JPS59162743A - Continuous coil forming method and device - Google Patents

Abstract

PURPOSE:To relieve the damage of a coil and realize the totally automated formation by a method wherein the coil is formed step by step by dividing the process into a forming process of the inside and outside diameter of the end of the coil, a forming process of the height of the end of the coil and the forming process of the coil in a core slot. CONSTITUTION:A driving roller 7 is driven by a motor 6 and is pressed against a circumference of a rotating table 2. When the rotating table 2 is turned by the required angle, positioning blocks 8 are driven by an instruction and coupled with positioning rollers 9 to stop in order to maintain an accurate turning angle. Four stations A-D for partial formation are provided for insertion stands 10. An open end formation device IN, an inside and outside diameter formation device NG, a height formation device HH and an inside slot formation device SS are provided to the stations A-D respectively. A station E is provided for unloading and loading the formed coils to and from the equipment.

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical field to which the invention pertains] The present invention relates to preforming or final forming of a coil wound around an iron core of a rotating electric machine.

[Prior art and its problems]

The coil inserted into the slot of the iron core through the insulation material,
After being preformed, the ends are processed. Terminal processing is usually carried out on a linear conveyor, and consists of multiple steps such as inserting insulation between phases, wiring, connecting leads, and fastening the coil ends with strings or the like. After the terminal treatment, the coil is finished molded and insulated with varnish to complete the rotor or stator.

The finishing molding must be as small and accurate as possible in order to reduce the outer dimensions of the rotary ML machine as much as possible, and to avoid tampering and to improve varnish penetration and retention.

- It is necessary to apply an appropriate pressure to avoid damage to the coil insulation due to over-forming or minute scratches that may cause insulation breakdown in the future.

In addition, in preforming, although final forming is not performed to the final shape, the end of the coil still inserted in the slot must be formed into a shape that fits the next step, which is terminal processing. At this time, care must be taken to avoid damage to the insulation.

Furthermore, when the coil is inserted by an inserter (automatic coil insertion machine), the tip of the coil in the insertion direction is closed in the inner diameter direction, so an open end forming process is performed to partially form this closed coil end into an almost cylindrical shape. This is preceded by the preforming described above.

Conventionally, for example, finishing forming or preforming of a stator has been done manually by hammering the coil ends or coils in slots and using a wooden hammer, etc., to a power press machine that forms the inner and outer diameters and heights of the coil ends all at once. Further, coils in slots have been improved to methods that use power machines to insert jigs into slots. Similarly, in the case of inserters, machines are also used for open-end forming.

However, even when such equipment and machines are used, poor insulation or dimensional defects at the ends of the coils as described above sometimes occur, so additional manual work is required, or the slots are cut out due to the focus on shaping the ends of the coils. There was a drawback that there was a risk that the inner wedge insulation would protrude to the inner diameter side of the stator. In addition, since the products to be molded are carried in and out of the conveyor after terminal processing before finishing molding, the conveyor is lengthened and the floor space is increased due to coil end molding, slot molding, and these auxiliary operations. was there.

The same goes for preforming prior to terminal processing, and especially in the case of coils using inserters, there is a drawback that an open end forming process and a bed for this are required.

When we carefully cut and observe a stator in which poor insulation was discovered after varnish treatment, we found that some of the conductors were bent in a more complicated way than others at the ends of the coils and within the slots, and that the conductors crossed and were strongly pressed together. It turns out that there are some cases.

[Purpose of the invention]

This invention eliminates the above-mentioned drawbacks, eliminates auxiliary manual work, fully automates the forming process, prevents insulation defects, minimizes and accurately shapes the ends of some coils, and improves electrical equipment. It is an object of the present invention to provide a method and apparatus for forming coils, which is expected to minimize the jacket dimensions and thus allows the conveyor and therefore floor space for forming to be reduced.

[Key points of the invention]

The first aspect of this invention is to divide the forming process into at least the partial forming steps of forming the inner and outer diameters of the coil ends, forming the height of the coil ends, and forming the coils in the core slots, and forming the coils in stages. This method minimizes damage and performs these multiple partial steps in parallel at each station on the rotary table, even though the number of steps is increased, and molding is performed by connecting to one point on a linear conveyor.

Although the inner and outer diameters of the coil ends are restricted to predetermined dimensions by forming the inner and outer diameters, damage to the coils is drastically reduced because they are free in the height direction. In this case, the coil end is generally moved toward the outer diameter of the stator and is lightly secured to the core end of the slot via the insulation, so the coil end can be inserted into the slot by the next round forming. This prevents damage to the coil when forming the coil in the slot. For height forming of the coil end, a jig is provided to prevent deformation to the inner and outer diameters, and this jig is a two-step process so that it moves to the coil end just before the height forming jig starts forming. good.

In slot coil forming, a jig placed along all the slots is pressed from the inside to the outside, but it is preferable to perform two steps: moving the jig to the inner diameter portion of the stator and pressing. It is preferable to perform inner/outer diameter shaping and height shaping at both ends of the stator coils at the same time.

According to this invention, by making the partial forming process at least the three steps described above, coil damage can be drastically reduced and a good shape can be obtained. However, depending on the type of coil, the order does not necessarily have to be as described above. If the filling rate of the inner coil is high, better results can be obtained by performing height shaping followed by inner and outer diameter shaping. Further, other preliminary or auxiliary steps may be added to the three steps described above. For example, in the case of an inserter, it is natural to perform an open end forming process prior to the inner/outer diameter process.

The second aspect of the present invention is an apparatus according to claim 2, which is basically an apparatus for carrying out the above-described continuous coil forming method.

[Embodiments of the invention]

Embodiments of the present invention will be explained based on FIGS. 1 to 5. These figures relate to preforming including open end forming. Perform four partial moldings.

The final molding is almost the same as the following example, except that the open end molding is omitted and the dimensions of the jig are slightly different so that the final shape can be achieved.

Now, referring to FIGS. 1 and 2, reference numeral 1 denotes a machine frame, and a rotary table 2 is attached to the machine frame 1 by appropriate means so as to be rotated by a shaft 8. rotary table 2
An insertion seat 10 is provided in which a stator 6 around which a coil 4 is wound is removably fitted.

In FIG. 2 showing the top surface of the one-turn table 2, the electric motor 6
is fixed to the inside of the machine frame 1, and a drive roller 7 driven by an electric motor 6 comes into contact with the outer periphery of the rotary table 2, and the rotary table 2 advances to a desired rotation angle, and the positioning flock 8 It operates to lock the positioning roller 9 and ensure accurate stepping. There are a plurality of positioning rollers 9, which act to lock each station and maintain the molding time in response to the advancement of the rotary table 2, which will be described later. In this embodiment, five insertion seats 10 are provided on the rotary table 2, and the four partial molding stations A, B, 0 correspond to the insertion seats 10.
and D, an open end forming device IN, an inner/outer diameter forming device NG, a height forming device an, and a slot forming device ss, which will be described later, are provided in the machine frame l. Note that station E is for carrying molded products into the apparatus.

The open end forming device fN at station A will be explained with reference to FIG. 14 is a comb-shaped push-out rod that is biased by an air cylinder 16 under the upper mounting plate 15 of the machine frame l. 17 is attached by air cylinder 18.
It is a fin-type inserter that is

The comb-shaped push-out rod 14 is pushed through the hollow part of the stator 5 provided in the rotating chiffle 2 by the force of the air cylinder 16.
While expanding the closed inner diameters of both ends of the C coil 4 to a predetermined diameter, the C coil 4 is fitted with the fin-shaped inserter 17 that is pushed upward by the cylinder 18 on the F side and rises. In this way, the coil end whose l1II+ end is properly closed is subjected to open-end forming as rough forming. At this time, as shown in the figure, each of the comb-shaped pushing rod 14 and the fin-shaped inserter 17 has a concave fit 8 m 1
4A and 17A are coil 4 circular 611W4A
and 4B are inserted to prevent ribs caused by aligned winding during molding.

The comb-shaped pushing rod 14 and the fin-shaped inserter are provided with longitudinal grooves to effectively spread the coil.

Next, at station B, the inner and outer diameter molded flliNG
will be explained with reference to FIG. A cylinder 2o is mounted on an upper mounting plate 15 fixed to the machine frame l, and an intermediate mounting plate 27A is fixed to the tip of an operating rod of the cylinder 20 together with a push rod 22. A mounting plate 30A is fixed to the upper end of the support shaft 26 that is inserted through the intermediate mounting plate 27A.
is biased by a spring 24 to a predetermined dimension in the opening direction with respect to the intermediate mounting plate 27A.

Further, the lower end of a guide rod 15A that passes through the intermediate mounting plate 27A and the upper mounting plate 15 is fixed to the mounting plate 30A. The mounting plate 30A is provided with a three-split molding device 23 and a flange portion 30 that are guided by grooves in the radial direction of the mounting plate 30A. The collar portion 30 has a side wall 25 facing the outer periphery of the cylindrical portion of the former 23 . Slope 2 fixed to intermediate mounting plate 27A
The roller 13 provided on the outer diameter portion of the collar portion 30 comes into contact with the control body 27 having the number 8.

Now, the cylinder 20 moves the push rod 22 to the intermediate mounting plate 27A.
When lowered together, the mounting plate 3, which is biased by a spring 24,
0A is guided by the guide rod 15A and descends.

When the clamp 11 at the upper end of the system circular rod 15A comes into contact with the stopper 12 provided on the upper mounting plate, the lowering of the mounting plate 30A is stopped. Further, when the cylinder is gradually biased, the push rod 22 and the intermediate mounting plate 27A are further lowered, so that the push rod 22 is pushed into the tapered hole 23A of the forming machine 23.
The slanted surface 28 of the control body 27 presses the flange 30 inward through the roller 13 while pushing the three-split molding device 23 outwardly.

Thus, by the above-mentioned two-stage operation, the forming device 23 and the side wall 25 are lowered to a predetermined position relative to the coil 4, and then are compressed between the outer wall OW and the inner wall IW to form the inner and outer diameters of the coil 4. . The coils on the lower side of the stator 5 are also formed at the same time by similar means (not shown). In this way, the shaping of the inner and outer diameters of the coil 4 is completed. When the cylinder 20 is deenergized, these mechanical functions are restored.

Sarani height forming device HH at station C @4
This will be explained using figures. 32 is an air cylinder, and the flange 3 is attached to the upper mounting plate 15 that is integrated with the machine frame 1.
Activate extruder 33 with 3A.

A lower mounting plate 34 is fixed to the lower end of the guide shaft 35 through the upper mounting plate 15. 36 is a sliding rod communicating with the lower mounting plate 34, one of which is provided with a collar portion 33A, and the other is provided with a wheel 37 disposed below the lower mounting plate 34. 38
is a circular side wall body with an opening on one side and a lower mounting plate 3 on the other side.
Attach it under 4. 39 is a fitting which is inscribed in the wheel body 37 and attached to the bottom of the lower mounting plate 34. Inside the insert 39, there is a spring 4 under the flange 33A that resists repulsion.
Contains 0. When the air cylinder 32 is energized, the pusher 33 is lowered and the coil 4 of the stator 5 is inserted between the insert 39 and the side wall body 38.

When 34, 38, and 39 are lowered to a predetermined position relative to the coil 4, they are stopped by a stopper (not shown) provided on the upper part of the guide shaft 35, and only the ring 37 is further lowered, so that the upper side of the coil 4 becomes the ring. 37 and is molded to a predetermined height. During this molding, the inner diameter of the coil 4 is fitted by the fitting: J-39, and the outer diameter is held by the side wall body 38, so that unnecessary bulkiness is not given to the dimensions of the inner and outer diameters of the coil 4. Incidentally, the coils on the lower side of the stator 5 are also formed at the same time by the same means (not shown) as before. This completes the molding process.

Finally, the coil in-slot forming device 88 will be explained with reference to FIG. 41 is an air cylinder, and the air cylinder 41 penetrates the upper mounting plate 15 and is fixed to the lower mounting plate 50. Furthermore, the push rod 42 supports the lower mounting plate 60 and is provided with a circular insert 48 on the outside. Reference numeral 44 denotes a guide shaft which passes through the lower mounting plate 5o on one side and the upper mounting plate 15 on the other, and is biased by a cylinder (not shown). 4
Reference numeral 6 denotes a molded body in a slot that surrounds the inserter 48 and is open at the bottom, and the other is attached to the lower mounting plate 5o.

As shown in the figure, the slotted molded body 45 includes a plurality of thin blades 46 that are inclined along the outer periphery.

When the cylinder 41 is energized, as the molded body 45 enters the hollow part of the stator 5, the inserter 48 mounted on the push rod 42 slides from above the inside of the blade 46 and expands outward. Continue pushing through the wedge 47 of the slot 8 and down the effective length of the slot 48. As a result, the coil in the slot 48 is sufficiently closely aligned with the wedge 47 and molded, and all molding is completed. Next, when the cylinder 41 is released, the next station E
The stator is installed on the sidewalk.

At station E, the molded stator is removed, a new stator is placed, and the molding process described above is repeated. At stations D to D, each partial molding is carried out simultaneously and in parallel. In addition, a comb-shaped extrusion rod 14 and a fin-shaped inserter 17 at each station
, the extrusion rod 22, the mold 23, and other jigs can be detachably replaced from the device depending on the type of coil 4.

〔Effect of the invention〕

According to this invention, the following effects can be obtained.

a. Damage to the coil and insulation is prevented and quality is improved.

The amount of deformation for each partial molding is not small, and the deformation is carried out gently using a jig. The pressure weld is lost, and the insulation collapses (
Damage to the coil and insulation is prevented, such as by reducing the occurrence of splitting, cracking, thinning in some areas, etc.

b. The coil shape becomes smaller and more precise, making the outer frame of the electric machine smaller and lighter, eliminating the uneconomical need to discard defective products.

In other words, as mentioned above, damage to the coil and insulation is prevented, so the end of the coil can be downsized to the limit size using a jig, and the dimensions are accurate, and there are no dimensional defects that are conventionally found after varnish treatment. Therefore, the outer frame of the electric machine can be designed to be smaller. Since the coil size is smaller, the amount of varnish to be added can be saved, and since dimensional defects after varnish treatment cannot be molded, the uneconomical cost of discarding defective products can be avoided.

The manpower required for C1 molding is greatly reduced.

In other words, the conventional auxiliary manual labor and the handling between this auxiliary manual labor and the batch molding machine are eliminated, and molding is completely automated, and the connection with the terminal processing process, that is, the transportation to the device according to the present invention, is also controlled by robots. performance, and manpower is greatly reduced.

d. Conveyor and handling distances are shortened, reducing floor space.

In other words, the conveyor part required for manual molding is no longer necessary, and the connection between the end processing conveyor and molding is simplified.
As a result of the shortened handling distance and the elimination of the need for temporary storage space for forming, the conveyor length, handling length, and floor space are significantly shortened and reduced.

[Brief explanation of the drawing]

Fig. 1 is a side view of an embodiment of the present invention, Fig. 2 is a sectional view taken along the line X-X in Fig. 1, Fig. 8 is a side sectional view of the inner/outer diameter forming device NG, and Fig. 4 is an H-shaped forming device. Apparatus anX FIG. 5 is an in-slot forming apparatus. 2... Rotating table, 4... Coil, 5... Stator, 6... Electric motor, 7... Drive roller, 1o...
Insertion seat, IN...open end forming device, NG...inner/outer diameter forming device, kiH...height forming device, s8...intra-slot forming device. Figure 1 Figure 2

Claims (1)

[Scope of Claims] l) In a method of forming a coil wound around an iron core as a molded product, the forming process is performed at least by forming the inner and outer diameters of the coil ends, forming the height of the coil ends, and forming the coil in the core slot. The molded product is divided into a partial molding process and a plurality of stations are set up, and the molded product is carried and placed on a single moving rotary table, and the plurality of partial molding processes are performed in parallel at each desired station. A method for continuous coil forming, characterized in that the molded products that have been formed are sequentially carried out from the rotary table. 2) A rotary table provided with a plurality of insertion seats on which a coil-wound iron core is removably placed, a drive device that advances this rotary table at each desired rotation angle, and a position at which the rotary table stops. continuous forming of a coil, comprising a partial forming device installed in a vertical direction opposite to the insertion seat, the partial forming device being able to replace a partial forming jig for forming the coil. Device.