screw shaft 313a is coaxially coupled to the output shaft of the motor 312 and rotates when driven by the motor 312. The rotation of the ball screw shaft 313a causes the ball nut 313b to move on the ball screw shaft 313a, resulting in the movement of the movable member 314. The movement direction of the movable member 314 can be switched depending on the rotation direction of the motor 312.

[0042] The abutting member 317 abuts against the conductor piece 62 to form a bending fulcrum. FIG. 11 is a perspective view of the abutting member 317. The abutting member 317 is a cylindrical roller protruding from the movable member 314 in the -Z direction and supported by the movable member 314 so as to be rotatable about an axis in the Z direction. The abutting member 317 has a cylindrical abutting surface 317a that abuts against the conductor piece 62 and flange-shaped restricting portions 317b that are positioned on both sides of the abutting surface 317a in the Z direction and have a larger diameter than the abutting surface 317a. The restricting portions 317 prevent the conductor piece 62 abutting against the abutting surface 317a from coming off the abutting surface 317a in the Z direction. Even if a component force in the Z direction acts on the conductor piece 62 during bending, the abutting member 317 more securely holds the conductor piece 62, allowing for bending.

[0043] <Pressing units 320A to 320C> See Figures 7 to 9. The pressing units 320A to 320C are mechanisms that press the conductor piece 62 to perform the bending process. Each of the pressing units 320A to 320C includes a contact member 327 and a movement mechanism 321 that moves the contact member 327 to bend the conductor piece 62. The pressing units 320B and 320C also include a movement mechanism 331 that can move the contact member 327 in two directions (X direction and Y direction).

[0044] The moving mechanism 321 includes a plate-shaped base member 321a. The base member 321a is a support member that supports the other components of the moving mechanism 321. The base member 321a of the pressing unit 320A is rectangular, and is fixed to the upper plate member 301. The base members 321a of the pressing units 320B and 320C are each C-shaped, and are supported by the lower plate member 302 so as to be movable in the X direction.

[0045] The movement mechanism 321 includes a movable member 324 that supports an abutment member 327. A plurality of sliders 326 are provided on the surface of the movable member 324 that faces the base member 321a. Each slider 326 engages with a rail member 325 that extends on the base member 321a and is movable along the rail member 325. The rail member 325 of the pressing unit 320A extends in the X direction, so that the movable member 324 and the abutment member 327 can freely reciprocate in the X direction. The rail members 325 of the pressing units 320B and 320C extend in the Y direction, so that the movable member 324 and the abutment member 327 can freely reciprocate in the Y direction.

[0046] The movement mechanism 321 includes a motor 322 as a drive source. The motor 322 is fixed to a base member 321a via a bracket 322a. The movement mechanism 321 includes a drive mechanism 323 that converts the rotation of the motor 322 into translational motion of a movable member 324. In this embodiment, the drive mechanism 323 is a ball screw mechanism. However, the drive mechanism 323 may be another mechanism such as a belt transmission mechanism. The drive mechanism 323 includes a ball screw shaft 323a, a ball nut 323b, and a plurality of bearings 323c that rotatably support the ball screw shaft 323a.

[0047] The ball screw shaft 323a extends parallel to the rail member 325. The ball nut 323b is threadedly engaged with the ball screw shaft 323a and is fixed to the movable member 324. The ball screw shaft 323a is coaxially coupled to the output shaft of the motor 322 and rotates when driven by the motor 322. The rotation of the ball screw shaft 323a causes the ball nut 323b to move on the ball screw shaft 323a, resulting in the movement of the movable member 324. The movement direction of the movable member 324 can be switched depending on the rotation direction of the motor 322.

[0048] The abutting member 327 is a member that abuts against the conductive wire piece 62. In this embodiment, the abutting member 327 has the same configuration as the abutting member 317 shown in FIG. 11. Two abutting members 327 are provided in the pressing unit 320A, spaced apart in the Y direction. The two abutting members 327 are positioned in the same position in the X direction. One abutting member 327 is provided in each of the pressing units 320B and 320C.

[0049] The moving mechanism 331 provided in the pressing units 320B and 320C will be described with reference to FIGS. 9 and 10. FIG. 10 is a diagram in which the moving mechanism 321 and the abutting member 327 are omitted from FIG. 9. The moving mechanism 331 is a mechanism that moves the base member 321a in the X direction, thereby moving the abutting member 327 in the X direction together with the moving mechanism 321. Therefore, in the pressing units 320B and 320C, the abutting member 327 can be moved in the Y direction by the moving mechanism 321, and can also be moved in the X direction by the moving mechanism 331.

[0050] A rail member 336 is provided on the surface of the base member 321a that faces the upper surface 302a of the lower plate member 302. The rail member 336 extends in the X direction and engages with a plurality of engaging members 335 (corresponding to fixed sliders) provided on the upper surface 302a. This structure allows the base member 321a to move back and forth in the X direction.

[0051] The movement mechanism 331 includes a motor 332 as a drive source. The motor 332 is fixed to the lower plate member 302 via a bracket 332a. The movement mechanism 331 includes a drive mechanism 333 that converts the rotation of the motor 332 into translational motion of the base member 321a. In this embodiment, the drive mechanism 333 is a ball screw mechanism. However, the drive mechanism 333 may be another mechanism such as a belt transmission mechanism. The drive mechanism 333 includes a ball screw shaft 333a, a ball nut 333b, and a plurality of bearings 333c that rotatably support the ball screw shaft 333a.

[0052] The ball screw shaft 333a extends parallel to the rail member 335. The ball nut 333b is threadedly engaged with the ball screw shaft 333a and is fixed to the connecting member 334. An end of the connecting member 334 is fixed to the base member 321a. The ball screw shaft 333a is coaxially coupled to the output shaft of the motor 332 and rotates when driven by the motor 332. The rotation of the ball screw shaft 333a causes the ball nut 333b to move on the ball screw shaft 333a, which in turn moves the connecting member 334 and the base member 321a. The movement directions of the connecting member 334 and the base member 321a can be switched depending on the rotation direction of the motor 332.

[0053] The relative positional relationship between the fulcrum units 310A to 310C and the pressing units 320A to 320C will now be described. The conductor piece 62 before shaping is supplied to the shaping position 305 by the above-described supply device 200. The conductor piece 62 is supplied to the shaping position 305 with its longitudinal direction oriented in the Y direction.

[0054] 8 and 9, the positional relationship between forming position 305 and fulcrum units 310A to 310C and pressing units 320A to 320C indicates that each abutting member 317 of fulcrum units 310A to 310C is disposed on the +X side, and each abutting member 327 of pressing units 320A to 320C is disposed on the opposite, −X side, of conductor piece 62. Furthermore, fulcrum units 310A to 310C are disposed on the +X side, and pressing units 320A to 320C are disposed on the −X side of conductor piece 62.

[0055] Fulcrum units 310B and 310C are spaced apart from each other in the Y direction and are arranged so that their contact members 317 face each other in the Y direction. Fulcrum unit 310A is arranged between fulcrum units 310B and 310C in the Y direction. Pressing units 320B and 320C are spaced apart from each other in the Y direction and are arranged so that their contact members 317 face each other in the Y direction. Pressing unit 320A is arranged between pressing units 320B and 320C in the Y direction.

[0056] The fulcrum unit 310A and the pressing unit 320A are disposed so as to face each other in the X direction. When viewed in the Y direction, the contact member 317 of the fulcrum unit 310A is located between the two contact members 327 of the pressing unit 320A.

[0057] This arrangement allows each unit to be arranged in a well-balanced manner relative to the base member BM, preventing uneven weight distribution and making the device more compact.

[0058] <Operation Example> The procedure for bending the conductor piece 62 by the forming device 300 will be described with reference to Figures 12 and 13. Figures 12 and 13 are explanatory diagrams of the operation of the forming device 300, and show the arrangement of each movable member 314 and each abutting member 317 of the fulcrum units 310A to 310C, and each movable member 324 and each abutting member 327 of the pressing units 320A to 320C.

[0059] In order to distinguish between the movable members 314 and the abutment members 317 of each of the fulcrum units 310A to 310C, the movable member 314 and the abutment member 317 of the fulcrum unit 310A will be referred to as the movable member 314A and the abutment member 317A. The same applies to the movable members 314 and the abutment members 317 of the fulcrum units 310B and 310C, and the movable members 324 and the abutment members 327 of the pressing units 320A to 320C.

[0060] 12 shows a state ST1121 in which the conductor piece 62 is supplied to the forming position 305 by the supply device 200. The contact members 317A-317C and 327A-327C are positioned in their initial positions away from the conductor piece 62. The contact members 317B and 317C are positioned at their initial positions to form fulcrums (fulcrum positions). The other contact members 317A and 327A-327C are positioned in their standby positions before movement.

[0061] State ST1122 shows the stage where the holding operation for holding the conductor piece 62 has been performed. The abutting member 317A is moved in the -X direction and positioned at the fulcrum position. The fulcrum position of the abutting member 317A corresponds to the apex of the U-shape of the conductor piece 62 being bent into a U-shape. The two abutting members 327A are moved in the +X direction and positioned at the intermediate positions before bending. The conductor piece 62 is held by having its longitudinal center portion sandwiched between the abutting member 327A and the two abutting members 327A. The holding unit 223 of the supply device 200 releases its hold on the conductor piece 62 and returns to the position of state ST1061 in FIG. 6 .

[0062] After the conductor piece 62 is held by the abutment member 317A and the two abutment members 327A, the bending operation of the conductor piece 62 begins. As shown in state ST1123, the two abutment members 327A are moved in the +X direction. The abutment member 317A is positioned between the two abutment members 327A in the Y direction, and the conductor piece 62 is bent into a V shape with the abutment member 317A as the fulcrum. At this time, the support members 317B and 317C, which are positioned at the fulcrum positions, abut against the conductor piece 62, determining the position for the next bending of the conductor piece 62.

[0063] Next, as shown in state ST1131 in FIG. 13 , the abutting members 327B and 327C are moved in the +X direction so as to pass beside the abutting members 317B and 317C in the Y direction. The conductor piece 62 is bent from a V-shape to a U-shape, with the abutting members 317B and 317C as fulcrums. As shown in state ST1132, after passing beside the abutting members 317B and 317C in the Y direction, the abutting members 327B and 327C are moved in the +X direction, while the abutting member 327B is moved in the +Y direction and the abutting member 327C is moved in the -Y direction. In other words, the portion of the conductor piece 62 that will become the leg portion 64 of the conductor component 63 is pressed slightly inward. This suppresses the elastic restoring force of the conductor piece 62, ensuring that the conductor piece 62 is reliably shaped into a U-shape. As a result, the conductor piece 62 is shaped into a U-shaped conductor piece 63'.

[0064] Next, as shown in state ST1133, the conductor piece 63' is released. Specifically, the contact members 317A and 327A are returned to their initial positions and separated from the conductor piece 63'. The contact member 327B is moved in the -Y direction, and the contact member 327C is moved in the +Y direction, and separated from the conductor piece 63'. In this embodiment, the contact members 317B and 317C do not move, but they may move in a direction away from the conductor piece 63'.

[0065] The released conductor piece 63 ′ falls naturally under its own weight onto the discharge member 130 disposed below the forming position 305 , and is thereby discharged from the forming device 300 .

[0066] <Response to Specification Changes> In this embodiment, the positions of the contact members 317A to 317C that form the fulcrums can be changed by the position change mechanism 311. This makes it possible to flexibly respond to changes in the specifications of the conductor component 63. Figure 14 shows the fulcrum positions of the contact members 317A to 317C and the dimensional relationship between the fulcrum positions.

[0067] The Y-direction separation distance Y1 between the abutting members 317B and 317C can accommodate changes in the separation distance between the pair of legs 64 of the conductor part 63. Furthermore, the Y-direction separation distance Y2 between the abutting members 317A and 317B and the Y-direction separation distance Y3 between the abutting members 317A and 317C can adjust the position of the apex of the U-shape of the conductor part 63, making it possible to create a conductor part 63 in which the apex is biased to one of the pair of legs 64.

[0068] Furthermore, the curved shape of the intermediate portion 65 of the conductor component 63 can be adjusted by adjusting the distance X1 in the X direction between the abutting member 317A and the abutting members 317B and 317C. For example, if the position of the abutting member 317A in the X direction is moved away from the abutting members 317B and 317C to increase X1, the intermediate portion 65 will have a deep V-shape, and if the position of the abutting member 317A in the X direction is moved closer to the abutting members 317B and 317C to decrease X1, the intermediate portion 65 will have a shallow V-shape.

[0069] The positions of the contact members 327 of the pressing units 320A to 320C may be adjusted appropriately by the movement mechanisms 321 and 331 in accordance with the positions of the contact members 317A to 317C.

[0070] Although the specification change of the conductor component 63 has been mainly described above in terms of a change in the bending shape, it is also possible to accommodate a change in the thickness of the conductor piece 62 in the X direction (thickness of the wire material). In this case, the positions of the contact members 327 can be changed according to the thickness of the conductor piece 62.

[0071] In this manner, in this embodiment, a single molding device 300 can be used to manufacture lead wire components 63 with different specifications.

[0072] <Discharge Member 130 and Storage Device 140A> The discharge member 130 and storage device 140A will be described with reference to Figures 15 and 16. Figure 15 is a perspective view of the discharge member 130 and storage device 140A, and Figure 16 is an explanatory diagram of how the conductive wire pieces 63' that fall naturally from the molding device 300 are stored.

[0073] The storage device 140A is disposed below the forming position 305 in the Z direction, and the discharge member 130 is a guide member that bridges the wire pieces 63' between the forming position 305 and the storage device 140A. In this embodiment, the discharge member 130 is disposed directly below the forming position 305 in the Z direction. The discharge member 130 has the form of a tray and has a mounting surface 131 on which the wire pieces 63' that fall naturally from the forming device 300 are placed. The discharge member 130 is supported in an inclined position by the frame 153 (FIG. 1). The mounting surface 131 has a downward slope that slopes in the -Z direction toward the +X direction. The wire pieces 63' that fall naturally from the forming device 300 onto the mounting surface 131 slide downward in the +X direction on the mounting surface 131 and move to the storage device 140A.

[0074] Here, at the forming position 305, the conductor piece 63' is parallel to the XY plane and the pair of legs 64 extend in the +X direction from the middle part 65, but as it naturally falls and slides onto the mounting surface 131, its position is changed to an inverted U shape.

[0075] Storage device 140A includes a long, strip-shaped base member 141 extending in the X direction, and support posts 142 and 143 mounted on base member 141 and spaced apart in the X direction. Support posts 142 and 143 extend in the Z direction, with support post 142 being taller than support post 143. A stopper 144 is supported on support post 143. A support member 145 is supported between the upper end of support post 142 and stopper 144.

[0076] The support member 145 is a cylindrical shaft member that is supported in a downwardly inclined manner inclined in the -Z direction toward the +X direction. A plurality of support pillars 146a are also provided upright on the base member 141, and these support pillars 146a support a pair of guide members 146 that are spaced apart in the Y direction. The guide members 146 are elongated members that have a width in the Y direction and extend in the X direction, with the end on the -X side being narrower in width than the end on the +X side.

[0077] The support member 145 supports the inverted U-shaped conductor piece 63' from below. More specifically, the pair of legs 64 of the conductor piece 63' straddles the support member 145, and the middle portion 65 is hooked onto the support member 145, so that the conductor piece 63' is suspended from the support member 145. The suspended conductor piece 63' is encouraged to slide toward the +X side by the inclination of the support member 145 and its own weight. At this time, the pair of guide members 146 are positioned inside the pair of legs 64 to restrict the rotation of the pair of legs 64, thereby stabilizing the posture of the conductor piece 63'.

[0078] A plurality of pads 147 are fixed to the −X side surface of the stopper 144. The conductive piece 63′ abuts against the plurality of pads 147 and is stored in that position. The succeeding conductive piece 63′ abuts against the previously stored conductive piece 63′ and is stored on its −X side.

[0079] The storage state of the conductor piece 63' that falls naturally from the molding device 300 will be described with reference to Figure 16. The conductor piece 63'-1 that falls from the molding device 300 is in a horizontal position with its pair of legs 64 pointing horizontally. The conductor piece 63'-2 that falls onto the mounting surface 131 changes its position from horizontal to inclined due to the inclination of the mounting surface 131. The conductor piece 63'-3 that moves from the mounting surface 131 onto the support member 145 has its middle portion 65 caught on the support member 145 and changes to an inverted U-shaped vertical position with its pair of legs 64 pointing downward. The conductor piece 63'-4 that slides along the support member 145 then comes into contact with multiple pads 147 and is stored in that position.

[0080] From the completion of molding in the molding device 300 to storage in the storage device 140A, the movement of the conductor piece 63' utilizes the difference in height and its own weight, and does not use a conveying mechanism with a drive source such as a motor, which prevents the molding system 100 from becoming complicated.

[0081] In this embodiment, the molding system 100 has a discharge member 130 and a storage device 140A, and the conductive wire piece 63′ is stored in the storage device 140A via the discharge member 130, but only the storage device 140A may be provided. In that case, the storage device 140A is disposed directly below the molding position 305 in the Z direction.

[0082] <Supply device 400> The supply device 400 will be described with reference to Fig. 17. Fig. 17 is a front view of the supply device 400. The supply device 400 is disposed below the forming position 509 of the forming device 500 in the Z direction, and supplies the conductor wire pieces 63' stored in the storage device 140A to the forming position 509.

[0083] The supply device 400 includes a pad 401 , a pickup mechanism 410 , and a transport mechanism 420 .

[0084] Pad 401 is supported by bracket 401a so as to be located on the -X side of stopper 144 of storage device 140A. Pad 401 is provided so as to face pad 147 that abuts against middle portion 65 of conductive piece 63′ of stopper 144.

[0085] The pickup mechanism 410 includes a push-up member 411 that pushes up from below the leading conductor piece 63' (the conductor piece 63' that is in contact with the pad 147 of the stopper 144) in the storage device 140A. The push-up member 411 has a lower end connected to a movable member 412 and has a fork shape that branches into two branches from the lower end to the upper end.

[0086] The upper end of the lifting member 411 abuts against the inside (lower edge) of the middle portion 65 of the conductor piece 63′, and the lifting member 411 rises, thereby removing the conductor piece 63′ upward from the storage device 140A. The bifurcated structure of the lifting member 411 prevents interference between the lifting member 411 and the support member 145.

[0087] The pickup mechanism 410 also includes a lift guide mechanism 413. The lift guide mechanism 413 includes a rail member 413a extending in the Z direction and a plurality of sliders 413b that engage with the rail member 413a. The plurality of sliders 413b are movable in the Z direction along the rail member 413a. The movable member 412 is fixed to the plurality of sliders 413b.

[0088] The pickup mechanism 410 also includes a moving unit 414. The moving unit 414 is an electric cylinder or an air cylinder equipped with a rod 414a that moves back and forth in the Z direction. A connecting member 414b is provided at the tip of the rod 414a, and the rod 414a is connected to the movable member 412 via the connecting member 414b. The push-up member 411 can be raised and lowered by driving the moving unit 414.

[0089] Furthermore, in this embodiment, the push-up member 411 is raised and lowered by the lift guide mechanism 413 and the moving unit 414, but it may be raised and lowered by the moving unit 414 alone.

[0090] The transport mechanism 420 includes a holding unit 421, a moving unit 422 that moves the holding unit 421 in the Y direction, a moving unit 423 that moves the moving unit 422 in the X direction, and an elevating unit 424 that raises and lowers the moving unit 423 in the Z direction.

[0091] The holding unit 421 holds one of the pair of legs 64 of the conductor piece 63' pushed up by the pickup mechanism 410. In this embodiment, the holding unit 421 grips the middle portion of one of the legs 64 on the -Y side. The operation of the holding unit 421 will be described later. The holding unit 421 is moved in the X, Y, and Z directions by the moving units 422 and 423 and the lifting unit 424, and the held conductor piece 63' is transported to the forming position 509 of the forming device 500 while maintaining the inverted U-shaped position. The moving units 422 and 423 and the lifting unit 424 are, for example, electric cylinders or air cylinders.

[0092] The operation of supply device 400 will be described with reference to Figures 18 to 21 in addition to Figure 17. Figures 18 to 21 are explanatory views of the operation of supply device 400. Figure 18 is a side view showing supply device 400 together with storage device 140A, and also shows an enlarged view of the periphery of pad 401.

[0093] Figure 17 shows the push-up member 411 and the holding unit 421 in their standby positions. In the standby position, the push-up member 411 is in a lowered position. Figures 18 and 19 show the pick-up operation of the conductor piece 63'. When the moving unit 414 is driven, the push-up member 411 rises together with the movable member 412, thereby pushing up the leading conductor piece 63' from the support member 145 of the storage device 140A. When pushed up, the conductor piece 63' is pushed up so as to pass between the stopper 144 and the pad 401 in the X direction.

[0094] 18, the distance (gap) G between pad 401 and pad 147 is greater than the thickness of one conductor piece 63' but less than the thickness of two conductor pieces 63'. Therefore, even when push-up member 411 lifts up multiple conductor pieces 63', only one conductor piece 63' can be pushed up from storage device 140A, and the other conductor pieces 63' are brushed off by pad 401. Therefore, even when multiple conductor pieces 63' are stored in support member 145, the conductor pieces 63' can be separated one by one and only the leading conductor piece 63' can be pushed up.

[0095] Next, the pushed-up conductor piece 63' is held by the holding unit 421. Figure 20 shows the holding operation of the holding unit 421. The holding unit 421 has claws 421a and 421b and an actuator 421c that opens and closes the claws 421a and 421b. The actuator 421c is, for example, an electric chuck or an air chuck.

[0096] State ST1191 in Figure 20 shows the state in which the holding unit 421 is on standby. The claws 421a and 421b are in the open state. As shown in state ST1192, the holding unit 421 is moved in the +Y direction by the moving unit 422, and then the claws 421a and 421b are closed. As a result, the leg 65 of the conductor piece 63' is gripped by the claws 421a and 421b, and the conductor piece 63' is in the held state.

[0097] In order to transport the conductor piece 63' to directly below the forming position 509 of the forming device 500, the holding unit 421 is moved in the +X direction by the moving unit 423 as shown in state ST1193.

[0098] Thereafter, the holding unit 421 is raised by the lifting unit 424, as shown in FIG. 21. This positions the conductor piece 63' at the molding position 509 of the molding device 500. After the conductor piece 63' is held by the molding device 500, the holding unit 223 releases its hold on the conductor piece 63' and returns to the standby position shown in FIG. 17. The push-up member 411 also returns to the standby position. By repeating the above operations, the conductor piece 63' is sequentially supplied from the storage device 140A to the molding position 509 of the molding device 500.

[0099] <Molding Apparatus 500> The molding apparatus 500 will be described with reference to Figures 22 and 23. Figure 22 is a diagram of the molding apparatus 500 as seen from above, and Figure 23 is a diagram of the molding apparatus 500 as seen from below.

[0100] The molding device 500 includes a base member 501 as a structure supporting each component of the molding device 500. The base member 501 is an octagonal plate-shaped member with an opening 503 formed in its center. A reinforcing member 504 is provided on the upper surface 501a of the base member 501, crossing the opening 503 in the Y direction. The reinforcing member 504 is provided so as to straddle the opening 503 in the Y direction, improving the rigidity around the opening 503. The upper surface 501a of the base member 501 forms mounting portions for a plurality of pressing units 510A to 510D, and the lower surface 501b forms mounting portions for a plurality of pressing units 530A to 530D. The molding device 500 includes a total of eight pressing units.

[0101] <Pressing Units 510A-510D> The pressing units 510A-510D will be described with reference to Figures 22 and 24. Figure 24 is a cross-sectional view taken along line CC in Figure 22, with the pressing units 530A-530D omitted. The pressing units 510A-510D are mechanisms that bend the middle portion 65 of the conductor piece 63'. Each of the pressing units 510A-510D includes a contact member 517 and movement mechanisms 511 and 521 that move the contact member 517 to bend the middle portion 65. The movement mechanisms 511 and 521 allow the contact member 517 to move in two directions (the X direction and the Y direction). In other words, the contact member 517 can be moved in a direction (X direction) that crosses the intermediate portion 65 of the conductor piece 63' to be bent, and in a direction (Y direction) that follows the longitudinal direction of the intermediate portion 65.

[0102] The moving mechanism 511 includes a plate-shaped base member 511a. The base member 511a is a support member that supports the other components of the moving mechanism 511. The base member 511a has a rectangular shape that is long in the X direction, and is supported by the base member 501 so as to be movable in the Y direction.

[0103] The movement mechanism 511 includes a movable member 514 that supports an abutment member 517. A plurality of sliders 516 are provided on the surface of the movable member 514 that faces the base member 511a. Each slider 516 engages with a rail member 515 that extends on the base member 511a, and is movable along the rail member 515. The rail member 515 extends in the X direction, and therefore the movable member 514 and the abutment member 517 can freely move back and forth in the X direction.

[0104] The moving mechanism 511 includes a motor 512 as a drive source. The motor 512 is fixed to a base member 511a via a bracket 512a. The moving mechanism 511 includes a drive mechanism 513 that converts the rotation of the motor 512 into translational motion of a movable member 514. In this embodiment, the drive mechanism 513 is a ball screw mechanism. However, the drive mechanism 513 may be another mechanism such as a belt transmission mechanism. The drive mechanism 513 includes a ball screw shaft 513a, a ball nut 513b, and a plurality of bearings 513c that rotatably support the ball screw shaft 513a.

[0105] The ball screw shaft 513a extends parallel to the rail member 515. The ball nut 513b is threadedly engaged with the ball screw shaft 513a and is fixed to the movable member 514. The ball screw shaft 513a is coaxially coupled to the output shaft of the motor 512 and rotates when driven by the motor 512. The rotation of the ball screw shaft 513a causes the ball nut 513b to move on the ball screw shaft 513a, resulting in the movement of the movable member 514. The movement direction of the movable member 514 can be switched depending on the rotation direction of the motor 512.

[0106] The moving mechanism 521 is a mechanism that moves the base member 511a in the Y direction, thereby moving the contact member 517 together with the moving mechanism 511 in the Y direction.

[0107] A plurality of rail members 505 and 506 are fixed to the upper surface 501a of the base member 501. Two of the rail members 505 are disposed on the +X side of the opening 503, and two of the rail members 506 are disposed on the −X side of the opening 503. The rail members 505 and 506 extend in the Y direction, and the base members 511a of the pressing units 510A and 510B are positioned on the two rail members 505, and the base members 511a of the pressing units 510C and 510D are positioned on the two rail members 506.

[0108] A plurality of sliders 525 are provided on the surface of the base member 511a that faces the upper surface 501a of the base member 501. The sliders 525 of the pressing units 510A and 510B engage with the rail members 505, and the base members 511a of the pressing units 510A and 510B are capable of reciprocating in the Y direction. The sliders 525 of the pressing units 510C and 510D engage with the rail members 506, and the base members 511a of the pressing units 510C and 510D are capable of reciprocating in the Y direction.

[0109] The movement mechanism 521 includes a motor 522 as a drive source. The motor 522 is fixed to the base member 501 via a bracket 522a. The movement mechanism 521 includes a drive mechanism 523 that converts the rotation of the motor 522 into translational motion of the base member 511a. In this embodiment, the drive mechanism 523 is a ball screw mechanism. However, the drive mechanism 523 may be another mechanism such as a belt transmission mechanism. The drive mechanism 523 includes a ball screw shaft 523a, a ball nut 523b, and a plurality of bearings 523c that rotatably support the ball screw shaft 523a.

[0110] The ball screw shaft 523a extends parallel to the rail members 505 and 506. The ball nut 523b is threadedly engaged with the ball screw shaft 523a and is fixed to a connecting member 524. An end of the connecting member 524 is fixed to the base member 511a. The ball screw shaft 523a is coaxially coupled to the output shaft of the motor 521 and rotates when driven by the motor 521. The rotation of the ball screw shaft 523a causes the ball nut 523b to move on the ball screw shaft 523a, resulting in the movement of the connecting member 524 and the base member 511a. The movement direction of the connecting member 524 and the base member 511a can be switched depending on the rotation direction of the motor 521.

[0111] <Pressing Units 530A-530D> The pressing units 530A-530D will be described with reference to FIGS. 23 and 25. FIG. 25 is a cross-sectional view taken along line CC in FIG. 22, with the pressing units 510A-510D omitted. The pressing units 530A-530D are mechanisms that bend the middle portion 65 of the conductor piece 63', and are similar to the pressing units 510A-510D. Each of the pressing units 530A-530D includes a contact member 537 and movement mechanisms 531 and 541 that move the contact member 537 to bend the middle portion 65. The movement mechanisms 531 and 541 allow the contact member 537 to move in two directions (the X direction and the Y direction). In other words, the contact member 537 can be moved in a direction (X direction) that crosses the intermediate portion 65 of the conductive wire piece 63' to be bent, and in a direction (Y direction) along the longitudinal direction of the intermediate portion 65.

[0112] The moving mechanism 531 includes a plate-shaped base member 531a. The base member 531a is a support member that supports the other components of the moving mechanism 531. The base member 531a has a rectangular shape that is long in the X direction, and is supported by the base member 501 so as to be movable in the Y direction.

[0113] The movement mechanism 531 includes a movable member 534 that supports an abutment member 537. A plurality of sliders 536 are provided on the surface of the movable member 534 that faces the base member 531a. Each slider 536 engages with a rail member 535 that extends on the base member 531a, and is movable along the rail member 535. The rail member 535 extends in the X direction, and therefore the movable member 534 and the abutment member 537 can freely move back and forth in the X direction.

[0114] The moving mechanism 531 includes a motor 532 as a drive source. The motor 532 is fixed to a base member 531a via a bracket 532a. The moving mechanism 531 includes a drive mechanism 533 that converts the rotation of the motor 532 into translational motion of a movable member 534. In this embodiment, the drive mechanism 533 is a ball screw mechanism. However, the drive mechanism 533 may be another mechanism such as a belt transmission mechanism. The drive mechanism 533 includes a ball screw shaft 533a, a ball nut 533b, and a plurality of bearings 533c that rotatably support the ball screw shaft 533a.

[0115] The ball screw shaft 533a extends parallel to the rail member 535. The ball nut 533b is threadedly engaged with the ball screw shaft 533a and is fixed to the movable member 534. The ball screw shaft 533a is coaxially coupled to the output shaft of the motor 532 and rotates when driven by the motor 532. The rotation of the ball screw shaft 533a causes the ball nut 533b to move on the ball screw shaft 533a, resulting in the movement of the movable member 534. The movement direction of the movable member 534 can be switched depending on the rotation direction of the motor 532.

[0116] The moving mechanism 541 is a mechanism that moves the base member 531a in the Y direction, thereby moving the contact member 537 together with the moving mechanism 531 in the Y direction.

[0117] A plurality of rail members 507 and 508 are fixed to the lower surface 501b of the base member 501. Two of the rail members 507 are disposed on the +X side of the opening 503, and two of the rail members 508 are disposed on the −X side of the opening 503. The rail members 507 and 508 extend in the Y direction, and the base members 531a of the pressing units 530A and 530B are positioned on the two rail members 507, and the base members 531a of the pressing units 530C and 530D are positioned on the two rail members 508.

[0118] A plurality of sliders 545 are provided on the surface of the base member 531a that faces the lower surface 501b of the base member 501. The sliders 545 of the pressing units 530A and 530B engage with the rail members 507, and the base members 531a of the pressing units 530A and 530B are capable of reciprocating in the Y direction. The sliders 545 of the pressing units 530C and 530D engage with the rail members 508, and the base members 531a of the pressing units 530C and 530D are capable of reciprocating in the Y direction.

[0119] The movement mechanism 541 includes a motor 542 as a drive source. The motor 542 is fixed to the base member 501 via a bracket 542a. The movement mechanism 541 includes a drive mechanism 543 that converts the rotation of the motor 542 into translational motion of the base member 531a. In this embodiment, the drive mechanism 543 is a ball screw mechanism. However, the drive mechanism 543 may be another mechanism such as a belt transmission mechanism. The drive mechanism 543 includes a ball screw shaft 543a, a ball nut 543b, and a plurality of bearings 543c that rotatably support the ball screw shaft 543a.

[0120] The ball screw shaft 543a extends parallel to the rail members 507 and 508. The ball nut 543b is threadedly engaged with the ball screw shaft 543a and is fixed to the connecting member 544. An end of the connecting member 544 is fixed to the base member 531a. The ball screw shaft 543a is coaxially coupled to the output shaft of the motor 541 and rotates when driven by the motor 541. The rotation of the ball screw shaft 543a causes the ball nut 543b to move on the ball screw shaft 543a, which in turn moves the connecting member 544 and the base member 531a. The movement direction of the connecting member 544 and the base member 531a can be switched depending on the rotation direction of the motor 541.

[0121] <Contact Members 517 and 537> The contact members 517 of the pressing units 510A to 510D and the contact members 537 of the pressing units 530A to 530D will now be described. Figure 26 is a perspective view of the contact member 517 and end 514a of the movable member 514 of the pressing unit 510C, and the contact member 537 and end 534a of the movable member 534 of the pressing unit 530C. The contact members and end portions of the movable members of the other pressing units have similar configurations. Figure 27 is an explanatory diagram showing the positional relationship of the contact members 517 and 537 in the Z direction relative to the molding position 509.

[0122] The abutting members 517 and 537 are both columnar or cylindrical shaft members extending in the Z direction. Because the intermediate portion 65 of the conductor piece 63′ has an inverted V-shape that is convex in the Z direction, the contact points between the abutting members 517 and 537 and the intermediate portion 65 may change in the Z direction during bending. For this reason, by making the abutting members 517 and 537 shaft members that are long in the Z direction, stable contact with the intermediate portion 65 can be obtained.

[0123] The forming position 509 of the forming device 500 is a space immediately below the opening 503, and the conductor piece 63' is supplied to the forming position 509 with the longitudinal direction of its middle portion 65 oriented in the Y direction and with the pair of legs 64 oriented in the Z direction. Because the pressing units 510A to 510D are disposed above the base member 501, the abutting member 517 is configured with an end 514a passing through the opening 503 in the Z direction so as to reach the forming position 509. Furthermore, the upper end of the abutting member 517 is supported by the end 514a and the lower end is open, while the upper and lower ends of the abutting member 537 are both supported by the end 534a, ensuring high rigidity.

[0124] <Positional Relationship Between Contact Members and Pressing Unit> With reference to Figures 22 to 25, the arrangement of the contact members 517 and 537 will be described.

[0125] When viewed in the Y direction, each abutting member 537 is disposed inside the corresponding abutting member 517. Specifically, each abutting member 537 of pressing units 530A and 530B is located between the abutting member 517 of pressing unit 510A and the abutting member 517 of pressing unit 510B in the Y direction. Similarly, each abutting member 537 of pressing units 530C and 530D is located between the abutting member 517 of pressing unit 510C and the abutting member 517 of pressing unit 510D in the Y direction.

[0126] When viewed in the X direction, relative to the molding position 305 (i.e., relative to the intermediate portion 65), the contact members 517 and 537 of the pressing units 510A, 510B, 530A, and 530B are located on the +X side, and the contact members 517 and 537 of the pressing units 510C, 510D, 530C, and 530D are located on the −X side.

[0127] With the above configuration, eight contact points (pressure points) can be obtained for the intermediate portion 65 by the eight contact members 517 and 537 .

[0128] The arrangement of pressing units 510A to 510D and 530A to 530D will now be described. When viewed in the X direction, pressing units 510A and 510B are arranged on the +X side of molding position 305 (i.e., intermediate portion 65), and pressing units 510C and 510D are arranged on the opposite, −X side. Similarly, pressing units 530A and 530B are arranged on the +X side, and pressing units 530C and 530D are arranged on the opposite, −X side.

[0129] When viewed in the Y direction, the pressing units 510A and 510C are arranged symmetrically to the pressing units 510B and 510D. Similarly, the pressing units 530A and 530C are arranged symmetrically to the pressing units 530B and 530D.

[0130] This arrangement allows each unit to be arranged in a well-balanced manner relative to the base member 501, preventing uneven distribution of weight and making the device more compact.

[0131] 28 and 29, the procedure for bending the intermediate portion 65 of the conductor piece 63′ by the forming device 500 will be described. Figures 28 and 29 are explanatory diagrams of the operation of the forming device 500, showing the arrangement of the contact members 517 of the pressing units 510A to 510D and the arrangement of the contact members 537 of the pressing units 530A to 530D as viewed from above.

[0132] In order to distinguish between the contact members 317 and 537 of the pressing units 510A to 510D and 530A to 530D, the contact member 517 of the pressing unit 510A will be referred to as the contact member 517A. The same applies to the contact members 517 of the pressing units 510B to 510D and the contact members 537 of the pressing units 530A to 530D.

[0133] 28 shows a state ST1271 in which the conductor piece 63' is supplied to the forming position 509 by the supply device 400. The contact members 517A to 517D and 537A to 537D are positioned at initial positions away from the intermediate portion 65 of the conductor piece 63'. In the initial positions, the contact members 517A to 517D and 537A to 537D are adjusted to their respective contact positions in the Y direction.

[0134] State ST1272 shows the stage where the holding operation for holding the conductor piece 63' has been performed. The abutting member 537B is moved in the -X direction, and the abutting members 537C and 537D are moved in the +X direction. The abutting member 537B abuts against the intermediate portion 65 from the +X side, and the abutting members 537C and 537D abut against it from the -X side. The conductor piece 63' is held by clamping the longitudinal center of the intermediate portion 65 between the abutting member 537B and the abutting members 537C and 537D. In the Y direction, the abutting member 537C abuts at a position on the -Y side relative to the abutting position between the abutting member 537B and the intermediate portion 65, and the abutting member 537D abuts at a position on the +Y side. The holding unit 223 of the supply device 400 releases its hold on the conductor piece 63' and returns to the position shown in state ST1191 in FIG. 20 .

[0135] After the conductive wire piece 63' is held by the contact members 537B and 537C and 537D, the bending operation of the middle portion 65 begins. As shown in state ST1273, the contact members 537C and 537D are moved in the +X direction. The stroke of the movement of the contact member 537D is longer than that of the contact member 537C. The middle portion 65 is bent into a shallow V-shape.

[0136] Next, as shown in state ST1281 in FIG. 29 , the abutting member 537A is moved in the −X direction and abuts against the intermediate portion 65 from the +X side. The abutting position of the abutting member 537A is on the −Y side of the abutting positions of the abutting members 537B to 537D. The intermediate portion 65 is bent into an S shape. As shown in state ST1282, the abutting members 517A and 517B are moved in the −X direction and abut against the intermediate portion 65 from the +X side. At the same time, the abutting members 517C and 517D are moved in the +X direction and abut against the intermediate portion 65 from the −X side. The intermediate portion 65 is bent into a W shape. In this way, the conductor piece 63′ is formed into the conductor part 63.

[0137] Next, as shown in state ST1283, the lead wire component 63 is released. Specifically, the contact members 517A to 517D and 537A to 537D are returned to their initial positions to separate from the lead wire component 63. The released lead wire component 63 falls naturally by its own weight onto the support member 145 of the storage device 140B disposed below the forming position 305, and is thereby discharged from the forming device 500.

[0138] <Response to Specification Changes> In this embodiment, the positions of the contact members 517 and 537 can be changed in the X and Y directions. The amount of pressure (pressing distance) applied to the intermediate portion 65 of the conductor piece 63' in the X direction can also be changed by the movement mechanisms 511 and 531. This allows the depth of bending of the intermediate portion 65 to be changed. Furthermore, the contact position of the conductor piece 63' in the Y direction with the intermediate portion 65 can be changed by the movement mechanisms 521 and 541. This allows the bending position of the intermediate portion 65 to be changed.

[0139] While the specification change for the conductor component 63 has been described above as involving a change in the bending shape, it is also possible to accommodate a change in the thickness of the conductor piece 63' in the X direction (thickness of the wire material). In this case, the positions of the contact members 517 and 537 in the X direction and the Y direction can be changed according to the thickness of the conductor piece 63'.

[0140] Therefore, in this embodiment, one molding device 500 can be used to manufacture lead wire components 63 with different specifications.

[0141] In this embodiment, the contact members 517 and 537 are movable in both the X and Y directions, but they may be movable only in the X direction, which also accommodates changes in the bending depth of the intermediate portion 65. In this embodiment, eight pressing units 510A to 510D and 530A to 530D are used, but any number necessary to match the bending shape of the intermediate portion 65 may be used, and the holding and bending operations of the intermediate portion 65 can be performed with at least one pressing unit on each side of the intermediate portion 65 in the X direction, that is, a total of two pressing units.

[0142] <Storage Device 140B> The storage device 140B will be described with reference to FIG. 30. FIG. 30 is a perspective view of the storage device 140B. The storage device 140B has the same configuration as the storage device 140A. The lead wire components 63 fall naturally from the forming position 509 of the molding device 500 onto the support member 145 while maintaining an inverted U-shaped vertical position with a pair of legs 64 pointing downward. In this embodiment, the storage device 140B is disposed directly below the forming position 509 in the Z direction. The lead wire components 63 that slide along the support member 145 come into contact with multiple pads 147 and are stored in that position. From the completion of molding in the molding device 500 to storage in the storage device 140B, the lead wire components 63 are moved by utilizing the difference in height and their own weight, without using a transport mechanism with a drive source such as a motor. This prevents the molding system 100 from becoming too complicated.

[0143] <Summary of the System> In the molding system 100, the storage device 140A is located below the molding position 305 of the molding device 300. When moving the conductive wire pieces 63' from the molding device 300 to the storage device 140A, the difference in height and their own weight can be utilized, and there is no need to use a conveying mechanism with a drive source such as a motor. This allows the molding system 100 to be simplified.

[0144] Furthermore, the supply device 400 that supplies the conductor piece 63' from the storage device 140A to the molding device 500 is disposed below the molding position 509 of the molding device 500. Although a drive source is required to move the conductor piece 63' from the supply device 400 to the molding position 509, by disposing the supply device 400 below the molding position 509, the molding system 100 can be made smaller in the X direction than in a configuration in which the supply device 400 is disposed on the +X side. Therefore, according to this embodiment, a molding system that is relatively small and can be configured simply can be provided.

[0145] Furthermore, in the molding system 100, the storage device 140B is disposed below the molding position 509 of the molding device 500. When the lead wire components 63 are moved from the molding device 500 to the storage device 140B, the difference in height and their own weight can be utilized, and there is no need to use a conveying mechanism having a drive source such as a motor. This further simplifies the molding system 100.

[0146] Second Embodiment In the molding apparatus 300 of the first embodiment, the position change direction of each of the contact members 317 of the fulcrum units 310A to 310C is one direction (X direction or Y direction), the movement direction of the contact member 327 of the pressing unit 320A is one direction (X direction), and the movement direction of each of the contact members 327 of the pressing units 320B and 320C is two directions (X direction and Y direction). However, depending on the specifications of the conductor component 63, the position change direction of all or some of the contact members 317 of the fulcrum units 310A to 310C may be two directions, and the movement direction of the contact member 327 of the pressing unit 320A may be two directions. Conversely, the movement direction of each of the contact members 327 of the pressing units 320B and 320C may be one direction.

[0147] When the movement direction of the contact member 327 of the pressing unit 320A is set to two directions, the pressing unit 320A may have the same configuration as the pressing units 320B and 320C. That is, a mechanism equivalent to the movement mechanism 331 may be added.

[0148] When the position of each of the contact members 317 of the fulcrum units 310A to 310C can be changed in two directions, a mechanism equivalent to the movement mechanism 331 may be added. Figure 33 shows an example of this.

[0149] 33 shows a configuration in which the contact member 317 of the fulcrum unit 310B is movable in the X and Y directions. Differences from the configuration of the fulcrum unit 310B shown in FIG.

[0150] 8 is replaced with a base member 311a' similar to the base member 321a, and the base member 311a' is provided so as to be able to move back and forth in the X direction on the upper plate member 301. The position change mechanism 311' has the same structure as the movement mechanism 311, and changes the X-direction position of the abutment member 317 by moving the base member 311a' in the X direction. As a result, the abutment member 317 of the fulcrum unit 310B can move in the X and Y directions.

[0151] 33 shows the fulcrum unit 310B as an example, similar modifications can be made to the fulcrum units 310A and 310C to change the positions of their contact members 317 in the X and Y directions. This configuration increases the number of options for the fulcrum position, thereby increasing the number of specification changes for the conductor component 63 that can be accommodated by a single molding device 300.

[0152] Although the embodiments of the invention have been described above, the invention is not limited to the above-described embodiments, and various modifications and changes are possible within the scope of the gist of the invention.

Claims

1. A forming system comprising: a first forming device that forms a straight piece of wire into a U-shaped piece of wire having a pair of legs and an intermediate portion between the pair of legs at a first forming position; a second forming device that forms the intermediate portion into a predetermined shape at a second forming position; a first storage means that stores the U-shaped piece of wire discharged from the first forming device; and a first supply means that supplies the U-shaped piece of wire stored in the first storage means to the second forming device, wherein the first storage means is positioned below the first forming position, and the first supply means is positioned below the second forming position.

2. A molding system according to claim 1, comprising: a second storage means for storing the straight conductor wire pieces; and a second supply means for supplying the straight conductor wire pieces stored in the second storage means to the first molding position of the first molding device.

3. A molding system as claimed in claim 1, comprising: a discharge means for changing the U-shaped conductor pieces discharged from the first molding device into an inverted U-shape and discharging them into the first storage means; the first storage means comprising a support member for supporting from below the middle portion of the conductor pieces in the inverted U-shape; and the first supply means comprising: a holding means for holding the pair of legs; and a lifting means for raising and lowering the holding means relative to the second molding position; and the U-shaped conductor pieces are separated one by one from the support member and supplied to the second molding position of the second molding device.

4. A molding system as claimed in claim 1, comprising a third storage means for storing the conductor pieces discharged from the second molding device, the third storage means being arranged below the second molding device and comprising a support member for supporting the middle portion of the conductor piece from below in an inverted U-shaped position.

5. A molding method for molding a straight conductor piece into a U-shaped conductor piece having a pair of legs and a middle portion between the pair of legs by using a molding system, the molding system comprising: a first molding device for molding the straight conductor piece into a U-shaped conductor piece having a pair of legs and a middle portion between the pair of legs at a first molding position; a second molding device for molding the middle portion into a predetermined shape at a second molding position; a first storage means for storing the U-shaped conductor piece discharged from the first molding device; and a first supply means for supplying the U-shaped conductor piece stored in the first storage means to the second molding device, the first storage means being located below the first molding position and the first supply means being located below the second molding position, the molding method comprising: a first molding step for molding the unmolded conductor piece supplied to the first molding device into a U-shaped conductor piece by the first molding device; A molding method comprising: a first storage step of storing the U-shaped conductor wire pieces discharged from the first molding device in the first storage means; a first supply step of supplying the U-shaped conductor wire pieces stored in the first storage means to the second molding device by the first supply means; and a second molding step of molding the middle portion of the U-shaped conductor wire pieces supplied to the second molding device by the first supply means into a predetermined shape by the second molding device.

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