End processing means and winding device

Abstract

[Problem] To provide an end processing means and a winding device for twisting together the ends of parallel wires wound around a stator core which constitutes an electric motor so that the ends of the parallel wires do not easily become spread out. [Solution] A mechanism 10 constituting an end processing means 1 is provided with a clamping means 20, a pair of disks 30, a synchronous driving means 40, a rotary motion transmission means 50, and a cutting means 60. A second slit 22 and a third slit 23 provided respectively in the pair of disks arranged on the inside are synchronously rotated by the synchronous driving means and the transmission means in a state in which parallel wires 100 are clamped and held by a first slit 21 and a fourth slit 24 which constitute the clamping means and which are arranged on the outside, thereby making the parallel wires between the first slit 21 and the second slit 22 and the parallel wires between the third slit 23 and the fourth slit 24 into twisted wires. The parallel wires between the second slit and the third slit are cut to make the twisted wires into the ends of the parallel wires.

Description

End processing means and winding device

[0001] The present invention relates to end processing means and a winding device for twisting the ends of parallel wires wound around a stator core forming an electric motor, so that the ends of the parallel wires are less likely to spread.

[0002] More specifically, the ends of parallel wires in which a plurality of coil wires are in a parallel state are twisted together to form an integrated coil wire group capable of passing a large current, similar to a coil wire having a thick wire diameter over the entire parallel wire, and relates to end processing means and a winding device for preventing the ends of the coil wire group from spreading.

[0003] In an electric motor that requires high output and miniaturization, it is required to reduce the electrical resistance value of the coil bundle and improve the performance of the electric motor. To reduce the electrical resistance value, the wire diameter of the coil wire may be increased to increase the cross-sectional area, but a coil wire with a thick wire diameter has high rigidity and is difficult to wind.

[0004] Conventionally, to increase the winding density in the slot and reduce the electrical resistance value, a flat wire with a rectangular cross-sectional shape is shaped into a substantially U-shape, inserted into the slot from the protruding end of the substantially U-shape, and the protruding end is welded to form a coil forming a loop. However, in the case of this conventional technology, there is a problem that it takes time for forming, bending, welding, etc. of the flat wire, and it is difficult to increase the production efficiency.

[0005] On the other hand, as a technique for reducing the electrical resistance value of the coil bundle, a coil wire group formed by coil wires having a circular cross-sectional shape is wound around a winding frame to form a coil bundle, and the coil bundle is inserted into a stator core by a coil insertion machine, and individual coil wires are connected in parallel to a power source. This technique is also known. In the case of this conventional technology, since there is an appropriate gap in the coil wires in the slot, the heat dissipation is excellent, and even when a large current flows, the coil wires are less likely to generate heat and the electrical resistance value does not increase.

[0006] However, because bundles of coil wires are inserted into the stator core, the pressure during insertion makes the ends of the coil wires (hereinafter referred to as lead wires) prone to bending, and the lead wires tend to become scattered. In particular, in stator cores with a concentrated winding method, bundles of multiple phase coils are inserted adjacent to each other in each slot, and the lead wires are also drawn out of the slots adjacent to each other, making it easy for the lead wires of multiple phase coils to get mixed up.

[0007] Therefore, when connecting the lead wires to the electrical terminals, it was time-consuming for workers to manually select only the lead wires for the coil bundles of the same phase from among the many scattered and mixed lead wires. Specifically, in a concentrated winding system where two-phase coil wires are inserted into one slot, if there are 10 coil wires and 9 slots, a total of 180 lead wires had to be selected and connected per stator core.

[0008] Patent Document 1 discloses a technology for a tap wire processing device for a variable-speed motor. According to the technology described in this document, in a winding device that continuously forms bundles of single-wire coils, the connecting wires between the previously wound coil bundle and the next coil bundle to be wound are twisted together during the winding process to reduce the effort required for connection.

[0009] However, according to the technology described in Patent Document 1, a hook is attached to the jumper wire, and the hook is rotated around its axis to fold the jumper wire in half and form a twisted section. With this technology, when the number of parallel coil wires is increased, the twisted section becomes enlarged, which presents a problem in that inserting the coil wires becomes difficult.

[0010] Patent Document 2 discloses a method for winding a parallel coil bundle. According to the technique described in this document, a parallel coil bundle is manufactured by winding multiple coil wires in parallel onto a winding frame, and the coil wires spanning between the previously wound coil bundle and the next coil bundle are twisted by 180 degrees.

[0011] More specifically, an example is disclosed in which a fan-shaped gear is equipped with slits, and multiple coil wires are inserted into the slits and twisted 180 degrees. However, the technique described in this document only reverses the top and bottom of the coil bundle and twists it, so there is a problem that the twisted lead wires may unravel and scatter in subsequent processes such as the coil bundle insertion process.

[0012] Patent Document 1: Japanese Unexamined Patent Publication No. 57-206202 Patent Document 2: Japanese Unexamined Patent Publication No. 2010-246243

[0013] The problem that the present invention aims to solve is a means for processing ends and a winding device that, even when there are many parallel coil wires, pre-twist the ends of the parallel wires to form a group of coil wires, so that the ends of the coil wires do not unravel when the group of coil wires is inserted into the stator core, and so that the lead wires of each phase do not scatter even after insertion into the stator core.

[0014] The first aspect of the present invention is an end processing means for twisting the ends of parallel wires formed by a coil, comprising a clamping means for clamping the parallel wires, a pair of discs, a synchronous driving means, a transmission means, and a cutting means, wherein the clamping means is a slit consisting of a first slit, a second slit, a third slit, and a fourth slit, the slits clamp the extending parallel wires, the first slit and the fourth slit clamp and hold the parallel wires, the second slit and the third slit are positioned between the first slit and the fourth slit and are slits that cross the center of each disc and extend to the outer edge, and the synchronous driving means rotates the pair of discs in a synchronous motion. The transmission means is arranged on the outer circumference of each of the disks and transmits the rotational motion so that the parallel lines sandwiched between the second and third slits rotate around the central axis of the parallel lines. The parallel lines remain aligned outward from the first slit, between the second and third slits, and outward from the fourth slit. Between the first and second slits, and between the third and fourth slits, the parallel lines are twisted together. The cutting means is arranged between the second and third slits and cuts the parallel lines, so that the twisted ends on both sides of the cut parallel lines become the ends of the parallel lines.

[0015] According to the first invention, parallel wires are held between four slits, from the first to the fourth slit. The first and fourth slits, which are located on the outside, are not rotated, while the second and third slits, which are located on the inside, are rotated in sync. As a result, between the first and second slits, and between the third and fourth slits, the parallel wires held between the slits are rotated around their central axis and twisted together, making a portion of the connected parallel wires a twisted wire.

[0016] The second and third slits on each disk rotate synchronously due to a synchronous drive mechanism, so the parallel wires between the second and third slits do not twist together and remain aligned. Furthermore, since the first and fourth slits do not rotate, the coil wires remain parallel even beyond the first slit and beyond the fourth slit.

[0017] By cutting parallel wires between the second and third slits, a single coil wire group can be divided into two: a parallel wire formed by twisting the rear ends of the coil wire group beyond the second slit, and a parallel wire formed by twisting the front ends of the coil wire group behind the third slit. By applying the end processing means of the first invention to a winding device that produces windings by winding coil wires onto a winding frame, it is possible to produce a coil wire group that corresponds to the winding tendency of the winding to be inserted into the stator core.

[0018] Even when a coil bundle formed by twisted parallel wires is inserted into a stator core using a conventional coil insertion machine, the lead wires formed by the ends of the individual coil wires do not scatter, making it easier to connect them to electrical terminals.

[0019] Furthermore, the ends of the coil wires beyond the stranded wires remain aligned, with no overlapping coil wires. Therefore, when removing the insulation coating from the coil wires, it is easier to strip the insulation coating from each coil wire almost uniformly, making the insulation stripping process easier even with a large number of coil wires.

[0020] While arranging the four slits in a straight line is preferable as it makes it easier to insert parallel wires into the slits and twist them together in a neat manner, it is not limited to this arrangement. For example, the slits may be offset from each other depending on the layout of the manufacturing equipment, and the spacing between each slit does not have to be uniform. Furthermore, the pair of discs on which the second and third slits are formed may be integrally formed as long as a cutting means for cutting the coil wire functions between the second and third slits.

[0021] The synchronous drive means may involve synchronously controlling multiple motors to rotate a pair of disks in a synchronous manner, or it may involve using a single motor to rotate a pair of disks in a synchronous manner. The manner in which a single motor synchronizes each disk is not limited. For example, the rotational motion can be mechanically transmitted to each disk by combining gears, timing pulleys, etc.

[0022] The transmission means are arranged on the outer circumference of each disk and transmit the rotational motion to the outer circumference of the disk, causing the second and third slits to rotate. Therefore, even if a parallel line sandwiched between slits that cross the center of the disk and reach the outer edge is rotated around its central axis, the parallel line will not come into contact with the transmission means. The transmission means is not limited to gears; it may also transmit rotational motion by the frictional force of a rubber roller with a high coefficient of friction, or by magnetic force, and is not limited to these.

[0023] According to the first invention, numerous lead wires are not scattered, and the effort required for connecting the lead wires is reduced, which is an advantageous effect not found in conventional technology. Furthermore, because the simple structure allows the rear and front ends of two connected parallel wires to be twisted together simultaneously, it is possible to produce parallel wires with twisted ends with high production efficiency.

[0024] The second invention of the present invention is an end processing means of the first invention, characterized in that each of the slits forming the clamping means is arranged in a straight line, and the centerlines of the parallel lines extend in a straight line.

[0025] According to the second invention, each slit and the center line of the parallel wires extend in a straight line. This allows the ends of the parallel wires to be twisted around the center line, resulting in the advantageous effect of creating neatly arranged twisted wires. Furthermore, it makes it easier to insert the parallel wires into each slit, and the end processing means can be made simple, increasing versatility.

[0026] The third invention of the present invention is an end processing means of the first invention, wherein the transmission means comprises a disc gear formed on the outer circumference of each of the discs forming the second slit and the third slit, a plurality of first rotational transmission gears that mesh with each of the disc gears, and a plurality of second rotational transmission gears that mesh with each adjacent first rotational transmission gear, wherein each first rotational transmission gear is distributed around the disc gear, and at least one second rotational transmission gear that meshes with adjacent first rotational transmission gears is omitted, the outer diameter portion of the omitted second rotational transmission gear is an insertion portion of the parallel line into the slit, and the first rotational transmission gear and the second rotational transmission gear transmit the rotational motion generated by the synchronous driving means to rotate the pair of discs on which the disc gears are arranged in synchronous motion.

[0027] In the third invention, the transmission means includes an internally positioned disc gear and, in order, a first rotational transmission gear and a second rotational transmission gear positioned outside it. Since both transmission means are mechanical motion transmission means through gear meshing, synchronized rotational motion can be reliably transmitted.

[0028] Specifically, the first rotary transmission gear, positioned on the inside, receives the rotational force generated by the synchronous drive mechanism from one of the second rotary transmission gears positioned on the outside, and transmits it to the other second rotary transmission gear positioned on the outside. This process is repeated in sequence, causing all the first rotary transmission gears to rotate in one direction and all the second rotary transmission gears to rotate in the opposite direction to the first rotary transmission gears.

[0029] Then, rotational motion is transmitted from both sides to the position where the second rotational transmission gear is omitted. Since the first rotational transmission gear is not located inside where the second rotational transmission gear is omitted, when the slit is in that position, the parallel wires can be inserted into the slit and removed outwards from the slit.

[0030] According to the third invention, since the rotation of any of the second rotary transmission gears rotates all of the first and second rotary transmission gears, only one motor needs to be used as the synchronous drive means. This results in simple power control, reliable synchronization of the pair of discs, no change in the position where one of the second rotary transmission gears is omitted, and easy insertion and removal of parallel wires into the slits.

[0031] The fourth invention of the present invention is an end processing means according to the first to third inventions, further characterized in that the end processing means comprises a first moving means, the first moving means is capable of changing the position of each slit along the direction in which the parallel lines extend.

[0032] The length of the lead wires needs to be adjusted according to the distance to the connection point. According to the fourth invention, the position of each slit can be changed along the direction in which the parallel wires extend. This allows the position where the coil wires are twisted together to be arbitrarily adjusted according to the length of the lead wires, resulting in the advantageous effect of providing a highly versatile end treatment means.

[0033] The end processing means of the fifth invention of the present invention is the first to third inventions, further characterized in that the end processing means comprises a second moving means, the second moving means is capable of changing the position of each slit in the same direction in any direction intersecting the direction in which the parallel lines extend.

[0034] When forming a coil bundle, if the center of the width of the parallel wires is aligned with the rotation center of a pair of discs, depending on the width of the parallel wires due to the different number of coil wires, the stranded wires can be twisted together in an orderly manner. Furthermore, when winding the parallel wires onto the reel, it is preferable to wind them in a spiral pattern with staggered positions to prevent tangling.

[0035] According to the fifth invention, even when the number of parallel wires differs, the center of the width of the parallel wires can be aligned with the center of the disk, and the parallel wires can be wound in a way that prevents them from becoming tangled. This has the effect of forming a coil group of stranded wires with neatly shaped ends, and winding the coil group onto a winding frame in a neat manner.

[0036] The sixth invention of the present invention is a winding device that winds parallel wires onto a winding frame and manufactures a coil bundle of parallel wires to be inserted into a stator core, characterized in that it is equipped with the end processing means of the first to third inventions. This makes it possible to provide a winding device that facilitates the connection work of lead wires.

[0037] - According to the first invention of the present invention, numerous lead wires are not scattered, the effort required for lead wire connection work is reduced, and parallel wires with twisted ends can be produced with high production efficiency. - According to the second invention of the present invention, the ends of the parallel wires can be twisted around a center line, resulting in the advantageous effect of having neatly arranged twisted wires.

[0038] - According to the third invention of this invention, the power control is simple, the pair of discs are reliably synchronized, the position where one second rotation transmission gear is omitted does not change, and the insertion and removal of parallel wires into the slit is easy. - According to the fourth invention of this invention, the position where the coil wires are twisted together can be arbitrarily adjusted according to the length of the lead wire, which has the advantageous effect of providing a highly versatile end processing means.

[0039] - According to the fifth invention of the present invention, stranded wires with neatly shaped ends can be used as a coil group, and the coil group can be wound neatly onto a winding frame. - According to the sixth invention of the present invention, a winding device can be provided that facilitates the connection work of lead wires.

[0040] Perspective view (Example 1) explaining the mechanism of the end processing means. Explanatory drawing (Example 1) showing the position where parallel lines are twisted together. Front view (Example 1) explaining the first moving means. Front view (Example 1) explaining the second moving means. Top view (Example 1) explaining the winding frame forming the winding device. Process drawing 1 of the end processing of the parallel lines forming the coil bundle (Example 1). Process drawing 2 of the end processing of the parallel lines forming the coil bundle (Example 1). Another specific example of the end processing means (Example 2). Another specific example of the end processing means (Example 3).

[0041] Four slits were used to sandwich the parallel lines, and the two inner slits were rotated synchronously so that the parallel lines were twisted between the end slit and the inner slit adjacent to it.

[0042] Specifically, with the parallel lines held sandwiched between the first slit and the fourth slit arranged on the outside, the second slit and the third slit provided respectively on each of the pair of disks arranged on the inside were rotated synchronously by the synchronous drive means and the transmission means, and the parallel lines between the first slit and the second slit and the parallel lines between the third slit and the fourth slit were made into twisted lines.

[0043] In Example 1, the end processing means 1 for twisting the ends of the parallel lines will be described with reference to FIGS. 1 to 7. FIG. 1 shows a perspective view explaining the mechanism of the end processing means. In FIG. 1, for the purpose of easily distinguishing the first rotation transmission gear and the second rotation transmission gear, the second rotation transmission gear is shown in color. FIG. 2 shows an explanatory drawing based on the cross section at the A - A position of FIG. 1. FIG. 2(A) shows the state where the parallel lines are twisted, and FIG. 2(B) shows the state where the parallel lines are cut.

[0044] FIG. 3 shows an explanatory drawing of the first moving means for moving the position of the slit along the direction in which the parallel lines extend. FIG. 3(A) shows an example where the lead wire is short, and FIG. 3(B) shows an example where the lead wire is long. FIG. 4 shows an explanatory drawing of the second moving means for moving the position of the slit in a direction intersecting the direction in which the parallel lines extend.

[0045] FIG. 5 shows a top view for explaining a winding frame forming a winding device. FIGS. 6 and 7 show process diagrams for explaining a series of manufacturing processes from the winding process of parallel wires to the end processing process of parallel wires and the delivery process to the coil inserter.

[0046] In the first embodiment, a specific example of applying the end processing means 1 to a winding device 200 (see FIG. 3) that manufactures a coil bundle by winding parallel wires 100 around a winding frame will be described. Hereinafter, for ease of understanding, the left-right direction in the figure will be described as the first horizontal axis direction, the depth direction as the second horizontal axis direction, and the height direction as the vertical axis direction. Also, an example in which a coil wire group forming parallel wires is arranged in the vertical axis direction will be described, but it is needless to say that the direction in which the coil wire group is arranged is not limited to the vertical axis direction.

[0047] The mechanism part 10 of the end processing means 1 includes four slits forming the parallel wire clamping means 20, a pair of disks 30, a synchronous drive means 40 for synchronously rotating the pair of disks, a transmission means 50 for transmitting the rotational motion to the disks, and a cutting means 60 for the coil wire group (see FIG. 1). Further, it includes a first moving means 70 and a second moving means 8() for changing the position of the slits forming the clamping means (see FIGS. 3 and 4).

[0048] The slits forming the clamping means 20 consist of a first slit 21, a second slit 22, a third slit 23, and a fourth slit 24 (see FIGS. 1 and 2). The arrangement of the four slits is arranged in a straight line so that the parallel wires 100 can be easily inserted into the slits. The width of each slit is a narrow width adapted to the wire diameter of one coil wire.

[0049] The first slit 21 and the fourth slit 24 are arranged on both sides of the pair of disks 30 so that the parts other than the ends of the extending parallel wires 100 are not twisted together, and the parallel wires 100 are clamped and held (see FIG. 1). The first slit 21 and the fourth slit 24 are provided with a guide part 25 in which one of the both side parts forming the slit extends long and a curved tip part 26 in the other, making it easy to insert the parallel wires 100 into the inside of the slit.

[0050] The second slit 22 and the third slit 23 are provided in a pair of discs 30, 30 positioned between the first slit 21 and the fourth slit 24. The second slit 22 and the third slit 23 are slits that cross the center of each disc 30 and extend to the outer edge. The parallel lines 100 are inserted into the slits and held in place so that their central axes align with the center of the disc 30.

[0051] Furthermore, the arrangement of the slits is not limited to being aligned in a straight line; some slits may be positioned at different angles depending on the layout of the winding device and the bobbins that store the coil wires. The spacing between the slits is also not limited; they may be spaced equally or at different intervals.

[0052] In the end processing means 1 shown in Example 1, an example is described in which a pair of discs 30, 30 arranged on the left and right sides are synchronized by a mechanical motion transmission means using the rotational motion generated by a single servo motor 41 as the synchronous drive means 40 (see Figure 1).

[0053] The synchronous drive means 40 branches the rotational motion using a servo motor 41, a first timing pulley 42 attached to the servo motor, a second timing pulley 43, a timing belt 44 stretched between the pair of timing pulleys, a pair of shafts 45, 45 extending from both sides of the second timing pulley, and gears 46 attached to each shaft 45. The gears 46 mesh with gears that form the transmission means 50.

[0054] The transmission means 50 transmits the rotational motion generated by the synchronous drive means 40 to the respective disks 30, 30, causing the second slit 22 and the third slit 23 to rotate synchronously. Below, an example of using gears, which are mechanical motion transmission means, as the transmission means will be specifically described.

[0055] The transmission means 50 consists of a disc gear 31 formed on the outer circumference of each disc, a first rotation transmission gear 51 that meshes with the disc gear 31, and a second rotation transmission gear 52 (see colored area in Figure 1) that meshes with each adjacent first rotation transmission gear. The disc gear 31 is provided along the entire outer circumference of the disc 30, except for the positions of the second slit 22 and third slit 23 into which the parallel lines 100 are inserted from the side. The first rotation transmission gears 51 are distributed at five locations along the outer circumference of the disc gear 31.

[0056] The four second rotary transmission gears 52 are meshed with adjacent first rotary transmission gears 51. The rotational motion generated by the synchronous drive means 40 is first transmitted to the first rotary transmission gears 51 which are meshed with the gear 46. This rotational motion of the first rotary transmission gears 51 is transmitted to the adjacent second rotary transmission gears 52, 52 and the disc gear 31, causing the disc gear 31 and all the second rotary transmission gears 52 to rotate in one direction, and all the first rotary transmission gears 51 to rotate in the opposite direction to the rotation of the disc gear 31 (see arrows in Figure 1).

[0057] Furthermore, the second rotary transmission gear 52 omits one of the five gaps formed by the adjacent first rotary transmission gears 51, specifically the one on the lower side of the disc 30. The parallel wires 100 are inserted into the second slit 22 and the third slit 23 from the lower side of the disc where the second rotary transmission gear is omitted.

[0058] The central axes of the first rotational transmission gear 51 and the second rotational transmission gear 52 are rotatably supported on a support plate (not shown) that does not come into contact with the parallel line 100. Since each of the discs 30, 30 is supported by the first rotational transmission gear 51 and the second rotational transmission gear 52, it is not necessary to support the discs themselves.

[0059] The cutting means 60 consists of scissors 61 and an air cylinder 62, with the tip of the scissors positioned between the second slit 22 and the third slit 23. The tip of the scissors 61 is open to a width that does not come into contact with the parallel wires 100 (see Figure 1). When cutting the parallel wires, the tip of the scissors 61 is closed by the air cylinder 62, cutting the parallel wires 100 that extend between the second slit 22 and the third slit 23 (Figure 2(A)).

[0060] By rotating the pair of discs 30, 30, the parallel lines between the first slit 21 and the second slit 22, and the parallel lines between the third slit 23 and the fourth slit 24 are twisted together to form a stranded wire 101. Then, by cutting the parallel line 100 between the second slit 22 and the third slit 23, the parallel line 100 is divided into a parallel line 102 with twisted ends and a parallel line 103 with twisted beginnings (Figure 2(B)).

[0061] The first moving means 70 moves the mechanism 10, which constitutes the end processing means 1, along the direction in which the parallel lines 100 extend, thereby changing the positions of the four slits 21, 22, 23, and 24, and making it possible to change the length of the lead wire (see arrow α in Figure 3).

[0062] Specifically, the first moving means 70 consists of a first slide plate 71 on which the mechanism 10 is mounted, a first ball screw shaft 72 extending in the direction of the first horizontal axis, a first drive motor 73 that rotates the first ball screw shaft around its axis, and a first rail 74 extending along both the upper and lower sides of the first ball screw shaft (see Figure 3).

[0063] The first slide plate 71 has a female screw portion on the back side of the surface on which the mechanism 10 is arranged, which is screwed onto the first ball screw shaft 72, and a recess that fits onto the first rail 74. When changing the length of the lead wires, the parallel wires 100 are inserted into the four slits, and then the first drive motor 73 is driven to slide the first slide plate 71 along the direction in which the parallel wires 100 extend (see arrow α in Figure 3).

[0064] The length by which the first slide plate 71 is slid can be adjusted according to the length of the lead wire. For example, the distance the slit moves can be registered in a memory means that constitutes a programmable logic controller (hereinafter referred to as PLC), which is a control device for industrial machinery, and the rotation angle of the first drive motor can be controlled according to the distance read by the control means that constitutes the PLC to adjust the length of the lead wire.

[0065] It should be noted that the first moving means 70 is not limited to a ball screw shaft, but may be a known air cylinder or the like.

[0066] The second moving mechanism 80 allows the positions of the four slits 21, 22, 23, and 24 to be changed in the same direction in any direction intersecting the direction in which the parallel wires 100 extend (see arrow β in Figure 4 and Figure 3(B)). Here, the parallel wires 100 are inserted into each slit by moving the four slits that make up the mechanism 10 in the vertical axis direction using the second moving mechanism 80. When the number of turns of the coil bundle is changed, the distance by which the slits are moved by the second moving mechanism can be adjusted.

[0067] The second moving mechanism 80 consists of a second slide plate 81 on which the first moving mechanism 70 is mounted, a second ball screw shaft 82 extending in the vertical axis direction, a second drive motor 83 that rotates the second ball screw shaft around its axis, a second rail 84 extending along the side of the second ball screw shaft, and legs 85 that support these (see Figure 4). The legs 85 can be installed on the base of the winding device 200 or the like.

[0068] The second slide plate 81, like the first slide plate, is equipped with a female screw portion on its back side for screwing onto the second ball screw shaft 82 and a recess for fitting onto the second rail 84.

[0069] Here, the winding device 200 to which the present invention is applied will be briefly described with reference to the front view of the winding device shown in Figure 4 and the top view of the winding frame 201 shown in Figure 5. In Figure 5, hatching is added to a pair of winding sections for ease of understanding. Figure 5(A) shows the state before winding is started, and Figure 5(B) shows the state after winding is completed.

[0070] The winding device 200 includes a winding frame 201 for winding the parallel wires 100, a nozzle 202 for bundling multiple coil wire groups 104 and pulling the parallel wires 100 towards the other end, and a multi-joint arm 203 that allows the nozzle 202 to move in three axes (see Figure 4).

[0071] The winding frame 201 (see Figure 5) comprises a base 210, a gripping portion 211 for gripping the starting ends of parallel wires, a pair of winding portions 212 for winding the parallel wires 100 to form a coil bundle, and a spacing changing means 213 for changing the spacing between the pair of winding portions 212. The base 210 is rotated along a horizontal plane around the drive shaft 214 of a servo motor (see Figure 4). The gripping portion 211, the pair of winding portions 212, and the spacing changing means 213 are provided on the lower side of the base 210, and the drive shaft 214 is provided on the upper side of the base 210 (see Figure 4).

[0072] The pair of winding sections 212 are shaped such that the outer circumference of each winding section 212 is curved in an arc shape so that the parallel wires 100 form an oval shape (see Figure 5). The spacing changing means 213 can remove the parallel wires 100 from the pair of winding sections 212 by narrowing the distance between them after the winding is complete. The spacing changing means 213 can be any known ball screw shaft or the like, and its form is not limited.

[0073] The nozzle 202 pulls the coil wires 104, which have been drawn out from multiple bobbins, into the nozzle through a row of vertically aligned holes, forming a line of parallel wires 100 (see Figure 4). The ends of the parallel wires 100 extending from the nozzle 202 are pre-treated to form stranded wires 101 by an end processing means. The articulated arm 203 can be any known industrial articulated robot.

[0074] Here, referring to the process diagrams shown in Figures 6 and 7, we will explain the winding process of the parallel wire 100 (Figures 6(A) to 6(D)), the end processing process of the parallel wire (Figures 7(E) and 7(F)), and the transfer process of handing over the coil bundle formed by winding the parallel wire to the coil insertion machine (Figures 7(G) and 7(H)). Note that in each process diagram, the ball screw shaft and rail forming the first and second moving means have been omitted for ease of understanding.

[0075] First, the articulated arm 203 is activated to move the nozzle 202 closer to the gripping portion 211 that forms the winding frame 201, and the tip of the parallel wire 100 is gripped by the gripping portion 211 (Figure 6(A)). The nozzle 202 is moved in the first horizontal axis direction so that the parallel wire 100 drawn out from the nozzle 202 is aligned along the side of the pair of winding portions 212 (see arrow in Figure 6(B)).

[0076] From this state, the reel 201 is rotated along the horizontal plane, and the nozzle 202 is lowered, spirally winding the parallel wires 100 supplied from the nozzle onto the pair of winding sections 212 to form a coil bundle 105 (see Figure 6(C)). The reel 201 is rotated n.5 turns (where n is an integer) so that the stranded wires 101 at both ends of the coil bundle 105 are outside the blade shaft 302 that forms the coil insertion machine 300, as shown by the dashed line (see Figure 7(G)).

[0077] Once the winding of the parallel wire 100 is complete, the articulated arm 203 moves the nozzle 202 along the first horizontal axis direction, positioning the parallel wire 100 below the four slits 21, 22, 23, and 24 provided in the mechanism 10, and the process moves on to the end processing step (see Figure 6(D)).

[0078] In the end processing step, first, the second moving means 80 lowers the four slits 21, 22, 23, and 24 toward the parallel wire 100, so that the parallel wire 100 is clamped by the slits (see Figure 7(E)). If the length of the lead wire needs to be adjusted, at this stage the first moving means 70 moves the positions of the four slits along the direction in which the parallel wire 100 extends.

[0079] After adjusting the positions of the four slits 21, 22, 23, and 24 to match the length of the lead wire, the pair of discs 30, 30 are rotated in synchronous motion to create stranded wire 101 between the first slit 21 and the second slit 22, and between the third slit 23 and the fourth slit 24 (see Figures 7(F) and 7(G)).

[0080] Subsequently, the cutting means 60 cuts between the second slit 22 and the third slit 23. After the parallel lines are cut, the second moving means 80 raises the four slits 21, 22, 23, and 24, removing the parallel lines 100 from the slits (see Figure 7(G)).

[0081] In the coil bundle transfer process, the coil insertion machine 300 is first raised by the lifting shaft 301 to align the tip position of the blade shaft 302 that makes up the coil insertion machine with the lower end position of the coil bundle 105 wound around the winding frame 201 (see Figure 7(G)). Subsequently, the spacing changing means 213 narrows the spacing between the pair of winding sections 212 to loosen the tension of the coil bundle 105.

[0082] As the tension of the coil bundle 105 is released, the coil bundle slides from the pair of winding sections 212 to the coil insertion machine 300 and is hooked onto the blade shaft 302 (see Figure 7(H)). Once the coil bundle is transferred, the coil insertion machine 300 is lowered by the lifting shaft 301. The steps shown in Figures 6(A) to 7(H) are repeated for the number of coil bundles to be inserted into the stator core simultaneously, completing the series of steps.

[0083] In Embodiment 2, the end processing means 2 will be described with reference to Figure 8. Figure 8 shows the end processing means 2, which includes two servo motors that rotate the disc on which the second slit and the third slit are formed, respectively, as a synchronous drive means. In Embodiment 2, components identical to those in Embodiment 1 are denoted by the same reference numerals and their descriptions are omitted.

[0084] The end processing means 2 includes a synchronous drive means 40 which comprises two servo motors 41, 41 and a control means 47 which synchronizes the two servo motors (see Figure 8). The rotational motion generated by each servo motor 41 is transmitted by a transmission means 50 arranged on the outer circumference of each disc 30, 30. The two servo motors are motors of the same performance.

[0085] The control means 47 electrically connects a known PLC or microcontroller to the servo motor 41 and inputs the same electrical signal to the two servo motors 41, 41 so that the rotation direction and rotation speed of the two servo motors are synchronized at the start and end of their operation.

[0086] In Embodiment 3, the end treatment means 3 will be described with reference to Figure 9. Figure 9 shows the end treatment means 3 in which a pair of discs are integrated. In Embodiment 3, the same components as in Embodiment 1 are denoted by the same reference numerals and their description is omitted. In the end treatment means 3, a pair of discs 32, 32 are integrated by a connecting shaft 33 that connects their opposing end faces, so that they rotate synchronously. The connecting shaft 33 is provided on the upper edge of the discs 32.

[0087] The synchronous drive means 40 includes two servo motors 41, 41 and a control means 47 for synchronously controlling the servo motors 41. The transmission means 53 consists of two rubber rollers 54, 54 that contact the outer circumference of at least one of the discs and are rotated synchronously by the servo motors 41. In this case, a disc gear does not need to be provided on the outer circumference of the disc 32. Of course, the number of rubber rollers and servo motors is not limited.

[0088] The leading end of the cutting means 60 is set wider than the orbital path of the connecting shaft 33 so that it does not come into contact with the connecting shaft 33, which rotates around the central axis of the disc 32, except when cutting parallel lines 100. In addition, the scissors 61 that make up the cutting means have their cutting blades opened and closed by air cylinders 62, 62 so that the leading end can be set wide open.

[0089] When cutting the parallel wires 100, the rotation of the pair of discs 32, 32 should be stopped when they reach the opposite side of the cutting means 60, so that the connecting shaft 33 does not come into contact with the leading edge of the scissors 61, and the leading edges of the scissors should be closed to cut. Specifically, when the connecting shaft reaches the lowest position of the circular orbit, the rotation of the discs 32 should be stopped to cut the parallel wires 100. After cutting the parallel wires 100, when removing the parallel wires 100 from the slits, the discs 32 should be rotated another half turn so that the open ends of the second slit 22 and the third slit 23 face downwards, and the parallel wires should be pulled out.

[0090] (Other) ・In the above-described embodiments, examples were given in which the transmission means were gears or rubber rollers, but the transmission means are not limited to these, and a non-contact transmission mechanism that transmits rotational motion to a pair of discs by magnetic force may also be used. ・In Embodiment 1, the movement by the first moving means and the second moving means are separated, but of course, the respective movement directions of the first moving means and the second moving means may be combined to move in an oblique direction. ・In Embodiment 1, all slits are moved by the first moving means, but of course, only some of the slits may be moved. ・The embodiments disclosed herein should be considered in all respects to be illustrative and not restrictive. The technical scope of the present invention is indicated by the claims and is not limited to the above-described description, and all modifications in the sense and scope equivalent to the claims are intended to be included.

[0091] 1, 2, 3... End processing means, 100... Parallel wire, 101... Stranded wire, 10... Mechanism, 20... Clamping means, 30... Disc, 40... Synchronous driving means, 50... Transmission means, 60... Cutting means, 70... First moving means, 80... Second moving means, 21... First slit, 22... Second slit, 23... Third slit, 24... Fourth slit, 25... Guide part, 26... Curved tip part, 31... Disc gear, 32... Disc, 33... Connecting shaft, 41... Servo motor, 42... First timing pulley, 43... Second timing pulley, 44... Timing belt, 45... Shaft, 46... Gear, 47... Control means, 51... First rotational transmission gear, 52... Second rotational transmission gear, 53... Transmission means, 54... Rubber roller, 61... Scissors, 62... Air cylinder, 71...First slide plate, 72...First ball screw shaft, 73...First drive motor, 74...First rail, 81...Second slide plate, 82...Second ball screw shaft, 83...Second drive motor, 84...Second rail, 85...Legs, 102, 103...Parallel wires, 104...Coil wire group, 105...Coil bundle, 200...Winding device, 201...Winding frame, 202...Nozzle, 203...Multi-joint arm, 210...Base, 211...Gripping part, 212...Winding part, 213...Spacing changing means, 214...Drive shaft, 300...Coil insertion machine, 301...Lifting shaft, 302...Blade shaft

Claims

1. An end processing means for twisting the ends of parallel wires formed by a coil, comprising: a clamping means for clamping the parallel wires; a pair of discs; a synchronous driving means; a transmission means; and a cutting means, wherein the clamping means is a slit consisting of a first slit, a second slit, a third slit, and a fourth slit, the slits clamp the parallel wires extending from it; the first slit and the fourth slit clamp and hold the parallel wires; the second slit and the third slit are positioned between the first slit and the fourth slit and are slits that cross the center of each disc and extend to the outer edge; the synchronous driving means rotates the pair of discs in a synchronous manner; and the transmission means is positioned on the outer circumference of each disc and transmits the rotational motion so that the parallel wires clamped in the second slit and the third slit rotate around the central axis of the parallel wires. An end processing means characterized in that the parallel lines remain aligned outward from the first slit, between the second and third slits, and outward from the fourth slit, the parallel lines are twisted together between the first and second slits, and between the third and fourth slits, and the cutting means is positioned between the second and third slits and cuts the parallel lines, so that the twisted lines on both sides that have been cut become the ends of the parallel lines.

2. The end processing means according to claim 1, characterized in that each of the slits forming the clamping means is arranged in a straight line, and the centerlines of the parallel lines extend in a straight line.

3. The end processing means according to claim 1, wherein the transmission means comprises a disc gear formed on the outer circumference of each of the discs forming the second slit and the third slit, a plurality of first rotational transmission gears meshing with each of the disc gears, and a plurality of second rotational transmission gears meshing with each adjacent first rotational transmission gear, wherein each first rotational transmission gear is distributed around the disc gear, and at least one second rotational transmission gear that meshes with adjacent first rotational transmission gears is omitted, the outer diameter portion of the omitted second rotational transmission gear is an insertion portion of the parallel line into the slit, and the first rotational transmission gears and the second rotational transmission gears transmit the rotational motion generated by the synchronous drive means to rotate the pair of discs in a synchronous manner.

4. The end processing means according to any one of claims 1 to 3, further comprising a first moving means, the first moving means enabling the position of each slit to be changed along the direction in which the parallel lines extend.

5. The end processing means according to any one of claims 1 to 3, further comprising a second moving means, the second moving means enabling the position of each slit to be changed in the same direction in any direction intersecting the direction in which the parallel lines extend.

6. A winding device for manufacturing a coil bundle formed of parallel wires, which is wound onto a winding frame and inserted into a stator core, characterized in that it comprises the end processing means described in any one of claims 1 to 3.

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