Method for manufacturing coil

Abstract

This method for manufacturing a coil involves, using a tool (91) for deforming a conductor (W), winding the conductor (W) to form a first coil (C1), forming a crossover wire (C12) between a winding end part (C1b) of the first coil (C1) and a winding start end part (C2a) of a second coil (C2) to be formed next, deforming the crossover wire (C12) so that the first coil (C1) retracts to at least a region (AR2) where the first coil (C1) does not interfere with the tool (91) when forming the second coil (C2), and winding the conductor (W) to form the second coil (C2) after deforming the crossover wire (C12).

Description

Method for manufacturing a coil

[0001] The present disclosure relates to a method for manufacturing a coil.

[0002] Patent Document 1 describes an axial motor using a rectangular wire coil. In this axial motor, a plurality of rectangular wire coils are arranged around a rotation axis, and the respective winding start terminal portions and winding end terminal portions are electrically connected to a substrate.

[0003] Patent Document 2 describes a spring forming machine that continuously forms coil springs from wire rods. This spring forming machine includes a base plate and a quill protruding from the center of the base plate, and feeds a wire rod from a wire feed hole at the axial center of the quill into a processing space which is a front space of the base plate in a direction orthogonal to the base plate for supply. In the processing space, a plurality of linear tool drive mechanisms each mounted with a processing tool are radially arranged to be able to approach and separate from the wire rod, and arbitrary forming such as coil forming is performed on the wire rod supplied into the processing space by an arbitrary processing tool.

[0004] Japanese Patent Application Laid-Open No. Hei 7-067307, Japanese Patent Application Laid-Open No. 2014-161884

[0005] In applications where a plurality of coils are connected and used as described in Patent Document 1, a connecting member such as a substrate or a crossover wire that electrically connects each of the plurality of coils is required. Therefore, an improvement that can reduce the number of parts and manufacturing man-hours to manufacture a plurality of connected coils is desired.

[0006] A first aspect of one or more embodiments is a method for manufacturing a coil, comprising: using a tool that deforms a conductor, winding the conductor to form a first coil, forming a crossover wire between a winding end portion of the first coil and a winding start portion of a second coil to be formed next, deforming the crossover wire such that the first coil retracts to a region that does not interfere with at least the tool when forming the second coil, and winding the conductor to form the second coil after deforming the crossover wire.

[0007] A second aspect of one or more embodiments is a method for manufacturing a coil, comprising using a tool to deform a conductor, winding the conductor to form a k-th coil (where k is a positive integer), forming a connecting wire between the end of the winding of the k-th coil and the beginning of the winding of the (k+1)th coil to be formed next, deforming the connecting wire so that when forming the (k+1)th coil, the k coils already formed are moved to an area where they do not interfere with the tool, and after deforming the connecting wire, winding the conductor to form the (k+1)th coil.

[0008] According to the coil manufacturing method of one or more embodiments, the effect is obtained that multiple connected coils can be manufactured while reducing the number of parts and connection work.

[0009] Figure 1A is a front view showing a forming apparatus S used in a method for manufacturing a flat wire coil according to one or more embodiments of the present disclosure. Figure 1B is a top view showing the processing space V of the forming apparatus S. Figure 2 is a first step diagram illustrating a first aspect of a method for manufacturing a flat wire coil according to one or more embodiments of the present disclosure. Figure 3 is a second step diagram illustrating a first aspect. Figure 4 is a third step diagram illustrating a first aspect. Figure 5 is a fourth step diagram illustrating a first aspect. Figure 6 is a fifth step diagram illustrating a first aspect. Figure 7 is a sixth step diagram illustrating a first aspect. Figure 8 is a seventh step diagram illustrating a first aspect. Figure 9 is an eighth step diagram illustrating a first aspect. Figure 10 is a ninth step diagram illustrating a first aspect. Figure 11 is a tenth step diagram illustrating a first aspect. Figure 12 is an eleventh step diagram illustrating a first aspect. Figure 13 is a twelfth step diagram illustrating a first aspect. Figure 14 is a diagram of the 13th step illustrating the first embodiment. Figure 15 is a diagram of the 14th step illustrating the first embodiment. Figure 16 is a diagram of the 15th step illustrating the first embodiment. Figure 17 is a diagram of the 16th step illustrating the first embodiment. Figure 18 is a diagram of the 17th step illustrating the first embodiment. Figure 19 is a diagram of the 18th step illustrating the first embodiment. Figure 20 is a diagram of the 19th step illustrating the first embodiment. Figure 21 is a diagram of the 20th step illustrating the first embodiment. Figure 22 is a perspective view of a coil product CP manufactured in the first embodiment. Figure 21 is a diagram of the 21st step illustrating a second embodiment of the method for manufacturing a flat wire coil in one or more embodiments of the present disclosure. Figure 24 is a diagram of the 22nd step illustrating the second embodiment. Figure 25 is a diagram of the 23rd step illustrating the second embodiment. Figure 26 is a diagram of the 24th step illustrating the second embodiment. Figure 27 is a diagram of the 25th step illustrating the second embodiment. Figure 28 is a diagram of the 26th step illustrating the second embodiment. Figure 29 is a diagram of the 27th step illustrating the second embodiment. Figure 30 is a diagram of the 28th step illustrating the second embodiment. Figure 31 is a diagram of the 29th step illustrating the second embodiment. Figure 32 is a diagram of the 30th step illustrating the second embodiment.Figure 33 is a 31st step diagram illustrating a second embodiment. Figure 34A is a top view illustrating a common step in the first and second embodiments of the method for manufacturing a flat wire coil in one or more embodiments of the present disclosure. Figure 34B is a front view illustrating a common step in the first and second embodiments of the method for manufacturing a flat wire coil in one or more embodiments of the present disclosure. Figure 35A is a top view illustrating a step unique to the first embodiment after the common step shown in Figure 34A. Figure 35B is a front view illustrating a step unique to the first embodiment after the common step shown in Figure 34B. Figure 36A is a top view illustrating a step unique to the second embodiment after the common step shown in Figure 34A. Figure 36B is a front view illustrating a step unique to the second embodiment after the common step shown in Figure 34B.

[0010] (Forming device S) A method for manufacturing a coil according to one or more embodiments of the present disclosure involves manufacturing a coil using a forming device S. This forming device S will be described with reference to Figures 1A and 1B.

[0011] Figure 1A is a front view showing a forming apparatus S used in a coil manufacturing method of one or more embodiments of the present disclosure. Figure 1B is a top view showing the processing space V of the forming apparatus S. For convenience of explanation, the up, down, left, right, front, and back directions are denoted as U, D, L, R, F, and B respectively, and are defined by arrows in Figures 1A and 1B. These directions correspond to the general installation state of the forming apparatus S.

[0012] The forming apparatus S is a device for manufacturing wire components such as coil springs, and comprises a base plate S2, a wire supply unit Q, a first tool mounting unit 1 to a ninth tool mounting unit 9, and a control unit E. The first tool mounting unit 1 to the ninth tool mounting unit can each mount interchangeable tools, and in the first embodiment, some of them are equipped with tools for deforming conductors W for use in manufacturing flat wire coils.

[0013] The base plate S2 is an upright plate extending in the vertical, horizontal, and vertical directions, with a wire supply unit Q located in the center. The wire supply unit Q has a quill Q1 that supplies wire to the processing space V, which is the space in front of the base plate S2. In this example, the wire that will become the conductor W of the coil is a rectangular wire W, and the quill Q1 supplies the rectangular wire W forward along a supply axis CL that extends horizontally in the front-rear direction. At the rear of the base plate S2, a straightening machine (not shown) or the like is arranged to correct any twisting or distortion of the supplied rectangular wire W. The wire supply unit Q is equipped with a rotation mechanism (not shown) that allows the quill Q1 to rotate about the supply axis CL. That is, the rectangular wire W is supplied to the processing space V in a position rotated around the supply axis CL according to the rotational position of the quill Q1. The control unit E controls the operation of the entire forming apparatus S, including the wire supply operation, the wire supply operation and rotation operation of the quill Q1, and the operation of the first tool mounting section 1 to the ninth tool mounting section 9, based on a coil manufacturing program stored in the control unit E in advance.

[0014] As shown in Figure 1A, the first to eighth tool mounting sections 1 to 8 are arranged roughly radially around the supply axis CL, and each can move independently away from and approach the supply axis CL. The second to fifth tool mounting sections 2 to 5 are located to the left of the supply axis CL, while the first tool mounting section 1 and the sixth to eighth tool mounting sections 6 to 8 are located to the right of the supply axis CL. The first to eighth tool mounting sections 1 to 8 are each independently movable in the forward / backward and up / down directions. Below the supply axis CL, the ninth tool mounting section is arranged to be movable in the forward / backward, left / right, up / down directions. The movement and operation of the first to nineth tool mounting sections 1 to 9 are controlled by the control unit E so as not to interfere with each other.

[0015] (First Embodiment) Next, a method for manufacturing a coil according to the first embodiment using a forming device S will be described with reference to Figures 2 to 22. Figures 2 to 21 are diagrams of the first to 20 steps for illustrating the first embodiment of the method for manufacturing a coil according to one or more embodiments of the present disclosure. Figure 22 is a perspective view of a coil product CP manufactured according to the first embodiment.

[0016] (Tools used in the first embodiment) The tool mounting section and the tools mounted on the forming device S used in the coil manufacturing method of the first embodiment are as follows: First tool mounting section 1: Cutting tool 11 Third tool mounting section 3: Left pressing tool 31 Fourth tool mounting section 4: Left clamping tool 41 Sixth tool mounting section 6: Right pressing tool 61 Seventh tool mounting section 7: Right clamping tool 71 Ninth tool mounting section 9: Edgewise tool 91

[0017] The cutting tool 11 is a tool for cutting the rectangular wire W. The left clamping tool 31 is a tool that contacts the rectangular wire W from the left side to restrict its movement to the left. The right clamping tool 61 is a tool that contacts the rectangular wire W from the right side to restrict its movement to the right. The left clamping tool 41 is a tool that clamps the rectangular wire W from the left side in the thickness direction. The right clamping tool 71 is a tool that clamps the rectangular wire W from the right side in the thickness direction. The edgewise tool 91 has a rotatable twin-pin section 91a equipped with a pair of protruding pins, and is a tool that bends the rectangular wire W edgewise by rotating the twin-pin section 91a with the rectangular wire W passing between the pair of protruding pins. Unless otherwise noted, the operations described below are performed under the control of the control unit E.

[0018] First, as shown in Figures 2 and 3, the rectangular wire W is supplied from the quill Q1 to the processing space V in front. The rectangular wire W is held down from the left and right by the left-hand pressing tool 31 and the right-hand pressing tool 61, respectively, restricting its movement up, down, left, and right. In this state, while the rectangular wire W is fed forward from the wire supply unit Q, the rectangular wire W is passed between the pair of protruding pins of the rotating twin-pin section 91a of the edgewise tool 91, and the rotating twin-pin section 91a is rotated at a predetermined feeding position to perform edgewise bending, thereby winding it into a predetermined coil shape with no gaps in the thickness direction. As a result, as shown in Figure 4, the starting end C1a is positioned at the top, and a first coil C1 is formed with a predetermined number of turns and shape.

[0019] Hereinafter, the end of the first coil C1 that marks the start of winding will be referred to as the winding start end C1a, and the end that marks the end of winding will be referred to as the winding end C1b. The first coil C1 has a roughly triangular shape in plan view, having a narrow section C1c and a wide section C1d, and the winding start end C1a extends linearly from one side (the left side in Figure 4) of the roughly triangular wide section C1d. Furthermore, for the first coil C1, the coil axis CL1 is set as a virtual axis perpendicular to the winding plane of the coil at the center positions of the long and short sides of its roughly triangular shape. The same applies to the second coil C2 and third coil C3, which will be described later, regarding the winding start end, winding end, coil shape, and coil axis. In the following description, the first coil C1 to the third coil C3 may be simply referred to as coils C1 to C3, respectively.

[0020] Next, as shown in Figures 5 and 6, the rectangular wire W is fed out while restricting its movement in the left-right direction by gripping the portion immediately extending from the quill Q1 with the left-holding tool 31 and the right-holding tool 61, and the edgewise tool 91 forms a U-shape extending in the horizontal plane to form the first connecting wire C12. The horizontal plane is a surface that extends in the left-right and front-back directions. Figure 5 shows the state in which the corner of the first connecting wire C12 on the side closer to the first coil C1 is being formed, and Figure 6 shows the state in which the corner of the first connecting wire C12 on the side further from the first coil C1 is being formed. In Figure 6, the winding end C1b of the first coil C1 extends from the left side of the wide portion C1d of the first coil C1, so the formation of the U-shaped first connecting wire C12 causes the first coil C1 to be in a position where the wide portion C1d is facing forward.

[0021] Once the first connecting wire C12 is formed, the left clamping tool 31, the right clamping tool 61, and the edgewise tool 91 are retracted from the machining space V, and the quill Q1 is rotated 180° as shown in Figure 7 (see arrow DR1). As a result, the first coil C1 rotates 180° around the supply axis CL, moving from the right side to the left side relative to the supply axis CL, and also inverts vertically, so that the winding end C1b is at the top. In this position, the corner on the first coil C1 side and the other corner of the pair of corners of the U-shaped first connecting wire C12 become clamping points P1 and P2, respectively, which will be clamped by the left clamping tool 41 and the right clamping tool 71 in the next step.

[0022] After clamping clamp portion P1 with the left clamping tool 41 and clamping clamp portion P2 with the right clamping tool 71, as shown in Figure 8, the right clamping tool 71 maintains its position, while the left clamping tool 41 is rotated approximately 90° clockwise when viewed to the left (see arrow DR2). As a result, the first connecting wire C12 is twisted to form a twisted portion Ct1, and the first coil C1 is in an upright position of approximately 90° with the narrow portion C1c on top and the wide portion C1d on the bottom (hereinafter referred to as the twisted upright position).

[0023] The vertical position of a coil in a twisted upright position is outside (above) the vertical region (coil formation height region) where the coil is formed (retraction region). In other words, a formed coil is placed in a twisted upright position, and that formed coil is retracted outside the formation region of the coil to be formed.

[0024] Once the first coil C1 is twisted into an upright position, the flat wire W extending from the quill Q1 is again held down by the left-holding tool 31 and the right-holding tool 61 to restrict its movement in the left-right direction, as shown in Figures 9 and 10. Then, while feeding the flat wire W from the quill Q1, the edgewise tool 91 is used to wind and form the second coil C2, with the portion of the first connecting wire C12 opposite to the first coil C1 as the starting end C2a, in the same manner as the first coil C1, with a predetermined number of turns.

[0025] At this time, the first coil C1 is in a twisted upright position, retracted into a retraction space Vt, which is an upper space that does not interfere with the left pressing tool 31, the right pressing tool 61, and the edgewise tool 91 that are moving towards the rectangular wire W, so no problems occur in the winding formation of the second coil C2. As shown in Figure 10, with the second coil C2 formed, the connection point of the first connecting wire C12 with the winding end C1b of the first coil C1 and the connection point with the winding start end C2a of the second coil C2 become clamping points P3 and P4, respectively, which will be clamped by the right clamping tool 71 and the left clamping tool 41 in the next step.

[0026] Next, as shown in Figure 11, clamp portion P4 is clamped with the left clamping tool 41, and clamp portion P3 is clamped with the right clamping tool 71. Then, the left clamping tool 41 maintains its clamped position, and the right clamping tool 71 is rotated approximately 90° clockwise in a leftward view to release the twist of the twisted portion Ct1, i.e., to untwist it (see arrow DR3). As a result, the first coil C1 and the second coil C2 are in a position where their respective first coil axis CL1 and second coil axis CL2 extend parallel in the vertical direction, and as shown in Figure 12, while feeding the flat wire W from the quill Q1 in this position, edgewise bending is performed with the edgewise tool 91 to form a roughly U-shaped second connecting wire C23.

[0027] In this second connecting wire C23, the corner on the connection side with the winding end C2b of the second coil C2 and the corner on the quill Q1 side become clamped portions P5 and P6, respectively, which are clamped by the left clamping tool 41 and the right clamping tool 71 in the next step.

[0028] As shown in Figure 13, clamp portion P5 with the left clamping tool 41 and clamp portion P6 with the right clamping tool 71. Then, as shown in Figure 14, the right clamping tool 71 maintains its position, and the left clamping tool 41 is rotated approximately 90° counterclockwise in a leftward view (see arrow DR4). As a result, the second connecting wire C23 is twisted, and a twisted portion Ct2 is formed.

[0029] Here, when the first coil C1 and the second coil C2 are combined to form a coil body CT12, a twisted portion Ct2 is formed, so that the coil body CT12 is tilted downwards by approximately 90°, with the narrow portions C1c and C2c facing downwards and the wide portions C1d and C2d facing upwards (hereinafter referred to as the twisted tilted position).

[0030] Next, the left clamping tool 41 and the right clamping tool 71 release the clamp on the rectangular wire W and move them out of the machining space V (see Figure 14: dashed arrow DR41). Then, as shown in Figure 15, the quill Q1 is rotated 180° clockwise in a forward view (see arrow DR5), and the coil body CT12 is twisted upright with the narrow sections C1c and C2c facing upward. Next, as shown in Figure 16, the third coil C3 is formed between the second connecting wire C23 and the quill Q1 by feeding the rectangular wire W from the quill Q1, restricting the position of the rectangular wire W in the up, down, left, and right directions by the left pressing tool 31 and the right pressing tool 61, and by the operation of the edgewise tool 91.

[0031] At this time, the vertical position of the coil body CT12 is in a twisted upright position, retracted into the retraction space Vt, which is the space above that does not interfere with the left pressing tool 31, the right pressing tool 61, and the edgewise tool 91 that are close to the rectangular wire W. Therefore, no problems occur in winding the third coil C3.

[0032] Once the third coil C3 is formed, the left clamping tool 31, the right clamping tool 61, and the edgewise tool 91 are retracted from the machining space V, and the quill Q1 is rotated 180° as shown in Figure 17 (see arrow DR6). As a result, the coil body CT12 and the third coil C3 are rotated 180° around the supply axis CL. As a result, the coil body CT12 moves from the right side to the left side with respect to the supply axis CL and is inverted vertically, taking on a twisted and tilted position with the narrow sections C1c and C2c facing downwards, and the winding end C3b of the third coil C3 is positioned at the top. In this position, the ends of the second connecting wire C23, the end on the coil body CT12 side and the end on the third coil C3 side, become clamped portions P7 and P8, respectively, which will be clamped by the left clamping tool 41 and the right clamping tool 71 in the next step.

[0033] Next, as shown in Figure 18, clamp portion P7 is clamped with the left clamping tool 41, and clamp portion P8 is clamped with the right clamping tool 71. Then, as shown in Figure 19, the right clamping tool 71 maintains its position, and the left clamping tool 41 is rotated approximately 90° clockwise in a leftward view (see arrow DR7). As a result, the twisted portion Ct2 of the second connecting wire C23 is untwisted and the twist is eliminated. The coil body CT12 and the third coil C3 are then positioned so that the first coil axis CL1 to the third coil axis CL3 extend parallel to each other vertically.

[0034] Next, as shown in Figure 20, the quill Q1 is rotated 180° (see arrow DR8) to change its orientation so that the winding end C3b of the third coil C3 is at the bottom of the third coil C3. Then, while restricting the lateral movement of the rectangular wire W with a left-holding tool 31 and a right-holding tool 61 (not shown), the shape of the third coil C3 is adjusted with the edgewise tool 91 so that the winding end C3b extends from the wide section C3d side (see Figure 21).

[0035] Next, the cutting position P9 is cut with the cutting tool 11 set on the first tool mounting section 1 so that the winding end C3b in Figure 21 is of a predetermined length, thereby obtaining a three-coil product CP1 in which the first coil C1 to the third coil C3 shown in Figure 22 are connected in series.

[0036] As described above, the first embodiment is a manufacturing method for forming (k+1) multi-coils, where k is a positive integer, and includes a step of twisting the connecting wire between the (k+1)th coil and the kth coil to move the k already formed coils into a retraction area, which is a non-interference area, so that the k already formed coils do not interfere with the tools of the forming device S when forming the next (k+1) coil. The coil manufacturing method of this first embodiment includes a twist-back step in which, after forming the (k+1)th coil, the twist-back step is performed to return the k retracted coils to their position before twisting.

[0037] (Second Embodiment) Next, a second embodiment of a coil manufacturing method using a forming device S will be described with reference to Figures 23 to 33. Figures 23 to 33 are diagrams of steps 21 to 31 for illustrating the second embodiment.

[0038] (Tools used in the second embodiment) The tool mounting section of the forming apparatus S used in the coil manufacturing method of the second embodiment and the tools mounted thereon are as follows: First tool mounting section 1: Cutting tool 12 Fourth tool mounting section 4: Flatwise tool 42 Sixth tool mounting section 6: Pressing tool 62 Ninth tool mounting section 9: Edgewise tool 92

[0039] The cutting tool 12 is a tool for cutting the rectangular wire W. The flatwise tool 42 is a tool for flatwise bending the rectangular wire W. The bending press tool 62 is a press tool that restricts the movement of the rectangular wire W, excluding the feeding, during flatwise bending by the flatwise tool 42. The edgewise tool 92 is a tool that edgewise bends the rectangular wire W, similar to the edgewise tool 91. Figures 23 to 33 are top views, and since the operation of each tool is the same as in the first embodiment, the drawing is omitted for ease of understanding. The operation of the forming device S is performed under the control of the control unit E, as in the first embodiment.

[0040] First, as shown in Figure 23, a rectangular wire W is supplied from the quill Q1 to the processing space V in front. While the rectangular wire W is fed forward from the wire supply unit Q, its movement in the up, down, left, and right directions is restricted by the clamping tool 62. A predetermined portion of the fed-out rectangular wire W is gripped by the rotating twin pin portion of the edgewise tool 92 and rotated to wind it into a predetermined coil shape. This forms a first coil C1 with a predetermined number of turns wound downwards, with the winding start end C1a at the top (towards the viewer). Hereinafter, as in the first embodiment, the end that marks the beginning of winding of the first coil C1 will be referred to as the winding start end C1a, and the end that marks the end of winding will be referred to as the winding end end C1b. The first coil C1 has a roughly triangular shape in plan view, having a narrow part C1c and a wide part C1d, and the winding start end C1a extends linearly from one side (the left side in Figure 23) of the roughly triangular narrow part C1c. The same applies to the second coil C2 and the third coil C3, which will be described later.

[0041] Furthermore, for the first coil C1, the coil axis CL1 is set as a virtual axis perpendicular to the winding plane of the coil at the center of its roughly triangular longitudinal and transverse sides. The same applies to the coil axes CL2 and CL3 of the second coil C2 and third coil C3, which will be described below.

[0042] Once the first coil C1 is formed, as shown in Figure 24, while feeding the rectangular wire W from the quill Q1, the first connecting wire C12, which connects to the winding end C1b, is formed using the edgewise tool 92, while restricting the movement of the rectangular wire W in the up, down, left, and right directions with the pressing tool 62.

[0043] Once the first connecting wire C12 is formed, the quill Q1 is rotated 180° as shown in Figure 25 (see arrow DR15). This moves the first coil C1 to the left with respect to the supply axis CL, so that the winding end C1b is at its highest point (towards the front of the page).

[0044] Next, the rectangular wire W is fed from the quill Q1 while the movement in the vertical and horizontal directions is regulated by the pressing tool 62, and as shown in FIG. 26, the flatwise tool 42 performs flatwise bending on the first crossover wire C12 so that the first coil C1 rises (see arrow DR16). Accordingly, the attitude of the first coil C1 is changed such that the first coil axis CL1, which extended in the vertical direction before the flatwise bending, is now oriented in the horizontal direction. A bent portion Ct3 formed by flatwise bending is formed in the first crossover wire C12.

[0045] After this attitude change, the second coil C2 is wound and formed by the pressing tool 62 and the edgewise tool 92 (see FIG. 27). At this time, the first coil C1 is in a bent upright attitude retracted to the retraction space Vt, which is an upper space that does not interfere with the pressing tool 62 and the edgewise tool 92, so no malfunction occurs in the winding formation of the second coil C2.

[0046] After the second coil C2 is formed, while the movement of the rectangular wire W fed from the quill Q1 in the vertical and horizontal directions is regulated by the pressing tool 62, the flatwise tool 42 unbends the bent portion Ct3 so as to eliminate the bending as shown in FIG. 28 (see arrow DR17). Accordingly, the coil body CT12 composed of the first coil C1 and the second coil C2 is in an attitude where the respective coil axes, the first coil axis CL1 and the second coil axis CL2, are parallel to each other and extend in the vertical direction (perpendicular to the paper plane).

[0047] Next, using the pressing tool 62 and the edgewise tool 92, as shown in FIG. 29, the second crossover wire C23 connected to the winding end C2b of the second coil C2 is formed. After the second crossover wire C23 is formed, as shown in FIG. 30, the quill Q1 is rotated 180° to move the coil body CT12 to the area on the left side of the supply axis CL (see arrow DR19). Accordingly, the attitude of the second coil C2 is changed such that the winding end C2b is located at the top (front side of the paper plane).

[0048] Next, while restricting the movement of the rectangular wire W in the up-down, left-right directions by the pressing tool 62, the second crossover C23 is subjected to flat-wise bending by the flat-wise tool 42 as shown in Fig. 31, so that the coil body CT12 is raised upward (toward the front of the drawing) (see arrow DR20). As a result, the posture of the coil body CT12 is changed such that the first coil axis CL1 and the second coil axis CL2, which extended in the up-down direction before the flat-wise bending, are oriented in the left-right direction. A bent portion Ct4 formed by flat-wise bending is formed on the second crossover C23.

[0049] After this posture change, the third coil C3 is wound and formed between the second crossover C23 and the quill Q1 by the pressing tool 62 and the edge-wise tool 92 as shown in Fig. 32. At this time, the coil body CT12 is in a bent standing posture retracted to the upper retraction space Vt that does not interfere with the pressing tool 62 and the edge-wise tool 92, so no malfunction occurs in the winding formation of the third coil C3.

[0050] After the third coil C3 is formed, while restricting the movement of the rectangular wire W fed from the quill Q1 in the up-down, left-right directions by the pressing tool 62, the flat-wise tool 42 bends back the wire to eliminate the bending of the bent portion Ct4 as shown in Fig. 33 (see arrow DR21). As a result, the coil body CT12 and the third coil C3 adopt a posture in which the first coil axis CL1, the second coil axis CL2, and the third coil axis CL3 are parallel and extend in the up-down direction (the direction orthogonal to the drawing surface).

[0051] Next, the cutting position P10 is cut by the cutting tool 12 mounted on the first tool mounting portion 1 such that the winding end portion C3b shown in Fig. 33 has a predetermined length. Thereby, a triple-series coil product CP2 in which the first coil C1 to the third coil C3 are connected in series is obtained.

[0052] As described above, the second embodiment is a manufacturing method for forming (k+1) multi-coils, where k is a positive integer, and includes a step of bending the connecting wire between the (k+1)th coil C(k+1) and the kth coil Ck to move the k already formed coils into a retraction area, which is a non-interference area, so that the k already formed coils do not interfere with the tools of the forming device S when forming the (k+1)th coil C(k+1). The coil manufacturing method of this second embodiment includes a bending back step after forming the (k+1)th coil C(k+1), which is performed by bending back to return the k retracted coils to their position before bending.

[0053] Figures 34A, 34B, 35A, 35B, and 36A, 36B are schematic diagrams illustrating the torsion and bending of the first and second embodiments described above. Figures 34A and 34B are schematic diagrams showing the state in which the k-th coil has been formed in the first and second embodiments of the coil manufacturing method of one or more embodiments of the present disclosure, with Figure 34A being a top view and Figure 34B being a front view. Figures 35A and 35B are schematic diagrams illustrating the steps unique to the first embodiment after the common steps shown in Figures 34A and 34B, with Figure 35A being a top view and Figure 35B being a front view. Figures 36A and 36B are schematic diagrams illustrating the steps unique to the second embodiment after the common steps shown in Figures 34A and 34B, with Figure 36A being a top view and Figure 36B being a front view.

[0054] As shown in Figures 34A and 34B, when forming the k-th coil Ck and then the (k+1)th coil C(k+1), if the (k+1)th coil C(k+1) is wound and formed in the same position, a problem may occur where the coil Ck is at approximately the same height as the formation region AR1 of the coil C(k+1) in the vertical position, causing interference with tools, etc. The formation region AR1 corresponds to the machining space V.

[0055] Therefore, in the first embodiment, as shown in Figures 35A and 35B, the connecting wire Ck(k+1) between the k-th coil Ck and the (k+1)-th coil C(k+1) is twisted to form a twisted portion Ctk1, the k coils already formed, including coil Ck, are twisted upward so that their coil axis CLk extends in the front-rear direction, and after forming coil C(k+1), the twisted portion Ctk1 is twisted back. This allows the k coils, including coil Ck, to be moved from the formation region AR1 to the retraction region AR2 corresponding to the retraction space Vt by twisting, thereby enabling the formation of coil C(k+1).

[0056] On the other hand, in the second embodiment, as shown in Figures 36A and 36B, the connecting wire Ck(k+1) is bent without twisting to form a bent portion Ctk2, and the k coils already formed, including coil Ck, are bent upward so that their coil axis CLk extends in the left-right direction to form coil C(k+1). After this, the bent portion Ctk2 is bent back. This allows the k coils, including coil Ck, to be moved from the formation region AR1 to the retraction region AR2 by bending, thereby enabling the formation of coil C(k+1).

[0057] When the coil conductor is a flat rectangular wire W, the coil Ck of the second embodiment is formed by edgewise bending, and the bending up to the retraction region AR2 is performed by flatwise bending.

[0058] In the first and second embodiments described above, a multi-coil formed by linking multiple coils together is obtained integrally using a forming device S. Therefore, connecting wires or substrates for linking each coil are unnecessary, reducing the number of parts and manufacturing man-hours. Furthermore, by applying coils manufactured using the coil manufacturing methods of the first and second embodiments to motor coils, the number of connection points in the coil windings can be reduced, thereby lowering the winding resistance value and improving motor performance.

[0059] One aspect of this disclosure is not limited to the configuration and procedure described above, and may be modified insofar as it does not depart from the gist of this disclosure.

[0060] Coil products CP1 and CP2 are described as multi-coils, specifically three integrated coils (three coils in total). However, they are not limited to three coils; they may also be two-coil or multi-coils with four or more coils.

[0061] The example described uses flat rectangular wire W as the conductor for the first coil C1 to the third coil C3, but the cross-sectional shape is not limited and may be, for example, round wire.

[0062] Although the shapes of the first coil C1 to the third coil C3 were described as roughly triangular, their shapes are not limited. They may be circular or rectangular.

[0063] The starting end C1a and ending end C1b of coil C1 can be freely set in either the narrow section C1c or the wide section C1d. The same applies to coils C2 and C3.

[0064] When the conductor is a rectangular wire W, the choice of which of the first and second embodiments to adopt, as well as the torsion ratio corresponding to the degree of change in twist in the first embodiment and the curvature corresponding to the degree of change in bending in the second embodiment, should be set according to the shape of the coil products CP1 and CP2, such that the degree of influence on the rectangular wire W due to the unwinding operation (untwisting or unbending) of the adopted embodiment is minimized. If the shape of the jumper wires is the same, the first embodiment, which involves twisting, is more likely to suppress the influence on the rectangular wire W during untwisting.

[0065] As described in detail above, a first aspect of one or more embodiments of the present disclosure is a method for manufacturing a coil, comprising using a tool 91 for deforming a conductor W to wind the conductor W to form a first coil C1, forming a connecting wire C12 between the winding end C1b of the first coil C1 and the winding start end C2a of the second coil C2 to be formed next, deforming the connecting wire C12 so that the first coil C1 is moved to an area AR2 where it does not interfere with the tool 91 when forming the second coil C2, and then winding the conductor W to form the second coil C2 after the connecting wire C12 has been deformed.

[0066] According to this first embodiment, multiple connected coils can be manufactured while reducing the number of parts and connection work.

[0067] In the first embodiment, after forming the second coil C2, the connecting wire C12 may be returned to its pre-deformation state.

[0068] This allows multiple connected coils to be formed in a configuration where the axes of each coil are parallel.

[0069] Furthermore, a second aspect of one or more embodiments of the present disclosure is a method for manufacturing a coil, comprising: using a tool 91 for deforming a conductor W, winding the conductor W to form the kth coil Ck (where k is a positive integer); forming a connecting wire Ck(k+1) between the winding end Ckb of the kth coil Ck and the winding start end C(k+1)a of the (k+1)th coil to be formed next; deforming the connecting wire Ck(k+1) so that the k coils C1 to Ck that have already been formed are moved to a region AR2 where at least the k coils C1 to Ck do not interfere with the tool 91 when forming the (k+1)th coil C(k+1); and after deforming the connecting wire Ck(k+1), winding the conductor W to form the (k+1)th coil C(k+1).

[0070] This allows for the manufacture of (k+1) connected coils while reducing the number of parts and connection steps.

[0071] In a second embodiment, after forming the (k+1)th coil, the connecting wire may be returned to its original state.

[0072] This allows (k+1) connected coils to be formed in a manner in which their respective coil axes (the first coil axis CL1 to the (k+1)th coil axis CL(k+1)) are parallel.

[0073] In the first and second embodiments, the conductor W may be a flat rectangular wire W, and the connecting wires C12, Ck(k+1) may be deformed by twisting.

[0074] This may help suppress the effect of the return movement on the conductor W.

[0075] In the first and second embodiments, the conductor W may be a flat rectangular wire W, and the connecting wires C12, Ck(k+1) may be deformed by flatwise bending.

[0076] This may help suppress the effect of the return movement on the conductor W.

[0077] The disclosures of this application are relating to the subject matter described in Japanese Patent Application No. 2025-039562, filed on 12 March 2025, all of which are incorporated herein by reference.

Claims

1. A method for manufacturing a coil, comprising: using a tool to deform a conductor, winding the conductor to form a first coil; forming a connecting wire between the end of the first coil and the beginning of a second coil to be formed next; deforming the connecting wire so that the first coil is moved to an area where it does not interfere with the tool when forming the second coil; and after deforming the connecting wire, winding the conductor to form the second coil.

2. The method for manufacturing a coil according to claim 1, wherein after forming the second coil, the connecting wire is returned to its state before deformation.

3. A method for manufacturing a coil, comprising: using a tool to deform a conductor, winding a conductor to form the kth coil (where k is a positive integer); forming a connecting wire between the end of the winding of the kth coil and the beginning of the winding of the (k+1)th coil to be formed next; deforming the connecting wire so that when forming the (k+1)th coil, the k coils already formed are moved to an area where they do not interfere with the tool; and after deforming the connecting wire, winding the conductor to form the (k+1)th coil.

4. The method for manufacturing a coil according to claim 3, wherein after forming the (k+1)th coil, the connecting wire is returned to its pre-deformation state.

5. A method for manufacturing a coil according to any one of claims 1 to 4, wherein the conductor is a flat rectangular wire and the connecting wire is deformed by twisting.

6. A method for manufacturing a coil according to any one of claims 1 to 4, wherein the conductor is a flat rectangular wire and the connecting wire is deformed by flatwise bending.

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