JP2021058076A - Conductor formation device and manufacturing method of wave winding coil - Google Patents

Conductor formation device and manufacturing method of wave winding coil Download PDF

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JP2021058076A
JP2021058076A JP2020072833A JP2020072833A JP2021058076A JP 2021058076 A JP2021058076 A JP 2021058076A JP 2020072833 A JP2020072833 A JP 2020072833A JP 2020072833 A JP2020072833 A JP 2020072833A JP 2021058076 A JP2021058076 A JP 2021058076A
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folding
conductor
conductor group
coil
clamp
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拓郎 吉村
Takuro Yoshimura
拓郎 吉村
賢一 大曲
Kenichi Omagari
賢一 大曲
洋介 本田
Yosuke Honda
洋介 本田
昭博 渡辺
Akihiro Watanabe
昭博 渡辺
貴士 隅田
Takashi Sumida
貴士 隅田
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Honda Motor Co Ltd
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Honda Motor Co Ltd
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0435—Wound windings
    • H02K15/0478—Wave windings, undulated windings

Abstract

To provide a conductor formation device capable of forming a conductor having an oblique part and a folding part at high accuracy, and provide a manufacturing method of a wave winding coil.SOLUTION: A conductor formation device 200 which forms a plurality of oblique parts 15 and a plurality of liner parts 14 to a conductor group 100 formed by a plurality of conductors 10 having a liner portion, and folds the conductor group 100 to a thickness direction in the oblique part 15, includes: an oblique part formation mechanism 206 that grips the liner portion of the plurality of conductors 10 corresponding to a part on both sides nipping a portion for forming the oblique part 15 of the conductor group 100, and forms the oblique part 15 by being relatively moved to a width direction of the conductor group 100; and a folding mechanism 207 that folds the oblique part 15 formed to the thickness direction of the conductor group 100. The conductor group 100 folded by the oblique part formation mechanism 206 is relatively moved to the oblique part formation mechanism 206 so that a part for subsequently forming the oblique part 15 comes at a position of the oblique part formation mechanism 206 to form the oblique part 15 with the oblique part formation mechanism 206.SELECTED DRAWING: Figure 9

Description

本発明は、導体成形装置及び波巻コイルの製造方法に関する。 The present invention relates to a conductor molding apparatus and a method for manufacturing a wave winding coil.

一般に、電動機や発電機等の回転電機のステータを構成するコイルとして、波巻コイルが知られている。波巻コイルは、ステータコアのスロット内に配置されるストレート状の複数のスロット配置部と、ステータコアの軸方向外側で、隣り合うスロット配置部同士を山型状又はアーチ状に連結する複数のターン部と、を有し、ステータコアの周方向に沿って波形状に成形される。 Generally, a wave winding coil is known as a coil constituting a stator of a rotating electric machine such as an electric motor or a generator. The wave winding coil has a plurality of straight slot arrangement portions arranged in the slots of the stator core and a plurality of turn portions for connecting adjacent slot arrangement portions in a chevron shape or an arch shape on the outer side in the axial direction of the stator core. And, and are formed into a wavy shape along the circumferential direction of the stator core.

このような波巻コイルとして、ステータコアの複数周分の長尺なシート状の波巻コイルが知られている。シート状の波巻コイルは、渦巻状に巻回され、各スロット配置部をステータコアの各スロット内に挿入することにより、複数層（複数ターン）のコイルを構成する。 As such a wave winding coil, a long sheet-shaped wave winding coil for a plurality of circumferences of the stator core is known. The sheet-shaped wave-wound coil is wound in a spiral shape, and each slot arrangement portion is inserted into each slot of the stator core to form a coil having a plurality of layers (multiple turns).

従来、このようなシート状の波巻コイルを製造する方法として、コイル導体の延在する面内において、コイル導体に対し、波巻コイルのターン部に対応する斜行状の複数の渡り導体部と、波巻コイルのスロット配置部に対応する直線状の複数のスロット導体部とを予め全て成形した後、各渡り導体部の中央部で順次折り返し、その折り返し部によって波巻コイルのターン部を成形する方法が知られている（例えば、特許文献１参照）。 Conventionally, as a method of manufacturing such a sheet-shaped wave-wound coil, in the extending plane of the coil conductor, with respect to the coil conductor, a plurality of oblique-shaped crossing conductor portions corresponding to the turn portion of the wave-wound coil are formed. After molding all of the linear slot conductors corresponding to the slot arrangements of the wave coil in advance, the conductors are folded back in sequence at the center of each crossing conductor, and the turn of the wave coil is formed by the folded parts. A method is known (see, for example, Patent Document 1).

特許第３９５２３４６号公報Japanese Patent No. 3952346

しかしながら、上記従来技術では、波巻コイルのターン部に対応する斜行状の渡り導体部（斜行部）を先に全て成形した後に、各斜行部を順次折り返してターン部を成形しているため、波巻コイルの成形精度が悪い、という問題があった。 However, in the above-mentioned conventional technique, after all the oblique crossover conductor portions (oblique portions) corresponding to the turn portions of the wave winding coil are first formed, each oblique portion is sequentially folded back to form the turn portion. Therefore, there is a problem that the molding accuracy of the wave winding coil is poor.

即ち、シート状の波巻コイルは、並列状態とされたＵＶＷの三相に対応する複数本のコイル線材に対して同時に成形を行う。しかし、全てのコイル線材で均等な形状のターン部を成形することは困難であり、あるコイル線材のターン部の頂点部分では比較的きつく折り返され、別のコイル線材のターン部の頂点部分では比較的緩く折り返される場合や、ある折り返し工程では比較的きつく折り返され、別の折り返し工程では比較的緩く折り返される場合等があり得る。このような場合、折り返し部の成形バラつきによるコイル線材毎又は折り返し部毎のずれ（コイル線材の延在方向のずれ）を発生させ、そのずれが、折り返しの度に既に成形済みの斜行部に次第に蓄積し、最終的に得られる波巻コイルのターン部及びスロット配置部の成形精度が悪くなる。 That is, the sheet-shaped wave-wound coil is simultaneously molded on a plurality of coil wires corresponding to the three phases of UVW in a parallel state. However, it is difficult to form a turn portion having an even shape with all coil wires, and the turn portion of one coil wire is folded back relatively tightly, and the apex of the turn portion of another coil wire is compared. It may be folded back loosely, or it may be folded back relatively tightly in one folding process and relatively loosely in another folding process. In such a case, a deviation (deviation in the extending direction of the coil wire) is generated for each coil wire or each folded portion due to the molding variation of the folded portion, and the deviation is caused to the already molded skewed portion each time the folded portion is folded. It gradually accumulates, and the molding accuracy of the turn portion and the slot arrangement portion of the finally obtained wave winding coil deteriorates.

そこで、本発明は、斜行部と折り返し部とを有する導体を精度良く成形することができる導体成形装置及び波巻コイルの製造方法を提供することを目的とする。 Therefore, an object of the present invention is to provide a conductor molding apparatus capable of accurately molding a conductor having a skewed portion and a folded portion, and a method for manufacturing a wave-wound coil.

（１） 本発明に係る導体成形装置は、直線部分を有する複数の導体（例えば、後述のコイル線材１０）からなる導体群（例えば、後述の導体群１００）に対し、複数の斜行部（例えば、後述の斜行部１５）と複数の直線部（例えば、後述の直線部１４）とを成形し、前記斜行部において前記導体群を厚さ方向に折り返す導体成形装置（例えば、後述の導体成形装置２００）であって、前記導体群の前記斜行部を成形する部分を挟んだ両側の部分に対応する前記複数の導体の直線部分を把持し、前記導体群の幅方向に相対的に移動させて前記斜行部を成形する斜行部成形機構（例えば、後述の斜行部成形機構２０６）と、成形された前記斜行部を前記導体群の厚さ方向に折り返す折り返し機構（例えば、後述の折り返し機構２０７）と、を有し、前記折り返し機構で折り返された前記導体群を、次に前記斜行部を成形する部分が前記斜行部成形機構の位置に来るように、前記斜行部成形機構に対して相対的に移動させて、前記斜行部成形機構で前記斜行部を成形する。 (1) The conductor forming apparatus according to the present invention has a plurality of skewed portions (for example, a conductor group 100 described later) with respect to a conductor group (for example, a conductor group 100 described later) composed of a plurality of conductors having a straight portion (for example, a coil wire rod 10 described later). For example, a conductor molding apparatus (for example, described later) that forms a slanted portion 15) described later and a plurality of straight portions (for example, the straight portion 14 described later) and folds the conductor group in the thickness direction at the skewed portion. In the conductor forming apparatus 200), the linear portions of the plurality of conductors corresponding to the portions on both sides of the portion for forming the oblique portion of the conductor group are gripped and relative to the width direction of the conductor group. A slanted portion forming mechanism (for example, a slanted portion forming mechanism 206 described later) that is moved to and forms the slanted portion, and a folding mechanism that folds the formed slanted portion in the thickness direction of the conductor group (for example, the slanted portion forming mechanism 206 described later). For example, the conductor group having the folding mechanism 207), which will be described later, and the conductor group folded by the folding mechanism, so that the portion for molding the skew portion next comes to the position of the skew portion molding mechanism. The oblique portion is formed by the oblique portion forming mechanism by moving the conductor relative to the oblique portion forming mechanism.

上記（１）によれば、導体群を斜行部で折り返した後に次の斜行部の成形を行うので、折り返し時の成形誤差が蓄積せず、斜行部と折り返し部とを有する導体を精度良く成形することができる。 According to the above (1), since the next skewed portion is formed after the conductor group is folded back at the skewed portion, a molding error at the time of folding back is not accumulated, and the conductor having the skewed portion and the folded portion is formed. It can be molded with high accuracy.

（２） （１）に記載の導体成形装置において、前記導体群の前記直線部を把持して、前記導体群を前記直線部の延在方向に移動可能な把持機構（例えば、後述の把持機構２０５）を更に有し、前記把持機構は、前記直線部を把持した状態で、前記導体群を前記直線部の延在方向に移動させて前記斜行部成形機構又は前記折り返し機構まで搬送し、前記斜行部成形機構は、前記把持機構によって前記複数の導体が把持された状態で、前記斜行部を成形し、前記折り返し機構は、前記把持機構によって前記複数の導体が把持された状態で、前記斜行部を折り返すようにしてもよい。 (2) In the conductor forming apparatus according to (1), a gripping mechanism (for example, a gripping mechanism described later) capable of gripping the straight portion of the conductor group and moving the conductor group in the extending direction of the straight portion. 205), the gripping mechanism moves the conductor group in the extending direction of the straight portion and conveys the conductor group to the slanted portion forming mechanism or the folding back mechanism while gripping the straight portion. The oblique portion forming mechanism forms the oblique portion in a state where the plurality of conductors are gripped by the gripping mechanism, and the folding back mechanism is a state in which the plurality of conductors are gripped by the gripping mechanism. , The skewed portion may be folded back.

上記（２）によれば、搬送機能を有する把持機構と折り返し機構とが別体で設けられるので、折り返し位置が常に一定になり、折り返し位置の精度が良好になる。 According to the above (2), since the gripping mechanism having the transport function and the folding mechanism are separately provided, the folding position is always constant and the accuracy of the folding position is improved.

（３） （２）に記載の導体成形装置において、前記把持機構は、成形された前記斜行部を挟んだ両側に配置される前記直線部を把持する一対の把持部材（例えば、後述の把持部材２０５Ａ，２０５Ｂ）を有してもよい。 (3) In the conductor molding apparatus according to (2), the gripping mechanism is a pair of gripping members (for example, gripping described later) that grip the straight portions arranged on both sides of the molded diagonal portion. Members 205A, 205B) may be provided.

上記（３）によれば、斜行部を挟んだ両側に配置される直線部の二点で導体群を把持しているので、導体群がばらけにくい。 According to the above (3), since the conductor group is gripped by two points of the straight line portions arranged on both sides of the skewed portion, the conductor group is hard to be separated.

（４） （２）又は（３）に記載の導体成形装置において、前記折り返し機構及び前記把持機構は、前記複数の導体を収容する溝部（例えば、後述の溝部２１０ａ）を有し、前記溝部は、前記導体の幅方向に開閉可能に構成され、前記導体を幅方向に把持及び把持解除するものであってもよい。 (4) In the conductor molding apparatus according to (2) or (3), the folding mechanism and the gripping mechanism have a groove portion (for example, a groove portion 210a described later) for accommodating the plurality of conductors, and the groove portion is , The conductor may be configured to be openable and closable in the width direction, and the conductor may be gripped and released in the width direction.

上記（４）によれば、導体を押さえるための別途の押さえ部材が不要であるため、装置の小型化が可能であるとともに、導体の幅方向を把持するため、複数の導体の間に厚さ方向のばらつきがあっても、複数の導体を一体に把持することが可能である。 According to the above (4), since a separate pressing member for pressing the conductor is not required, the device can be miniaturized, and in order to grip the width direction of the conductor, the thickness between the plurality of conductors is thick. It is possible to integrally grip a plurality of conductors even if the directions vary.

（５） （１）〜（３）のいずれかに記載の導体成形装置において、前記折り返し機構は、前記複数の導体を収容する溝部（例えば、後述の溝部２３０ａ）を有し、前記溝部の間隔は、前記導体群の前記直線部が収容されるステータコア（例えば、後述のステータコア２０）のスロット（例えば、後述のスロット２３）の間隔よりも狭いものであってもよい。 (5) In the conductor molding apparatus according to any one of (1) to (3), the folding mechanism has a groove portion (for example, a groove portion 230a described later) for accommodating the plurality of conductors, and the spacing between the groove portions. May be narrower than the spacing between the slots (for example, the slot 23 described later) of the stator core (for example, the stator core 20 described later) in which the straight portion of the conductor group is accommodated.

上記（５）によれば、折り返し時のピッチによって折り返し後の頂点部の幅をコントロールすることができる。 According to the above (5), the width of the apex portion after folding can be controlled by the pitch at the time of folding.

（６） （１）〜（５）の何れかに記載の導体成形装置において、前記斜行部成形機構は、前記斜行部と前記直線部との境界点である曲げ起点（例えば、後述の曲げ起点Ｐ）を中心とするとともに前記斜行部の長さを半径として、円弧状に移動させることによって前記斜行部を成形することが好ましい。 (6) In the conductor forming apparatus according to any one of (1) to (5), the oblique portion forming mechanism is a bending starting point (for example, described later) which is a boundary point between the oblique portion and the straight portion. It is preferable to form the skewed portion by moving it in an arc shape with the bending starting point P) as the center and the length of the skewed portion as a radius.

上記（６）によれば、導体を引っ張りながら斜行部成形を行うため、斜行部の成形精度が向上する。 According to the above (6), since the oblique portion is formed while pulling the conductor, the forming accuracy of the oblique portion is improved.

（７） （１）〜（６）のいずれかに記載の導体成形装置において、前記折り返し機構は、折り返した前記導体群の折り返し部（例えば、後述のターン部１２）を厚さ方向に押圧する押圧部材（例えば、後述の押圧部材２０３Ｄ，２０４Ｄ）を有することが好ましい。 (7) In the conductor molding apparatus according to any one of (1) to (6), the folding mechanism presses the folded portion (for example, the turn portion 12 described later) of the folded conductor group in the thickness direction. It is preferable to have a pressing member (for example, pressing members 203D and 204D described later).

上記（７）によれば、斜行部を折り返した後の折り返し部の成形精度が更に向上する。また、折り返し機構によって斜行部を折り返した後にそのまま押圧することができるため、押圧のためのステーションを別途に設ける必要がなく、装置を簡素化することができる。 According to the above (7), the molding accuracy of the folded portion after the skewed portion is folded is further improved. Further, since the slanted portion can be pressed as it is after being folded by the folding mechanism, it is not necessary to separately provide a station for pressing, and the device can be simplified.

（８） （１）〜（７）のいずれかに記載の導体成形装置において、前記折り返し機構は、折り返し完了後に、前記導体群を把持した状態で、前記導体の並び方向に移動させることが好ましい。 (8) In the conductor molding apparatus according to any one of (1) to (7), it is preferable that the folding mechanism is moved in the alignment direction of the conductors while holding the conductor group after the folding is completed. ..

上記（８）によれば、斜行部を折り返した後のスプリングバックを抑制することができる。 According to the above (8), it is possible to suppress the springback after the skewed portion is folded back.

（９） （１）〜（８）のいずれかに記載の導体成形装置において、前記折り返し機構は、辺縁部（例えば、後述の辺縁部２２０ａ）が前記斜行部の折り返し線（例えば、後述の折り返し線Ｒ）に沿って挿入される折り返し治具（例えば、後述の折り返し治具２２０）を備えることが好ましい。 (9) In the conductor molding apparatus according to any one of (1) to (8), in the folding mechanism, the edge portion (for example, the edge portion 220a described later) is a folding line (for example, the diagonal portion 220a) of the diagonal portion. It is preferable to provide a folding jig (for example, a folding jig 220 described later) that is inserted along the folding line R described later.

上記（９）によれば、斜行部を折り返し線に沿って精度良く折り返すことができる。 According to the above (9), the skewed portion can be folded back with high accuracy along the folding line.

（１０） （９）に記載の導体成形装置において、前記折り返し治具は、前記辺縁部に、前記斜行部の前記折り返し部の頂点部（例えば、後述の頂点部１２ｃ）に対応する部位をそれぞれ幅方向に挟むように配置される２つの突起（例えば、後述の突起２２０ｂ）を有することが好ましい。 (10) In the conductor forming apparatus according to (9), the folding jig has a portion corresponding to the edge portion and the apex portion (for example, the apex portion 12c described later) of the folding portion of the skew portion. It is preferable to have two protrusions (for example, protrusions 220b described later) arranged so as to sandwich each of them in the width direction.

上記（１０）によれば、折り返し治具の突起によって頂点部の幅の広がりを抑制することができる。 According to the above (10), the expansion of the width of the apex can be suppressed by the protrusion of the folding jig.

（１１） 本発明に係る波巻コイルの製造方法は、コイル線材（例えば、後述のコイル線材１０）により成形され、ステータコア（例えば、後述のステータコア２０）のスロット（例えば、後述のスロット２３）に配置される複数のスロット配置部（例えば、後述のスロット配置部１１）と、隣り合う前記スロット配置部同士を連結する複数のターン部（例えば、後述のターン部１２）と、を有する波巻コイル（例えば、後述の波巻コイル１）の製造方法であって、前記コイル線材の直線部（例えば、後述の直線部１４）を、前記コイル線材の延在する面内において、前記直線部の延在方向（例えば、後述のＺ方向、Ｄ１方向）と交差する方向（例えば、後述のＤ２方向）にオフセットさせることにより、前記コイル線材に斜行部（例えば、後述の斜行部１５）を成形する斜行部成形工程と、前記斜行部が成形された前記コイル線材を、前記斜行部における前記ターン部の頂点部（例えば、後述の頂点部１２ｃ）に対応する部位において折り返すことにより、折り返された前記斜行部で構成される前記ターン部と、前記斜行部に連続する前記直線部で構成される前記スロット配置部と、を成形する折り返し工程と、を有し、前記斜行部成形工程と前記折り返し工程とを交互に行うことで、前記波巻コイルを成形する。 (11) In the method for manufacturing a wave-wound coil according to the present invention, a coil wire rod (for example, a coil wire rod 10 described later) is formed, and a slot (for example, a slot 23 described later) of a stator core (for example, a stator core 20 described later) is used. A wave-wound coil having a plurality of slot arrangement portions to be arranged (for example, the slot arrangement portion 11 described later) and a plurality of turn portions (for example, the turn portion 12 described later) for connecting the adjacent slot arrangement portions to each other. (For example, in the method of manufacturing the wave winding coil 1 described later), the straight portion of the coil wire (for example, the straight portion 14 described later) is extended in the plane where the coil wire extends. By offsetting in a direction (for example, the D2 direction described later) that intersects the existing direction (for example, the Z direction and the D1 direction described later), a skew portion (for example, the skew portion 15 described later) is formed in the coil wire rod. By folding the coil wire rod in which the skewed portion is formed at a portion corresponding to the apex portion of the turn portion (for example, the apex portion 12c described later) in the skewed portion. It has a folding step of forming the turn portion formed of the folded portion and the slot arrangement portion formed of the straight portion continuous with the skew portion, and has the skewing step. The wave winding coil is formed by alternately performing the partial forming step and the folding step.

上記（１１）によれば、斜行部の成形と折り返しによるターン部の成形とを交互に行うため、折り返しの際に生じる成形誤差が蓄積されず、ターン部及びスロット配置部の成形精度の良い波巻コイルを製造することができる。 According to the above (11), since the forming of the skew portion and the molding of the turn portion by folding are performed alternately, the molding error generated at the time of folding is not accumulated, and the molding accuracy of the turn portion and the slot arrangement portion is good. A wave winding coil can be manufactured.

（１２） （１１）に記載の波巻コイルの製造方法において、前記コイル線材は、複数本の単位線材（例えば、後述の単位線材１０ａ）を前記コイル線材の厚さ方向（例えば、後述のＹ方向）に並べて構成され、前記斜行部成形工程及び前記折り返し工程は、前記複数本の単位線材を並べた状態で前記コイル線材を成形することが好ましい。 (12) In the method for manufacturing a wave-wound coil according to (11), the coil wire has a plurality of unit wires (for example, the unit wire 10a described later) in the thickness direction of the coil wire (for example, Y described later). It is preferable that the coil wire rods are formed in a state where the plurality of unit wire rods are arranged side by side in the diagonal portion forming step and the folding back step.

上記（１２）によれば、斜行部を折り返す際に、斜行部におけるコイル線材の延在方向と折り返し方向との角度差により、コイル線材を構成する複数本の単位線材間で周長差の問題が生じ得るが、斜行部の成形と折り返しによるターン部の成形とを交互に行うため、折り返しによる単位線材間の周長差が次の斜行部の成形時に実質的にキャンセルされ、複数本の単位線材からなるコイル線材によって、成形精度の良い波巻コイルを製造することができる。 According to the above (12), when the skewed portion is folded back, the peripheral length difference between a plurality of unit wires constituting the coil wire rod is due to the angle difference between the extending direction and the folded-back direction of the coil wire rod in the skewed portion. However, since the forming of the skewed portion and the forming of the turn portion by folding are performed alternately, the difference in peripheral length between the unit wires due to folding is substantially canceled at the time of forming the next oblique portion. A coil wire having a plurality of unit wires can be used to manufacture a wave-wound coil with good molding accuracy.

（１３） （１１）又は（１２）に記載の波巻コイルの製造方法において、複数本の前記コイル線材から前記波巻コイルを成形し、前記折り返し工程において、折り返し前の前記複数のコイル線材の前記直線部の間隔を、前記ステータコアの前記スロットの間隔よりも狭くすることが好ましい。 (13) In the method for manufacturing a wave-wound coil according to (11) or (12), the wave-wound coil is formed from a plurality of the coil wires, and in the folding step, the plurality of coil wires before folding is formed. It is preferable that the distance between the straight portions is narrower than the distance between the slots of the stator core.

上記（１３）によれば、折り返し時のピッチによって折り返し後の頂点部の幅をコントロールすることができる。 According to the above (13), the width of the apex portion after folding can be controlled by the pitch at the time of folding.

（１４） （１１）〜（１３）のいずれかに記載の波巻コイルの製造方法において、前記折り返し工程は、前記ターン部の成形後に、前記ターン部を、前記コイル線材の延在する面に直交する方向に押圧することが好ましい。 (14) In the method for manufacturing a wave-wound coil according to any one of (11) to (13), in the folding step, after molding the turn portion, the turn portion is placed on the extending surface of the coil wire rod. It is preferable to press in the orthogonal direction.

上記（１４）によれば、折り返し部が厚さ方向（ステータコアの径方向）に膨らむことを防止できる。 According to the above (14), it is possible to prevent the folded-back portion from bulging in the thickness direction (diameter direction of the stator core).

（１５） （１１）〜（１４）のいずれに記載の波巻コイルの製造方法において、前記波巻コイルは、前記ステータコアに巻回されて装着されることにより、前記ステータコアの複数周分に対応する複数の層（例えば、後述の１Ｔ〜８Ｔ）を構成する波巻コイルであり、前記折り返し工程は、前記層が前記ステータコアの径方向に切り替わる層替わり部（例えば、後述の層替わり部Ｔａ）において、前記斜行部の折り返し方向を逆にすることが好ましい。 (15) In the method for manufacturing a wave-wound coil according to any one of (11) to (14), the wave-wound coil is wound around the stator core and mounted so as to correspond to a plurality of circumferences of the stator core. It is a wave winding coil constituting a plurality of layers (for example, 1T to 8T described later), and in the folding step, a layer changing portion (for example, a layer changing portion Ta described later) in which the layer is switched in the radial direction of the stator core. In the above, it is preferable to reverse the folding direction of the skewed portion.

上記（１５）によれば、層替わり部において、ターン部の厚さ方向（ステータコアの径方向）のオフセットが逆方向になるため、波巻コイルがステータコアに装着された際に、層替わり部における層間の干渉を避けることができる。 According to the above (15), in the layer changing portion, the offset in the thickness direction (diameter direction of the stator core) of the turn portion is opposite, so that when the wave winding coil is mounted on the stator core, the layer changing portion is formed. Interference between layers can be avoided.

（１６） （１１）〜（１５）のいずれかに記載の波巻コイルの製造方法において、前記折り返し工程において、折り返し治具（例えば、後述の折り返し治具２２０）の辺縁部（例えば、後述の辺縁部２２０ａ）が折り返し線（例えば、後述の折り返し線Ｒ）に沿うように、前記斜行部に前記折り返し治具を挿入することが好ましい。 (16) In the method for manufacturing a wave-wound coil according to any one of (11) to (15), in the folding step, an edge portion (for example, described later) of a folding jig (for example, a folding jig 220 described later) is used. It is preferable to insert the folding jig into the diagonal portion so that the edge portion 220a) is along the folding line (for example, the folding line R described later).

上記（１６）によれば、斜行部を折り返し線に沿って精度良く折り返すことができる。 According to the above (16), the skewed portion can be folded back with high accuracy along the folding line.

（１７） （１１）〜（１６）のいずれかに記載の波巻コイルにおいて、前記折り返し工程において、前記斜行部における前記ターン部の頂点部（例えば、後述の頂点部１２ｃ）に対応する部位を幅方向に挟んだ状態で折り返すことが好ましい。 (17) In the wave winding coil according to any one of (11) to (16), in the folding step, a portion corresponding to the apex portion (for example, the apex portion 12c described later) of the turn portion in the skew portion. It is preferable to fold it back while sandwiching it in the width direction.

上記（１７）によれば、折り返し時に頂点部の幅の広がりを抑制することができる。 According to the above (17), it is possible to suppress the expansion of the width of the apex portion at the time of folding back.

本発明によれば、斜行部と折り返し部とを有する導体を精度良く成形することができる導体成形装置及び波巻コイルの製造方法を提供することができる。 According to the present invention, it is possible to provide a conductor molding apparatus capable of accurately molding a conductor having a skewed portion and a folded portion, and a method for manufacturing a wave winding coil.

波巻コイルを模式的に示す正面図である。It is a front view which shows typically the wave winding coil. ステータを模式的に示す平面図である。It is a top view which shows the stator schematically. コイル線材（導体）を成形する様子を示す図である。It is a figure which shows the state of forming a coil wire (conductor). 図３中のＡ−Ａ線に沿う断面図である。It is sectional drawing which follows the AA line in FIG. コイル線材（導体）の一部を拡大して示す正面図である。It is a front view which shows the part of the coil wire (conductor) enlarged. 図５に示すコイル線材（導体）をＺ方向に沿う方向から見た図である。It is a figure which looked at the coil wire (conductor) shown in FIG. 5 from the direction along the Z direction. 図５に示すコイル線材（導体）を複数本並列させて構成した導体群の一部を拡大して示す正面図である。FIG. 5 is an enlarged front view showing a part of a conductor group formed by arranging a plurality of coil wires (conductors) shown in FIG. 5 in parallel. 図７に示す導体群をＺ方向に沿う方向から見た図である。It is a figure which looked at the conductor group shown in FIG. 7 from the direction along the Z direction. 導体成形装置の概要を模式的に示す平面図である。It is a top view which shows the outline of the conductor molding apparatus schematically. 導体成形装置の概要を模式的に示す側面図である。It is a side view which shows typically the outline of the conductor molding apparatus. 導体成形装置のクランプ部が導体群をアンクランプした状態を示す図である。It is a figure which shows the state which the clamp part of the conductor forming apparatus unclamped a group of conductors. 導体成形装置のクランプ部が導体群をクランプした状態を示す図である。It is a figure which shows the state which the clamp part of the conductor forming apparatus clamped a group of conductors. 導体群を斜行部の成形位置に搬送する様子を示す導体成形装置の平面図である。It is a top view of the conductor molding apparatus which shows the state of transporting a group of conductors to the molding position of the oblique portion. 導体群を斜行部の成形位置に搬送する様子を示す導体成形装置の側面図である。It is a side view of the conductor molding apparatus which shows the state of transporting a conductor group to a molding position of an oblique portion. 導体群に斜行部を成形する様子を示す導体成形装置の平面図である。It is a top view of the conductor forming apparatus which shows the state of forming an oblique portion in a conductor group. 導体群に斜行部を成形する際のクランプ部の動作を示す平面図である。It is a top view which shows the operation of the clamp part at the time of forming the oblique part in a conductor group. 成形後の導体の斜行部を示す平面図である。It is a top view which shows the oblique part of the conductor after molding. 斜行部を成形した後の導体群を折り返し位置に搬送する様子を示す導体成形装置の平面図である。It is a top view of the conductor forming apparatus which shows the state of transporting a group of conductors after forming a slanting part to a folding position. 斜行部を成形した後の導体群に次の斜行部を成形する様子を示す導体成形装置の平面図である。It is a top view of the conductor forming apparatus which shows the state of forming the next oblique part in the conductor group after forming the oblique part. 導体群に成形した斜行部を折り返す際のクランプ部の動作を示す側面図である。It is a side view which shows the operation of the clamp part at the time of folding back the oblique part formed into a conductor group. 導体群に成形した斜行部を折り返した様子を示す導体成形装置の平面図である。It is a top view of the conductor molding apparatus which shows the state which the oblique part molded into a conductor group is folded back. 斜行部を折り返した後の導体群を示す平面図である。It is a top view which shows the conductor group after the oblique part is folded back. 斜行部を折り返した後のクランプ部の動作を示す図である。It is a figure which shows the operation of the clamp part after folding back the oblique part. 斜行部を折り返した後に折り返し部を押圧部材で押圧する動作を示す側面図である。It is a side view which shows the operation which presses the folded-back part with a pressing member after folding back the oblique part. 折り返した後の導体群に次の斜行部を成形する様子を示す導体成形装置の平面図である。It is a top view of the conductor forming apparatus which shows the state of forming the next oblique portion in the conductor group after folding back. 層替わり部に対応する斜行部を逆折りする様子を示す導体群の平面図である。It is a top view of the conductor group which shows the state of reversely folding the oblique part corresponding to a layer change part. 層替わり部が逆折りされた導体群によって構成されたシート状の波巻コイルを示す平面図である。It is a top view which shows the sheet-like wave winding coil which is composed of the conductor group which the layer change part is reverse-folded. シート状の波巻コイルを巻取り装置によって巻取り治具に巻き取る様子を模式的に示す図である。It is a figure which shows typically the state of winding a sheet-shaped wave winding coil around a winding jig by a winding device. 巻取り治具を示す斜視図である。It is a perspective view which shows the winding jig. インシュレータの一例を示す斜視図である。It is a perspective view which shows an example of an insulator. 図２９に示すインシュレータの要部拡大斜視図である。FIG. 9 is an enlarged perspective view of a main part of the insulator shown in FIG. 29. 巻取り治具にインシュレータを装着する様子を示す断面図である。It is sectional drawing which shows the state of attaching an insulator to a winding jig. 折り返し時に隣り合う直線部の間隔を狭くする様子を説明する説明図である。It is explanatory drawing explaining the mode that the space between adjacent straight lines part is narrowed at the time of folding back. 折り返し時に隣り合う直線部の間隔を狭くしない場合と狭くした場合のターン部の頂点部の幅の違いを説明する説明図である。It is explanatory drawing explaining the difference in the width of the apex part of the turn part when the space | interval of the adjacent straight line part is not narrowed at the time of folding back and is narrowed. 折り返し時に隣り合う直線部の間隔を狭くすることができるクランプ部材を示す図である。It is a figure which shows the clamp member which can narrow the space between adjacent straight lines at the time of folding back. 折り返し時に隣り合う直線部の間隔を狭くした状態のクランプ部材を示す図である。It is a figure which shows the clamp member in the state which the space between adjacent straight lines is narrowed at the time of folding back. 折り返し工程において直線部の間隔を狭くするための折り返し治具の一実施形態を示す斜視図である。It is a perspective view which shows one Embodiment of the folding jig for narrowing the space | interval of a straight line part in a folding process. 図３７に示す折り返し治具の辺縁部の突起を正面視した拡大図である。It is an enlarged view which looked at the protrusion of the edge part of the folding jig shown in FIG. 37 from the front view. ２つの突起によって挟着されたターン部の頂点部を示す拡大図である。It is an enlarged view which shows the apex part of the turn part sandwiched by two protrusions.

以下、導体成形装置を用いて波巻コイルを製造する方法について図面を参照して詳細に説明する。
まず、波巻コイル及びステータについて、図１及び図２を用いて説明する。本実施形態に示す波巻コイル１は、後段で説明する複数本の並列状態のコイル線材１０を用いて、図中のＹ方向に沿って長尺なシート状に成形される。このＹ方向は、図２に示すステータコア２０の周方向に対応する。 Hereinafter, a method of manufacturing a wave-wound coil using a conductor forming apparatus will be described in detail with reference to the drawings.
First, the wave winding coil and the stator will be described with reference to FIGS. 1 and 2. The wave winding coil 1 shown in the present embodiment is formed into a long sheet shape along the Y direction in the drawing by using a plurality of coil wires 10 in a parallel state described later. This Y direction corresponds to the circumferential direction of the stator core 20 shown in FIG.

ステータ２は、ステータコア２０と、ステータコア２０に装着される波巻コイル１とにより構成される。ステータコア２０は、中央の軸孔２１に向けて放射状に突出する複数のティース２２を有する。隣り合うティース２２，２２の間にスロット２３が形成される。本実施形態では７２個のスロット２３を有するステータコア２０を例示している。 The stator 2 is composed of a stator core 20 and a wave coil 1 mounted on the stator core 20. The stator core 20 has a plurality of teeth 22 that project radially toward the central shaft hole 21. A slot 23 is formed between the adjacent teeth 22, 22. In this embodiment, the stator core 20 having 72 slots 23 is illustrated.

波巻コイル１は、複数のスロット配置部１１と、複数のターン部１２と、を有する。スロット配置部１１は、ステータコア２０のスロット２３内に配置される部位であり、ステータコア２０の軸方向（図１中のＺ方向）に沿ってストレート状に延びている。ターン部１２は、ステータコア２０の軸方向の外側において、コイル線材１０の隣り合うスロット配置部１１，１１同士を山型状又はアーチ状に連結する部位である。波巻コイル１の一方端部は、駆動回路との電気的接続のための端子部１３となっている。なお、波巻コイル１のスロット配置部１１及びターン部１２は、複数本のコイル線材１０により構成されるが、図１では、これらスロット配置部１１、ターン部１２及び端子部１３を面で模式的に示している。 The wave winding coil 1 has a plurality of slot arrangement portions 11 and a plurality of turn portions 12. The slot arrangement portion 11 is a portion arranged in the slot 23 of the stator core 20, and extends straight along the axial direction (Z direction in FIG. 1) of the stator core 20. The turn portion 12 is a portion outside the stator core 20 in the axial direction in which the adjacent slot arrangement portions 11, 11 of the coil wire rod 10 are connected to each other in a mountain shape or an arch shape. One end of the wave winding coil 1 is a terminal portion 13 for electrical connection with the drive circuit. The slot arrangement portion 11 and the turn portion 12 of the wave winding coil 1 are composed of a plurality of coil wires 10, but in FIG. 1, the slot arrangement portion 11, the turn portion 12, and the terminal portion 13 are schematically shown in a plane. Is shown.

本実施形態の波巻コイル１は、ステータコア２０の４周分の長さを有し、ステータコア２０に全体で１Ｔ〜８Ｔの８層（８ターン）分のコイルを構成する。従って、波巻コイル１は、ステータコア２０の１周当たり２層（２ターン）分のコイルを構成し、ステータコア２０を１周する毎に層替わりする。図１に示す符号Ｔａは、７層（７Ｔ）と６層（６Ｔ）との間、５層（５Ｔ）と４層（４Ｔ）との間、３層（３Ｔ）と２層（２Ｔ）との間、にそれぞれ配置される層替わり部である。 The wave winding coil 1 of the present embodiment has a length of four circumferences of the stator core 20, and constitutes a coil for eight layers (8 turns) of 1T to 8T in total on the stator core 20. Therefore, the wave winding coil 1 constitutes a coil for two layers (two turns) per circumference of the stator core 20, and the layers are changed every time the stator core 20 is rotated once. The reference numeral Ta shown in FIG. 1 is between the 7th layer (7T) and the 6th layer (6T), between the 5th layer (5T) and the 4th layer (4T), and the 3rd layer (3T) and the 2nd layer (2T). It is a layer change part arranged in each of the spaces.

この波巻コイル１は、ステータコア２０を４周するように渦巻状に巻回され、スロット配置部１１をステータコア２０のスロット２３内に配置させることにより、ステータコア２０に装着される。これによりステータ２が構成される。なお、各スロット２３には、波巻コイル１とステータコア２０との間の絶縁を図るためのインシュレータが配置されるが、図２では図示を省略している。 The wave coil 1 is spirally wound around the stator core 20 four times, and is mounted on the stator core 20 by arranging the slot arrangement portion 11 in the slot 23 of the stator core 20. This constitutes the stator 2. An insulator for insulating the wave winding coil 1 and the stator core 20 is arranged in each slot 23, but the illustration is omitted in FIG.

次に、波巻コイル１を構成するコイル線材１０の一実施形態について、図３〜図６を用いて説明する。
コイル線材１０は、銅線等からなる導体である。コイル線材１０は、所定の長さに切断された後、図３に示すように、白抜き矢印に示す方向に移動する引出しツール３００によって、コイル線材１０の延在方向の略中央部において曲げ成形される。本実施形態のコイル線材１０は、図４に示すように、それぞれ平角線からなる３本の単位線材１０ａを、ステータコア２０の周方向に対応するＹ方向に並べて構成される。コイル線材１０は、３本の単位線材１０ａをＹ方向に並べた状態で、引出しツール３００によって、３本の単位線材１０ａの並び方向に一体に曲げ成形されている。 Next, an embodiment of the coil wire 10 constituting the wave winding coil 1 will be described with reference to FIGS. 3 to 6.
The coil wire rod 10 is a conductor made of a copper wire or the like. After being cut to a predetermined length, the coil wire 10 is bent and molded at a substantially central portion in the extending direction of the coil wire 10 by a drawer tool 300 that moves in the direction indicated by the white arrow as shown in FIG. Will be done. As shown in FIG. 4, the coil wire 10 of the present embodiment is configured by arranging three unit wires 10a, each of which is a flat wire, in the Y direction corresponding to the circumferential direction of the stator core 20. The coil wire rod 10 is integrally bent and molded in the alignment direction of the three unit wire rods 10a by the drawing tool 300 in a state where the three unit wire rods 10a are arranged in the Y direction.

引出しツール３００によって曲げ成形されたコイル線材１０は、図示しない成形金型によって、図５及び図６に示すように、山型状となるターン部１２（以下、このコイル線材１０に最初に成形されるターン部１２を第１ターン部１２Ａという場合がある。）と、その第１ターン部１２Ａの両端部から同一方向に平行に延在する２本の直線部１４，１４と、を有する略Ｕ字状に成形される。本実施形態のコイル線材１０の２本の直線部１４，１４の間隔は、ステータコア２０における６スロット離れた２つのスロット２３，２３に対応する間隔を有する。 As shown in FIGS. 5 and 6, the coil wire 10 bent and molded by the drawing tool 300 is first formed into a chevron-shaped turn portion 12 (hereinafter, the coil wire 10) by a molding die (not shown). The turn portion 12 is sometimes referred to as a first turn portion 12A), and two straight portions 14, 14 extending in parallel in the same direction from both ends of the first turn portion 12A. It is molded into a shape. The distance between the two straight portions 14, 14 of the coil wire rod 10 of the present embodiment has a distance corresponding to two slots 23, 23, which are 6 slots apart from each other in the stator core 20.

コイル線材１０の第１ターン部１２Ａは、図５及び図６に示すように、第１斜行部１２ａと、第２斜行部１２ｂと、頂点部１２ｃと、を有する。第１斜行部１２ａ及び第２斜行部１２ｂは、直線部１４，１４に一体に連結されると共に、直線部１４，１４との連結部位から互いに近づく方向に斜めに延び、頂点部１２ｃにおいて一体に連結されている。 As shown in FIGS. 5 and 6, the first turn portion 12A of the coil wire rod 10 has a first skew portion 12a, a second skew portion 12b, and an apex portion 12c. The first skew portion 12a and the second skew portion 12b are integrally connected to the straight portions 14 and 14, and extend diagonally from the connecting portion with the straight portions 14 and 14 in a direction approaching each other, and at the apex portion 12c. They are connected together.

図６に示すように、コイル線材１０の線幅（ステータコア２０の径方向の幅）をＷとしたとき、第１斜行部１２ａは、連結される直線部１４を基準として、Ｘ方向にオフセットすることなく、頂点部１２ｃに向けて傾斜状に延びている。一方、第２斜行部１２ｂは、第１斜行部１２ａに対してＸ１方向にＷだけオフセットした後、直線部１４に向けて傾斜状に延び、その直線部１４との連結部位において、上記と反対方向となるＸ２方向にＷだけオフセットしている。その結果、２つの直線部１４，１４のＸ方向に沿う位置は変わらない。即ち、２つの直線部１４，１４は、Ｙ方向に沿う同一の面内に配置されている。なお、Ｘ１方向及びＸ２方向で示されるＸ方向は、ステータコア２０の径方向に対応する。 As shown in FIG. 6, when the line width of the coil wire 10 (the radial width of the stator core 20) is W, the first skew portion 12a is offset in the X direction with respect to the connected straight portion 14. It extends in an inclined manner toward the apex portion 12c without doing so. On the other hand, the second skew portion 12b is offset by W in the X1 direction with respect to the first skew portion 12a, and then extends in an inclined manner toward the straight portion 14, and at the connecting portion with the straight portion 14, the above. It is offset by W in the X2 direction, which is the opposite direction to the above. As a result, the positions of the two straight portions 14 and 14 along the X direction do not change. That is, the two straight portions 14, 14 are arranged in the same plane along the Y direction. The X direction indicated by the X1 direction and the X2 direction corresponds to the radial direction of the stator core 20.

略Ｕ字状に成形されたコイル線材１０は、波巻コイル１の成形に際して、図７及び図８に示すように、複数本並列される。複数本のコイル線材１０が並列されることによって、導体群１００が構成される。本実施形態では、三相６本のコイル線材１０が使用され、６本のコイル線材１０が、所定ピッチでＹ方向にずれて並列されることによって、導体群１００を構成している。このとき、１２本の直線部１４は、ステータコア２０のスロット間隔に対応する均等間隔で平行に並べられている。各第１ターン部１２Ａの第１斜行部１２ａと第２斜行部１２ｂとは、コイル線材１０の線幅ＷだけＸ方向に沿う反対方向にオフセットしているため、隣り合う第１ターン部１２Ａ，１２Ａの第１斜行部１２ａと第２斜行部１２ｂとを交差させて、隣り合うコイル線材１０，１０同士を重ねると、１２本全ての直線部１４は、Ｙ方向に沿う同一の面内に配置される。 As shown in FIGS. 7 and 8, a plurality of coil wires 10 formed in a substantially U shape are arranged in parallel when the wave winding coil 1 is formed. The conductor group 100 is formed by arranging a plurality of coil wires 10 in parallel. In the present embodiment, three-phase six-coil wire rods 10 are used, and the six coil wire rods 10 are arranged in parallel at a predetermined pitch with a deviation in the Y direction to form the conductor group 100. At this time, the 12 straight portions 14 are arranged in parallel at equal intervals corresponding to the slot intervals of the stator core 20. Since the first skew portion 12a and the second skew portion 12b of each first turn portion 12A are offset in opposite directions along the X direction by the line width W of the coil wire rod 10, they are adjacent to each other in the first turn portion. When the first skew portion 12a and the second skew portion 12b of 12A and 12A are crossed and the adjacent coil wires 10 and 10 are overlapped with each other, all 12 straight portions 14 are the same along the Y direction. Placed in the plane.

次に、６本の並列状態のコイル線材１０からなる導体群１００から波巻コイル１を成形する方法について説明する。最初に、波巻コイル１を成形する際に用いられる導体成形装置２００の具体的な構成について、図９及び図１０を参照して説明する。 Next, a method of forming the wave winding coil 1 from the conductor group 100 composed of the six parallel coil wires 10 will be described. First, a specific configuration of the conductor forming apparatus 200 used when forming the wave winding coil 1 will be described with reference to FIGS. 9 and 10.

導体成形装置２００は、導体群１００を載置する載置台２０１と、それぞれ導体群１００を斜行部成形及び折り返しのために把持する第１クランプ部２０２、第２クランプ部２０３、第３クランプ部２０４と、導体群１００を搬送のために把持する把持機構２０５と、を有する。 The conductor forming apparatus 200 includes a mounting table 201 on which the conductor group 100 is placed, and a first clamp portion 202, a second clamp portion 203, and a third clamp portion that grip the conductor group 100 for forming and folding back the conductor group 100, respectively. It has 204 and a gripping mechanism 205 that grips the conductor group 100 for transportation.

載置台２０１の上面２０１ａには、図示しない搬送装置によって搬送されてきた導体群１００が、ターン部１２（第１ターン部１２Ａ）側を第１クランプ部２０２側に向けて平置きされる。 On the upper surface 201a of the mounting table 201, the conductor group 100 conveyed by a transfer device (not shown) is placed flat with the turn portion 12 (first turn portion 12A) side facing the first clamp portion 202 side.

第１クランプ部２０２、第２クランプ部２０３、第３クランプ部２０４は、成形対象の導体群１００の搬送経路に沿って配置され、導体成形装置２００の上下方向（図９における紙面に対して垂直方向、図１０における上下方向）に昇降移動可能に設けられる。第１クランプ部２０２、第２クランプ部２０３、第３クランプ部２０４は、導体群１００をクランプしない時は、導体群１００の搬送を邪魔しないように、載置台２０１の上面２０１ａよりも下位に配置され、導体群１００が第１クランプ部２０２、第２クランプ部２０３、第３クランプ部２０４の上方まで搬送されると上昇し、導体群１００を把持するように構成される。 The first clamp portion 202, the second clamp portion 203, and the third clamp portion 204 are arranged along the transport path of the conductor group 100 to be molded, and are perpendicular to the paper surface in FIG. 9 in the vertical direction of the conductor molding apparatus 200. It is provided so as to be movable up and down in the direction (vertical direction in FIG. 10). The first clamp portion 202, the second clamp portion 203, and the third clamp portion 204 are arranged below the upper surface 201a of the mounting table 201 so as not to interfere with the transportation of the conductor group 100 when the conductor group 100 is not clamped. Then, when the conductor group 100 is conveyed above the first clamp portion 202, the second clamp portion 203, and the third clamp portion 204, the conductor group 100 rises and is configured to grip the conductor group 100.

第１クランプ部２０２は、最も載置台２０１に近接して配置される。第１クランプ部２０２は、導体群１００を構成するコイル線材１０の直線部１４を一括して把持する一対のクランプ部材２０２Ａ，２０２Ｂを有する。クランプ部材２０２Ａ，２０２Ｂは、図７に示す導体群１００のＹ方向に沿う幅以上の幅をそれぞれ有し、導体群１００の搬送経路に面して、導体群１００の搬送方向であるＤ１方向に一定の間隔をおいて平行に配置される。この一定の間隔によって、クランプ部材２０２Ａ，２０２Ｂの間には、後述する把持機構２０５の一つの把持部材２０５Ａ又は２０５Ｂを収容可能な空間部２０２Ｃが形成される。 The first clamp portion 202 is arranged closest to the mounting table 201. The first clamp portion 202 has a pair of clamp members 202A and 202B that collectively grip the straight portion 14 of the coil wire rod 10 constituting the conductor group 100. The clamp members 202A and 202B each have a width equal to or larger than the width along the Y direction of the conductor group 100 shown in FIG. 7, facing the transport path of the conductor group 100, and in the D1 direction which is the transport direction of the conductor group 100. They are arranged in parallel at regular intervals. With this constant interval, a space portion 202C capable of accommodating one gripping member 205A or 205B of the gripping mechanism 205 described later is formed between the clamp members 202A and 202B.

第２クランプ部２０３は、第１クランプ部２０２に対して載置台２０１から遠い側に配置される。第２クランプ部２０３は、第１クランプ部２０２と同様に、導体群１００を構成するコイル線材１０の直線部１４を一括して把持する一対のクランプ部材２０３Ａ，２０３Ｂを有する。クランプ部材２０３Ａ，２０３Ｂも、導体群１００の幅以上の幅をそれぞれ有し、導体群１００の搬送経路に面して、導体群１００の搬送方向であるＤ１方向に一定の間隔をおいて平行に配置される。この一定の間隔によって、クランプ部材２０３Ａ，２０３Ｂの間には、後述する把持機構２０５の一つの把持部材２０５Ａ又は２０５Ｂを収容可能な空間部２０３Ｃが形成される。 The second clamp portion 203 is arranged on the side farther from the mounting table 201 with respect to the first clamp portion 202. Like the first clamp portion 202, the second clamp portion 203 has a pair of clamp members 203A and 203B that collectively grip the straight portion 14 of the coil wire rod 10 constituting the conductor group 100. The clamp members 203A and 203B also have a width equal to or larger than the width of the conductor group 100, and face the transport path of the conductor group 100 and are parallel to the transport direction of the conductor group 100 in the D1 direction at regular intervals. Be placed. With this constant interval, a space portion 203C capable of accommodating one gripping member 205A or 205B of the gripping mechanism 205 described later is formed between the clamp members 203A and 203B.

第３クランプ部２０４は、第２クランプ部２０３よりも更に載置台２０１から遠い側に配置される。第３クランプ部２０４は、第１クランプ部２０２及び第２クランプ部２０３と同様に、導体群１００を構成するコイル線材１０の直線部１４を一括して把持する一対のクランプ部材２０４Ａ，２０４Ｂを有する。クランプ部材２０４Ａ，２０４Ｂも、導体群１００の幅以上の幅をそれぞれ有し、導体群１００の搬送経路に面して、導体群１００の搬送方向であるＤ１方向に一定の間隔をおいて平行に配置される。この一定の間隔によって、クランプ部材２０４Ａ，２０４Ｂの間には、後述する把持機構２０５の一つの把持部材２０５Ａ又は２０５Ｂを収容可能な空間部２０４Ｃが形成される。 The third clamp portion 204 is arranged on the side farther from the mounting table 201 than the second clamp portion 203. Like the first clamp portion 202 and the second clamp portion 203, the third clamp portion 204 has a pair of clamp members 204A and 204B that collectively grip the straight portion 14 of the coil wire rod 10 constituting the conductor group 100. .. The clamp members 204A and 204B also have a width equal to or larger than the width of the conductor group 100, and face the transport path of the conductor group 100 and are parallel to the transport direction of the conductor group 100 in the D1 direction at regular intervals. Be placed. Due to this constant interval, a space portion 204C capable of accommodating one gripping member 205A or 205B of the gripping mechanism 205 described later is formed between the clamp members 204A and 204B.

第２クランプ部２０３及び第３クランプ部２０４には、上下方向に昇降移動可能な押圧部材２０３Ｄ，２０４Ｄがそれぞれ設けられる。押圧部材２０３Ｄ，２０４Ｄは、導体群１００を面で押圧する板状部材からなる。第２クランプ部２０３の押圧部材２０３Ｄは、クランプ部材２０３Ｂに対して、載置台２０１から遠い側に平行に並列するように近接して配置される。第３クランプ部２０４の押圧部材２０４Ｄは、クランプ部材２０４Ａに対して、載置台２０１に近い側に平行に並列するように近接して配置される。図１０は、押圧部材２０３Ｄ，２０４Ｄがそれぞれ下動した位置にある状態を示している。このときの押圧部材２０３Ｄ，２０４Ｄの上面は、導体群１００の搬送動作及び各クランプ部材２０３Ａ，２０３Ｂ、２０４Ａ，２０４Ｂによる把持動作及び導体群１００の搬送動作を阻害しないように、クランプ部材２０３Ａ，２０３Ｂ、２０４Ａ，２０４Ｂの上面よりも下位に配置される。 The second clamp portion 203 and the third clamp portion 204 are provided with pressing members 203D and 204D that can move up and down in the vertical direction, respectively. The pressing members 203D and 204D are composed of plate-shaped members that press the conductor group 100 on the surface. The pressing member 203D of the second clamp portion 203 is arranged close to the clamp member 203B so as to be parallel to the side far from the mounting table 201. The pressing member 204D of the third clamp portion 204 is arranged close to the clamp member 204A so as to be parallel to the side closer to the mounting table 201. FIG. 10 shows a state in which the pressing members 203D and 204D are in the downwardly moved positions, respectively. The upper surfaces of the pressing members 203D and 204D at this time are clamp members 203A and 203B so as not to interfere with the transport operation of the conductor group 100, the gripping operation by the clamp members 203A, 203B, 204A and 204B and the transfer operation of the conductor group 100. , 204A, 204B are arranged below the upper surface.

図９及び図１０に示すように、第１クランプ部２０２における載置台２０１から遠い側のクランプ部材２０２Ｂと、第２クランプ部２０３における載置台２０１に近い側のクランプ部材２０３Ａとは、距離Ｌ１だけ離れている。また、第２クランプ部２０３における載置台２０１から遠い側のクランプ部材２０３Ｂと、第３クランプ部２０４における載置台２０１に近い側のクランプ部材２０４Ａとは、距離Ｌ２だけ離れている。距離Ｌ２は、距離Ｌ１よりも短い。 As shown in FIGS. 9 and 10, the clamp member 202B on the side far from the mounting base 201 in the first clamp portion 202 and the clamp member 203A on the side close to the mounting base 201 in the second clamp portion 203 are only at a distance L1. is seperated. Further, the clamp member 203B on the side far from the mounting table 201 in the second clamp portion 203 and the clamp member 204A on the side close to the mounting table 201 in the third clamp portion 204 are separated by a distance L2. The distance L2 is shorter than the distance L1.

第３クランプ部２０４は、第１クランプ部２０２及び第２クランプ部２０３に対して、導体成形装置２００の幅方向（図９におけるＤ２−Ｄ３方向）の一方向（図９におけるＤ２方向）にオフセットして配置される。Ｄ２−Ｄ３方向は、導体群１００の搬送方向であるＤ１方向に対して直交する方向である。第２クランプ部２０３に対する第３クランプ部２０４のＤ２方向へのオフセット量は、導体群１００の幅の半分、すなわち、コイル線材１０の直線部１４の６本分のピッチに相当する。 The third clamp portion 204 is offset in one direction (D2 direction in FIG. 9) of the conductor forming apparatus 200 in the width direction (D2-D3 direction in FIG. 9) with respect to the first clamp portion 202 and the second clamp portion 203. And are placed. The D2-D3 direction is a direction orthogonal to the D1 direction, which is the transport direction of the conductor group 100. The amount of offset of the third clamp portion 204 with respect to the second clamp portion 203 in the D2 direction corresponds to half the width of the conductor group 100, that is, the pitch of six straight portions 14 of the coil wire rod 10.

第２クランプ部２０３と第３クランプ部２０４とは、図示しない移動機構によって、導体成形装置２００の幅方向に一体となって移動可能に設けられる。しかし、第１クランプ部２０２は不動である。そのため、少なくとも第１クランプ部２０２と第２クランプ部２０３とが導体群１００を把持した状態で、第２クランプ部２０３が第１クランプ部２０２に対して導体成形装置２００の幅方向に移動することによって、第１クランプ部２０２と第２クランプ部２０３との間に配置される導体群１００の直線部１４を斜めに折り曲げ、図１５に示す斜行部１５を形成することができる。したがって、第１クランプ部２０２と少なくとも第２クランプ部２０３とは、導体成形装置２００における斜行部成形機構２０６を構成する。 The second clamp portion 203 and the third clamp portion 204 are provided so as to be integrally movable in the width direction of the conductor forming apparatus 200 by a moving mechanism (not shown). However, the first clamp portion 202 is immovable. Therefore, the second clamp portion 203 moves in the width direction of the conductor forming apparatus 200 with respect to the first clamp portion 202 while at least the first clamp portion 202 and the second clamp portion 203 grip the conductor group 100. Therefore, the straight portion 14 of the conductor group 100 arranged between the first clamp portion 202 and the second clamp portion 203 can be bent diagonally to form the oblique portion 15 shown in FIG. Therefore, the first clamp portion 202 and at least the second clamp portion 203 form the oblique portion forming mechanism 206 in the conductor forming apparatus 200.

第３クランプ部２０４は、第２クランプ部２０３との間を幅方向に延びる折り返し線Ｒ（図９参照）を境にして、図示しない回転移動機構によって、図２０に示すように、第２クランプ部２０３上に重なるように回転移動可能に設けられる。第３クランプ部２０４の回転移動によって、クランプ部材２０３Ａとクランプ部材２０４Ｂ、クランプ部材２０３Ｂとクランプ部材２０４Ａ、空間部２０３Ｃ，２０４Ｄ同士、押圧部材２０３Ｄ，２０４Ｄ同士、がそれぞれ重なり合う。これによって、第２クランプ部２０３及び第３クランプ部２０４に把持される導体群１００は、折り返し線Ｒを境にして、厚さ方向（図８におけるＸ１−Ｘ２方向）に折り返される。したがって、第２クランプ部２０３と第３クランプ部２０４とは、導体成形装置２００における折り返し機構２０７を構成する。 The third clamp portion 204 has a second clamp as shown in FIG. 20 by a rotational movement mechanism (not shown) with a folding line R (see FIG. 9) extending in the width direction between the third clamp portion 204 and the second clamp portion 203 as a boundary. It is provided so as to be rotatable and movable so as to overlap the portion 203. Due to the rotational movement of the third clamp portion 204, the clamp member 203A and the clamp member 204B, the clamp member 203B and the clamp member 204A, the space portions 203C and 204D, and the pressing members 203D and 204D overlap each other. As a result, the conductor group 100 gripped by the second clamp portion 203 and the third clamp portion 204 is folded back in the thickness direction (X1-X2 direction in FIG. 8) with the folding line R as a boundary. Therefore, the second clamp portion 203 and the third clamp portion 204 form the folding mechanism 207 in the conductor forming apparatus 200.

把持機構２０５は、図１０に示すように、載置台２０１の上面２０１ａよりも上位に配置され、図示しない昇降機構によって、下方に配置される導体群１００に対して昇降可能に設けられる。把持機構２０５は、導体群１００の幅以上の幅をそれぞれ有する一対の把持部材２０５Ａ，２０５Ｂを有する。一対の把持部材２０５Ａ，２０５Ｂとは同一構造である。把持部材２０５Ａ，２０５Ｂは、Ｄ１方向に沿って一定の距離だけ離れて配置されるとともに、把持部材２０５Ｂが、把持部材２０５Ａに対して、Ｄ２方向にオフセットして配置される。 As shown in FIG. 10, the gripping mechanism 205 is arranged above the upper surface 201a of the mounting table 201, and is provided so as to be able to move up and down with respect to the conductor group 100 arranged below by an elevating mechanism (not shown). The gripping mechanism 205 has a pair of gripping members 205A and 205B having a width equal to or larger than the width of the conductor group 100, respectively. The pair of gripping members 205A and 205B have the same structure. The gripping members 205A and 205B are arranged at a certain distance along the D1 direction, and the gripping member 205B is arranged offset with respect to the gripping member 205A in the D2 direction.

本実施形態の把持機構２０５は、折り返し機構２０７を構成する第２クランプ部２０３及び第３クランプ部２０４とは別体で設けられている。そのため、折り返し機構２０７における折り返し位置を常に一定にすることができ、折り返し位置の精度を良好にすることができる。 The gripping mechanism 205 of the present embodiment is provided separately from the second clamp portion 203 and the third clamp portion 204 constituting the folding back mechanism 207. Therefore, the folding position of the folding mechanism 207 can always be constant, and the accuracy of the folding position can be improved.

把持機構２０５と第１クランプ部２０２、第２クランプ部２０３及び第３クランプ部２０４とは、Ｄ１方向に沿って相対的に移動可能である。本実施形態では、把持機構２０５が、Ｄ１方向に沿って移動可能に設けられる。これによって、把持機構２０５は、把持した導体群１００を、Ｄ１方向に沿う搬送経路に沿って搬送し、第１クランプ部２０２、第２クランプ部２０３及び第３クランプ部２０４に対する相対位置を変更させる。 The gripping mechanism 205, the first clamp portion 202, the second clamp portion 203, and the third clamp portion 204 are relatively movable along the D1 direction. In the present embodiment, the gripping mechanism 205 is provided so as to be movable along the D1 direction. As a result, the gripping mechanism 205 transports the gripped conductor group 100 along the transport path along the D1 direction, and changes the relative positions of the gripped conductor group 100 with respect to the first clamp portion 202, the second clamp portion 203, and the third clamp portion 204. ..

一対の把持部材２０５Ａ，２０５ＢのＤ１方向に沿う間隔は、図９に示す初期状態の第１クランプ部２０２の空間部２０２Ｃと第２クランプ部２０３の空間部２０３Ｃとの間隔よりも僅かに狭く、第２クランプ部２０３の空間部２０３Ｃと第３クランプ部２０４の空間部２０４Ｃとの間隔に等しい。把持部材２０５Ａに対する把持部材２０５ＢのＤ２方向に沿うオフセット量は、第２クランプ部２０３に対する第３クランプ部２０４のＤ２方向に沿うオフセット量に等しい。 The distance between the pair of gripping members 205A and 205B along the D1 direction is slightly narrower than the distance between the space portion 202C of the first clamp portion 202 and the space portion 203C of the second clamp portion 203 in the initial state shown in FIG. It is equal to the distance between the space portion 203C of the second clamp portion 203 and the space portion 204C of the third clamp portion 204. The offset amount of the gripping member 205B with respect to the gripping member 205A along the D2 direction is equal to the offset amount of the third clamp portion 204 with respect to the second clamp portion 203 along the D2 direction.

各クランプ部材２０２Ａ，２０２Ｂ、２０３Ａ，２０３Ｂ、２０４Ａ，２０４Ｂ及び把持部材２０５Ａ，２０５Ｂが導体群１００を把持するための具体的な構造は、各クランプ部材２０２Ａ，２０２Ｂ、２０３Ａ，２０３Ｂ、２０４Ａ，２０４Ｂ及び把持部材２０５Ａ，２０５Ｂで同一であってもよい。導体群１００を把持するための構造は、例えば、図１１及び図１２に示すように、導体群１００の幅方向（図７におけるＹ方向）に開閉可能に並置される複数のブロック２１０によって構成することができる。各ブロック２１０は、導体群００を構成する各コイル線材１０の直線部１４の幅（図４におけるＹ方向の幅）よりも僅かに細幅の溝部２１０ａを有する。各溝部２１０ａは、導体群１００の直線部１４の延在方向であるＤ１方向に沿って延びている。 Specific structures for the clamp members 202A, 202B, 203A, 203B, 204A, 204B and the gripping members 205A, 205B to grip the conductor group 100 include the clamp members 202A, 202B, 203A, 203B, 204A, 204B and The gripping members 205A and 205B may be the same. The structure for gripping the conductor group 100 is composed of, for example, as shown in FIGS. 11 and 12, a plurality of blocks 210 juxtaposed so as to be openable and closable in the width direction (Y direction in FIG. 7) of the conductor group 100. be able to. Each block 210 has a groove portion 210a that is slightly narrower than the width of the straight portion 14 (width in the Y direction in FIG. 4) of each coil wire rod 10 constituting the conductor group 00. Each groove 210a extends along the D1 direction, which is the extending direction of the straight portion 14 of the conductor group 100.

溝部２１０ａは、ブロック２１０の幅方向の一方の側面から上面の略半分にかけて切り欠かれることによって形成され、各ブロック２１０の上面の残りの半分によって、コイル線材１０の直線部１４を挟み付けるための挟着片２１０ｂが形成される。溝部２１０ａ及び挟着片２１０ｂは、１つのブロック２１０についてそれぞれ１つずつ形成される。溝部２１０ａ及び挟着片２１０ｂの数は、導体群１００の直線部１４の本数以上である。すなわち、本実施形態の場合、１つのクランプ部材２０２Ａ，２０２Ｂ、２０３Ａ，２０３Ｂ、２０４Ａ，２０４Ｂ又は把持部材２０５Ａ，２０５Ｂは、少なくとも１２本の溝部２１０ａ及び挟着片２１０ｂを有する。 The groove portion 210a is formed by notching from one side surface in the width direction of the block 210 to approximately half of the upper surface, and the other half of the upper surface of each block 210 sandwiches the straight portion 14 of the coil wire rod 10. The sandwiching piece 210b is formed. One groove portion 210a and one sandwich piece 210b are formed for each block 210. The number of groove portions 210a and sandwiching pieces 210b is equal to or greater than the number of straight portions 14 of the conductor group 100. That is, in the case of the present embodiment, one clamp member 202A, 202B, 203A, 203B, 204A, 204B or the gripping member 205A, 205B has at least 12 groove portions 210a and a sandwiching piece 210b.

図１１に示すように、各ブロック２１０が離れると、クランプ部材２０２Ａ，２０２Ｂ、２０３Ａ，２０３Ｂ、２０４Ａ，２０４Ｂ及び把持部材２０５Ａ，２０５Ｂは開いた状態となる。このとき、隣接する挟着片２１０ｂ，２１０ｂ間に配置される溝部２１０ａの幅は、コイル線材１０の直線部１４の幅よりも広くなる。そのため、各溝部２１０ａは、コイル線材１０の直線部１４を内部に収容可能又は内部から取り出し可能である。 As shown in FIG. 11, when the blocks 210 are separated, the clamp members 202A, 202B, 203A, 203B, 204A, 204B and the gripping members 205A, 205B are opened. At this time, the width of the groove portion 210a arranged between the adjacent sandwiching pieces 210b and 210b is wider than the width of the straight portion 14 of the coil wire rod 10. Therefore, each groove portion 210a can accommodate the straight portion 14 of the coil wire rod 10 inside or can be taken out from the inside.

一方、図１２に示すように、各ブロック２１０が密接すると、クランプ部材２０２Ａ，２０２Ｂ、２０３Ａ，２０３Ｂ、２０４Ａ，２０４Ｂ及び把持部材２０５Ａ，２０５Ｂは閉じた状態となる。このとき、隣接する挟着片２１０ｂ，２１０ｂ間に配置される溝部２１０ａの幅は、コイル線材１０の直線部１４の幅よりも僅かに狭くなる。そのため、各溝部２１０ａ内に収容されたコイル線材１０の直線部１４は、隣接する挟着片２１０ｂ，２１０ｂでそれぞれ個別に挟着される。これによって、導体群１００は把持される。 On the other hand, as shown in FIG. 12, when the blocks 210 are in close contact with each other, the clamp members 202A, 202B, 203A, 203B, 204A, 204B and the gripping members 205A, 205B are closed. At this time, the width of the groove portion 210a arranged between the adjacent sandwiching pieces 210b and 210b is slightly narrower than the width of the straight portion 14 of the coil wire rod 10. Therefore, the straight portion 14 of the coil wire rod 10 housed in each groove portion 210a is individually sandwiched by the adjacent sandwiching pieces 210b and 210b, respectively. As a result, the conductor group 100 is gripped.

このように、導体群１００を把持するクランプ部材２０２Ａ，２０２Ｂ、２０３Ａ，２０３Ｂ、２０４Ａ，２０４Ｂ及び把持部材２０５Ａ，２０５Ｂは、コイル線材１０の直線部１４の各々を幅方向から把持する。直線部１４の幅方向（図４及び図７に示すＹ方向）は、コイル線材１０を構成する複数の単位線材１０ａの積層方向である。そのため、複数の単位線材１０ａの間に厚さ方向（図４に示すＸ方向）のばらつきがあっても、コイル線材１０を構成する複数の単位線材１０ａを一体に挟着することによって把持可能である。しかも、単位線材１０ａがばらつかないようにコイル線材１０を押さえるための別途の押さえ部材が不要であるため、装置の小型化も可能である。 In this way, the clamp members 202A, 202B, 203A, 203B, 204A, 204B and the gripping members 205A, 205B that grip the conductor group 100 grip each of the straight portions 14 of the coil wire rod 10 from the width direction. The width direction of the straight portion 14 (the Y direction shown in FIGS. 4 and 7) is the stacking direction of the plurality of unit wires 10a constituting the coil wire 10. Therefore, even if there is a variation in the thickness direction (X direction shown in FIG. 4) among the plurality of unit wires 10a, it can be gripped by integrally sandwiching the plurality of unit wires 10a constituting the coil wire 10. is there. Moreover, since a separate holding member for holding the coil wire 10a is not required so that the unit wire 10a does not vary, the device can be miniaturized.

なお、図１１及び図１２は、導体群１００の直線部１４を下側から把持する場合を示している。これは、クランプ部材２０２Ａ，２０２Ｂ、２０３Ａ，２０３Ｂ、２０４Ａ，２０４Ｂによって導体群１００の直線部１４を下側から把持する場合に対応する。把持部材２０５Ａ，２０５Ｂよって導体群１００の直線部１４を上側から把持する場合は、図１１及び図１２を上下反転させた構成となる。 11 and 12 show a case where the straight portion 14 of the conductor group 100 is gripped from below. This corresponds to the case where the straight portion 14 of the conductor group 100 is gripped from below by the clamp members 202A, 202B, 203A, 203B, 204A, 204B. When the straight portion 14 of the conductor group 100 is gripped from above by the gripping members 205A and 205B, FIGS. 11 and 12 are inverted.

次に、この導体成形装置２００によって導体群１００に対して成形を行う際の具体的な成形動作について説明する。
まず、図９及び図１０に示すように、載置台２０１の上面２０１ａに、６本のコイル線材１０からなる導体群１００が、ターン部１２（第１ターン部１２Ａ）を第１クランプ部２０２側に向けて載置される。 Next, a specific molding operation when molding the conductor group 100 with the conductor molding device 200 will be described.
First, as shown in FIGS. 9 and 10, on the upper surface 201a of the mounting table 201, a conductor group 100 composed of six coil wire rods 10 has a turn portion 12 (first turn portion 12A) on the first clamp portion 202 side. It is placed toward.

把持機構２０５が載置台２０１上の導体群１００に向けて移動し、載置台２０１に近い側に配置される把持部材２０５Ａが導体群１００の上方に配置されると、把持機構２０５が下降し、把持部材２０５Ａが導体群１００のターン部１２（第１ターン部１２Ａ）近傍の直線部１４をそれぞれ把持する。このとき、もう一方の把持部材２０５Ｂは、載置台２０１と第１クランプ部２０２との間に配置され、導体群１００を把持しない。把持機構２０５は、導体群１００を把持した状態で、直線部１４の延在方向に沿うＤ１方向に直線的に移動し、図１３に示すように、導体群１００を、斜行部成形機構２０６を構成する第１クランプ部２０２及び第２クランプ部２０３の上方まで搬送する。 When the gripping mechanism 205 moves toward the conductor group 100 on the mounting table 201 and the gripping member 205A arranged on the side closer to the mounting table 201 is arranged above the conductor group 100, the gripping mechanism 205 is lowered. The gripping member 205A grips each of the straight portions 14 in the vicinity of the turn portion 12 (first turn portion 12A) of the conductor group 100. At this time, the other gripping member 205B is arranged between the mounting table 201 and the first clamp portion 202, and does not grip the conductor group 100. The gripping mechanism 205 linearly moves in the D1 direction along the extending direction of the straight portion 14 while gripping the conductor group 100, and as shown in FIG. 13, the conductor group 100 is moved by the oblique portion forming mechanism 206. To the upper part of the first clamp portion 202 and the second clamp portion 203 constituting the above.

図１３における符号２０８は、載置台２０１と第１クランプ部２０２との間に配置される複数のピンからなるガイド部材である。ガイド部材２０８は、導体群１００のターン部１２（第１ターン部１２Ａ）が第１クランプ部２０２の上方を通過した後に、導体群１００の下方から上昇し、隣接する直線部１４，１４の間にそれぞれ挿入される。これによって、搬送時の導体群１００の直線部１４同士の干渉が防止され、導体群１００の円滑な搬送がガイドされる。 Reference numeral 208 in FIG. 13 is a guide member composed of a plurality of pins arranged between the mounting table 201 and the first clamp portion 202. The guide member 208 rises from below the conductor group 100 after the turn portion 12 (first turn portion 12A) of the conductor group 100 passes above the first clamp portion 202, and is between the adjacent straight portions 14, 14. Is inserted into each. As a result, interference between the straight portions 14 of the conductor group 100 during transportation is prevented, and smooth transportation of the conductor group 100 is guided.

導体群１００を把持した把持部材２０５Ａは、図１３及び図１４に示すように、第２クランプ部２０３の空間部２０３Ｃの上方まで移動した後、第１クランプ部２０２、第２クランプ部２０３及び第３クランプ部２０４が一体に上昇することによって、空間部２０３Ｃ内に収容される。第１クランプ部２０２及び第２クランプ部２０３の上昇時、クランプ部材２０２Ａ，２０２Ｂ、２０３Ａ，２０３Ｂは、図１１に示すように開いた状態である。そのため、第１クランプ部２０２及び第２クランプ部２０３の上昇によって、隣接する挟着片２１０ｂ，２１０ｂ間の各溝部２１０ａ内に導体群１００の直線部１４がそれぞれ収容される。溝部２１０ａ内に直線部１４が収容された後、クランプ部材２０２Ａ，２０２Ｂ、２０３Ａ，２０３Ｂは閉じた状態となり、導体群１００を把持する。 As shown in FIGS. 13 and 14, the gripping member 205A that grips the conductor group 100 moves to the upper side of the space portion 203C of the second clamp portion 203, and then moves to the first clamp portion 202, the second clamp portion 203, and the second clamp portion 203. 3 The clamp portion 204 is integrally raised so as to be housed in the space portion 203C. When the first clamp portion 202 and the second clamp portion 203 are raised, the clamp members 202A, 202B, 203A, and 203B are in an open state as shown in FIG. Therefore, as the first clamp portion 202 and the second clamp portion 203 rise, the straight portion 14 of the conductor group 100 is accommodated in each groove portion 210a between the adjacent sandwiching pieces 210b and 210b. After the straight portion 14 is accommodated in the groove portion 210a, the clamp members 202A, 202B, 203A, and 203B are closed and grip the conductor group 100.

図１３及び図１４に示すように、第１クランプ部２０２及び第２クランプ部２０３がそれぞれ把持する直線部１４の被把持部１４０，１４０は、波巻コイル１のスロット配置部１１に対応する部位である。このため、直線部１４の延在方向に沿う一対のクランプ部材２０２Ａ，２０２Ｂの間隔（空間部２０２Ｃを含む第１クランプ部２０２のＤ１方向の長さ）及び一対のクランプ部材２０３Ａ，２０３Ｂの間隔（空間部２０３Ｃを含む第２クランプ部２０３のＤ１方向の長さ）は、それぞれ波巻コイル１のスロット配置部１１の長さに略等しい。 As shown in FIGS. 13 and 14, the gripped portions 140 and 140 of the straight portion 14 gripped by the first clamp portion 202 and the second clamp portion 203, respectively, correspond to the slot arrangement portion 11 of the wave winding coil 1. Is. Therefore, the distance between the pair of clamp members 202A and 202B along the extending direction of the straight line portion 14 (the length of the first clamp portion 202 including the space portion 202C in the D1 direction) and the distance between the pair of clamp members 203A and 203B (the distance between the pair of clamp members 203A and 203B). The length of the second clamp portion 203 including the space portion 203C in the D1 direction) is substantially equal to the length of the slot arrangement portion 11 of the wave winding coil 1, respectively.

図１３及び図１４に示すように、導体群１００の直線部１４において、第１クランプ部２０２と第２クランプ部２０３との間に配置される部位１４１は、導体群１００において斜行部１５が成形される部位であり、波巻コイル１のターン部１２に対応する部位である。この部位１４１の長さ、すなわち、図９及び図１０に示す第１クランプ部２０２と第２クランプ部２０３との距離Ｌ１は、波巻コイル１の１本のターン部１２を一直線状に延ばした場合の長さに略等しい。 As shown in FIGS. 13 and 14, in the straight portion 14 of the conductor group 100, the portion 141 arranged between the first clamp portion 202 and the second clamp portion 203 has the oblique portion 15 in the conductor group 100. It is a part to be molded and is a part corresponding to the turn portion 12 of the wave winding coil 1. The length of this portion 141, that is, the distance L1 between the first clamp portion 202 and the second clamp portion 203 shown in FIGS. 9 and 10, extends one turn portion 12 of the wave winding coil 1 in a straight line. Approximately equal to the length of the case.

第１クランプ部２０２及び第２クランプ部２０３が導体群１００を把持した後、把持機構２０５は、導体群１００の把持を解除するとともに上昇し、導体群１００の上方に退避する。その後、次の把持動作に備えて、図１５に示すように、把持部材２０５Ａが第１クランプ部２０２の空間部２０２Ｃの上方に配置されるように移動する。 After the first clamp portion 202 and the second clamp portion 203 grip the conductor group 100, the gripping mechanism 205 releases the grip of the conductor group 100 and rises, and retracts above the conductor group 100. After that, as shown in FIG. 15, the gripping member 205A moves so as to be arranged above the space portion 202C of the first clamp portion 202 in preparation for the next gripping operation.

次に、導体成形装置２００は、第１クランプ部２０２及び第２クランプ部２０３によって導体群１００を把持した状態から、第１クランプ部２０２に対して、第２クランプ部２０３及び第３クランプ部２０４を、図１５に示すように、Ｄ２方向に移動させる。すなわち、導体群１００におけるコイル線材１０の第１ターン部１２Ａと第２クランプ部２０３で把持された被把持部１４０とを、導体群１００のコイル線材１０の延在する面内（図１５の紙面内）において、直線部１４の延在方向と交差する方向（Ｄ２方向）に沿ってオフセットさせる。これによって、第１クランプ部２０２と第２クランプ部２０３との間に配置される１２本の直線部１４からなる部位１４１がオフセット方向（Ｄ２方向）に傾斜し、導体群１００を構成する各コイル線材１０に１番目の斜行部１５（斜行部１５Ａ）がそれぞれ成形される。 Next, the conductor forming apparatus 200 holds the conductor group 100 by the first clamp portion 202 and the second clamp portion 203, and then refers to the first clamp portion 202 with respect to the second clamp portion 203 and the third clamp portion 204. Is moved in the D2 direction as shown in FIG. That is, the first turn portion 12A of the coil wire rod 10 in the conductor group 100 and the gripped portion 140 gripped by the second clamp portion 203 are placed in the extending plane of the coil wire rod 10 of the conductor group 100 (paper surface of FIG. 15). (Inside), offset along the direction (D2 direction) intersecting the extending direction of the straight line portion 14. As a result, the portion 141 composed of the 12 straight portions 14 arranged between the first clamp portion 202 and the second clamp portion 203 is inclined in the offset direction (D2 direction), and each coil constituting the conductor group 100 is formed. The first skew portion 15 (skew portion 15A) is formed on the wire rod 10.

直線部１４に対する斜行部１５の傾斜角度は、図５に示すように、コイル線材１０に成形されるターン部１２の第１斜行部１２ａ又は第２斜行部１２ｂの傾斜角度に略等しい。導体群１００に斜行部１５が成形されることによって、第２クランプ部２０３によって把持される導体群１００のターン部１２（第１ターン部１２Ａ）側は、第１クランプ部２０２によって把持される直線部１４に対して、導体群１００の幅の半分、すなわち、コイル線材１０の直線部１４の６本分のピッチに相当するオフセット量で、Ｄ２方向にずれて配置される。 As shown in FIG. 5, the inclination angle of the oblique portion 15 with respect to the straight portion 14 is substantially equal to the inclination angle of the first oblique portion 12a or the second oblique portion 12b of the turn portion 12 formed on the coil wire rod 10. .. By forming the skew portion 15 into the conductor group 100, the turn portion 12 (first turn portion 12A) side of the conductor group 100 gripped by the second clamp portion 203 is gripped by the first clamp portion 202. The conductors are arranged so as to be offset in the D2 direction with respect to the straight portion 14 by an offset amount corresponding to half the width of the conductor group 100, that is, a pitch corresponding to the pitch of six straight portions 14 of the coil wire rod 10.

本実施形態の導体成形装置２００は、斜行部１５を成形する際、第２クランプ部２０３側をＤ２方向に直線移動させるのではなく、図１６に示すように、各斜行部１５と、この斜行部１５に連続し且つ第１クランプ部２０２によって把持される各直線部１４との境界点である曲げ起点Ｐを中心とするとともに斜行部１５の長さを半径として、第２クランプ部２０３側を円弧状に移動させるように構成される。このとき、第２クランプ部２０３側は、第１クランプ部２０２に対して平行を維持したまま円弧状に移動する。これによって、図１７に示すように、斜行部１５（部位１４１）は、反対方向に引っ張られながら成形されるため、成形後の斜行部１５の直線性が良好となり、斜行部１５の成形精度が向上する。 In the conductor forming apparatus 200 of the present embodiment, when the oblique portion 15 is formed, the second clamp portion 203 side is not linearly moved in the D2 direction, but as shown in FIG. The second clamp is centered on the bending starting point P, which is a boundary point between the straight portion 14 and the straight portion 14 which is continuous with the skew portion 15 and is gripped by the first clamp portion 202, and the length of the skew portion 15 is used as a radius. It is configured to move the portion 203 side in an arc shape. At this time, the second clamp portion 203 side moves in an arc shape while maintaining parallelism with the first clamp portion 202. As a result, as shown in FIG. 17, since the oblique portion 15 (site 141) is formed while being pulled in the opposite direction, the linearity of the oblique portion 15 after molding is improved, and the oblique portion 15 is formed. Molding accuracy is improved.

斜行部１５の成形のために第２クランプ部２０３がＤ２方向にオフセットすると、図１５に示すように、第１クランプ部２０２の空間部２０２Ｃと第２クランプ部２０３の空間部２０３Ｃとの間隔は、僅かに小さくなり、一対の把持部材２０５Ａ，２０５Ｂの間隔に一致する。したがって、導体群１００に最初の斜行部１５（斜行部１５Ａ）が成形された後、把持機構２０５が、図１５に示す位置において導体群１００に向けて下降すると、把持部材２０５Ａ，２０５Ｂは、空間部２０２Ｃ，２０３Ｃ内にそれぞれ収容され、導体群１００を把持することができる。 When the second clamp portion 203 is offset in the D2 direction due to the molding of the skew portion 15, the distance between the space portion 202C of the first clamp portion 202 and the space portion 203C of the second clamp portion 203 is as shown in FIG. Is slightly smaller and coincides with the distance between the pair of gripping members 205A and 205B. Therefore, when the gripping mechanism 205 descends toward the conductor group 100 at the position shown in FIG. 15 after the first skew portion 15 (skew portion 15A) is formed on the conductor group 100, the grip members 205A and 205B , Each of which is housed in the space portions 202C and 203C, and can grip the conductor group 100.

このとき、一対の把持部材２０５Ａ，２０５Ｂは、斜行部１５を挟んだ両側にそれぞれ配置される直線部１４，１４の二点で導体群１００を把持するため、導体群１００がばらけにくい。その後、把持機構２０５が導体群１００を把持すると、第１クランプ部２０２及び第２クランプ部２０３は、導体群１００の把持を解除して下降するとともに、Ｄ３方向に移動し、初期状態の位置に復帰する。 At this time, since the pair of gripping members 205A and 205B grip the conductor group 100 at two points of the straight lines 14 and 14 arranged on both sides of the oblique portion 15, the conductor group 100 is difficult to disperse. After that, when the gripping mechanism 205 grips the conductor group 100, the first clamp portion 202 and the second clamp portion 203 release the grip of the conductor group 100 and descend, and move in the D3 direction to the initial state positions. Return.

その後、導体群１００を把持した把持機構２０５は、Ｄ１方向に移動し、図１８に示すように、把持部材２０５Ａが第２クランプ部２０３の空間部２０３Ｃの上方に配置されるとともに、把持部材２０５Ｂが第３クランプ部２０４の空間部２０４Ｃの上方に配置されるまで、導体群１００を搬送する。第３クランプ部２０４は、第１クランプ部２０２及び第２クランプ部２０３に対して、予め導体群１００の幅の半分だけＤ２方向にオフセットし、把持機構２０５の把持部材２０５Ｂも把持部材２０５Ａに対して同様にオフセットしているため、第１クランプ部２０２、第２クランプ部２０３及び第３クランプ部２０４が上昇すると、最初の斜行部１５（斜行部１５Ａ）を成形した後の導体群１００を把持した把持部材２０５Ａ，２０５Ｂは、第２クランプ部２０３の空間部２０３Ｃと第３クランプ部２０４の空間部２０４Ｃとにそれぞれ収容される。 After that, the gripping mechanism 205 that grips the conductor group 100 moves in the D1 direction, and as shown in FIG. 18, the gripping member 205A is arranged above the space portion 203C of the second clamp portion 203, and the gripping member 205B is arranged. Conducts the conductor group 100 until is placed above the space portion 204C of the third clamp portion 204. The third clamp portion 204 is previously offset in the D2 direction by half the width of the conductor group 100 with respect to the first clamp portion 202 and the second clamp portion 203, and the grip member 205B of the grip mechanism 205 is also relative to the grip member 205A. Similarly, when the first clamp portion 202, the second clamp portion 203, and the third clamp portion 204 rise, the conductor group 100 after forming the first skew portion 15 (skew portion 15A) is formed. The gripping members 205A and 205B that grip the above are housed in the space portion 203C of the second clamp portion 203 and the space portion 204C of the third clamp portion 204, respectively.

第１クランプ部２０２、第２クランプ部２０３及び第３クランプ部２０４は、上昇後、それぞれ導体群１００の直線部１４を把持するとともに、把持機構２０５は導体群１００の把持を解除する。このとき、導体群１００に成形された斜行部１５は、第２クランプ部２０３のクランプ部材２０３Ｂと第３クランプ部２０４のクランプ部材２０４Ａとの間に配置される。すなわち、クランプ部材２０３Ｂとクランプ部材２０４Ａとの間の距離Ｌ２は、斜行部１５を挟んで隣接する直線部１４，１４間の距離に略等しい。また、第１クランプ部２０２と第２クランプ部２０３との間には、次に成形される斜行部１５となる部位１４１が新たに配置される。把持機構２０５は、導体群１００の上方に退避した後、図１９に示すように、次の把持に備えて、第１クランプ部２０２の空間部２０２Ｄ及び第２クランプ部２０３の空間部２０３Ｃの上方まで移動する。 The first clamp portion 202, the second clamp portion 203, and the third clamp portion 204 each grip the straight portion 14 of the conductor group 100 after ascending, and the gripping mechanism 205 releases the grip of the conductor group 100. At this time, the oblique portion 15 formed into the conductor group 100 is arranged between the clamp member 203B of the second clamp portion 203 and the clamp member 204A of the third clamp portion 204. That is, the distance L2 between the clamp member 203B and the clamp member 204A is substantially equal to the distance between the straight portions 14 and 14 adjacent to each other with the oblique portion 15 in between. Further, a portion 141 to be the oblique portion 15 to be formed next is newly arranged between the first clamp portion 202 and the second clamp portion 203. After retracting above the conductor group 100, the gripping mechanism 205 is above the space portion 202D of the first clamp portion 202 and the space portion 203C of the second clamp portion 203 in preparation for the next grip, as shown in FIG. Move to.

その後、図１５に示した場合と同様に、第２クランプ部２０３及び第３クランプ部２０４をＤ２方向に移動させることによって、図１９に示すように、第１クランプ部２０２と第２クランプ部２０３との間に、２番目の斜行部１５（斜行部１５Ｂ）をそれぞれ成形する（斜行部成形工程）。 After that, as in the case shown in FIG. 15, by moving the second clamp portion 203 and the third clamp portion 204 in the D2 direction, as shown in FIG. 19, the first clamp portion 202 and the second clamp portion 203 are moved. The second skewed portion 15 (skewed portion 15B) is molded between the two (skewed portion molding step).

次に、第２クランプ部２０３と第３クランプ部２０４との間に配置される最初の斜行部１５Ａの中央部、すなわち、第２クランプ部２０３と第３クランプ部２０４との間に配置される折り返し線Ｒ（図９、図１９参照）を境にして、第３クランプ部２０４が、図２０に示すように、第２クランプ部２０３上に重なるように回転移動して、最初の斜行部１５Ａを折り返す（折り返し工程）。 Next, it is arranged in the central portion of the first skew portion 15A arranged between the second clamp portion 203 and the third clamp portion 204, that is, between the second clamp portion 203 and the third clamp portion 204. As shown in FIG. 20, the third clamp portion 204 is rotationally moved so as to overlap the second clamp portion 203 with the folding line R (see FIGS. 9 and 19) as a boundary, and the first skew is performed. The part 15A is folded back (folding step).

第３クランプ部２０４の回転移動によって、導体群１００の最初の斜行部１５Ａが、導体群１００の厚さ方向に折り返される。折り返し線Ｒは、導体群１００の幅方向に沿うＤ２−Ｄ３方向に沿って配置され、斜行部１５Ａに対して交差している。そのため、斜行部１５Ａが折り返されることによって、その折り返し部は、折り返し線Ｒを頂点部（頂点部１２ｃ）とする山型状（三角形状）の新たな１２本のターン部１２（第２ターン部１２Ｂ）を構成する。本実施形態では、第３クランプ部２０４の回転移動によって、斜行部１５Ａを、折り返し線Ｒに沿って、図１９における紙面の手前側方向（Ｒ１方向）に順折りしている。 Due to the rotational movement of the third clamp portion 204, the first oblique portion 15A of the conductor group 100 is folded back in the thickness direction of the conductor group 100. The folding line R is arranged along the D2-D3 direction along the width direction of the conductor group 100, and intersects the oblique portion 15A. Therefore, when the oblique portion 15A is folded back, the folded portion has 12 new mountain-shaped (triangular) turn portions 12 (second turn) having the folding line R as the apex portion (apex portion 12c). Part 12B) is configured. In the present embodiment, the oblique portion 15A is sequentially folded along the folding line R in the front side direction (R1 direction) of the paper surface in FIG. 19 by the rotational movement of the third clamp portion 204.

図２２は、最初の斜行部１５Ａが折り返された後の導体群１００のみを示している。図２２に示すように、最初の斜行部１５Ａが折り返されると、第２クランプ部２０３と第３クランプ部２０４とによって把持されていた直線部１４の被把持部１４０，１４０同士の一部が平行に重なり合う。具体的には、第２クランプ部２０３で把持される１２本の被把持部１４０のうちの６本と、第３クランプ部２０４で把持される１２本の被把持部１４０のうちの６本とが、互いに重なり合う。これによって、直線部１４の１８本分の幅のスロット配置部１１が形成される。 FIG. 22 shows only the conductor group 100 after the first skew portion 15A is folded back. As shown in FIG. 22, when the first oblique portion 15A is folded back, a part of the gripped portions 140 and 140 of the straight portion 14 gripped by the second clamp portion 203 and the third clamp portion 204 is removed. Overlapping in parallel. Specifically, 6 of the 12 gripped portions 140 gripped by the 2nd clamp portion 203 and 6 of the 12 gripped portions 140 gripped by the 3rd clamp portion 204. However, they overlap each other. As a result, the slot arrangement portion 11 having a width equivalent to 18 of the straight portion 14 is formed.

なお、本実施形態では、導体群１００に対する最初の折り返し工程の前に、２つの斜行部１５（斜行部１５Ａ，１５Ｂ）を成形している。そのため、図２１に示すように、折り返し後の導体群１００のターン部１２（第１ターン部１２Ａ）は、２番目に成形された斜行部１５（斜行部１５Ｂ）上に重なるように配置される。したがって、折り返し後のターン部１２が導体群１００の直線部１４と干渉することはない。 In this embodiment, two skew portions 15 (skew portions 15A and 15B) are formed before the first folding step with respect to the conductor group 100. Therefore, as shown in FIG. 21, the turn portion 12 (first turn portion 12A) of the conductor group 100 after folding is arranged so as to overlap the second formed skew portion 15 (skew portion 15B). Will be done. Therefore, the turn portion 12 after folding does not interfere with the straight portion 14 of the conductor group 100.

斜行部１５を折り返す際は、図２０に示すように、第２クランプ部２０３と第３クランプ部２０４との間に折り返し治具２２０を挿入してもよい。折り返し治具２２０は、断面三角形状に形成され、鋭角な頂点側の辺縁部２２０ａを斜行部１５の折り返し線Ｒに沿わせて挿入される。これによって、第３クランプ部２０４は、斜行部１５を折り返し線Ｒに沿って精度良く折り返すことができる。折り返し治具２２０は、折り返し動作が完了する前に第２クランプ部２０３と第３クランプ部２０４との間から取り除かれる。 When folding back the skewed portion 15, as shown in FIG. 20, a folding jig 220 may be inserted between the second clamp portion 203 and the third clamp portion 204. The folding jig 220 is formed in a triangular cross section, and the edge portion 220a on the acute-angled apex side is inserted along the folding line R of the oblique portion 15. As a result, the third clamp portion 204 can accurately fold the oblique portion 15 along the fold line R. The folding jig 220 is removed from between the second clamp portion 203 and the third clamp portion 204 before the folding operation is completed.

また、斜行部１５の折り返し完了後は、図２３に示すように、導体群１００を把持した状態で、第３クランプ部２０４を、第２クランプ部２０３に対して相対的に、直線部１４の並び方向に沿って、折り返し部分の幅方向（Ｄ２−Ｄ３方向）に僅かに移動させてもよい。これによって、斜行部１５を折り返した後のターン部１２が開きながら戻ろうとするスプリングバックを抑制することができる。また、折り返された６本の直線部１４同士のピッチを調整することが可能になる。 Further, after the folding of the skewed portion 15 is completed, as shown in FIG. 23, the third clamp portion 204 is placed in the straight portion 14 relative to the second clamp portion 203 while holding the conductor group 100. May be slightly moved in the width direction (D2-D3 direction) of the folded portion along the arrangement direction of. As a result, it is possible to suppress the springback in which the turn portion 12 after turning back the skew portion 15 tries to return while opening. Further, it becomes possible to adjust the pitch between the six folded straight portions 14.

折り返し工程では、斜行部１５が折り返された後、第２クランプ部２０３と第３クランプ部２０４とが重なり合った状態で、図２４に示すように、第２クランプ部２０３の押圧部材２０３Ｄが第２クランプ部２０３に対して上昇するとともに、第３クランプ部２０４の押圧部材２０４Ｄが第３クランプ部２０４に対して上昇し、導体群１００の折り返し部であるターン部１２が、押圧部材２０３Ｄ，２０４Ｄ間に挟み付けられて厚さ方向に押圧される。これによって、ターン部１２がスプリングバックによって厚さ方向に膨らむことを抑制できるとともに、ターン部１２の成形精度も更に向上する。また、第２クランプ部２０３及び第３クランプ部２０４によってターン部１２を成形した後、そのまま押圧することができるため、押圧のためのステーションを別途に設ける必要がなく、装置及び工程を簡素化することができる。 In the folding step, after the skewed portion 15 is folded back, the pressing member 203D of the second clamp portion 203 is placed in a state where the second clamp portion 203 and the third clamp portion 204 are overlapped with each other, as shown in FIG. 2 As it rises with respect to the clamp portion 203, the pressing member 204D of the third clamp portion 204 rises with respect to the third clamp portion 204, and the turn portion 12, which is a folded portion of the conductor group 100, moves with respect to the pressing members 203D and 204D. It is sandwiched between them and pressed in the thickness direction. As a result, it is possible to prevent the turn portion 12 from swelling in the thickness direction due to the springback, and the molding accuracy of the turn portion 12 is further improved. Further, since the turn portion 12 can be pressed as it is after being molded by the second clamp portion 203 and the third clamp portion 204, it is not necessary to separately provide a station for pressing, which simplifies the apparatus and the process. be able to.

第２ターン部１２Ｂを成形した後、把持機構２０５は、導体群１００を更にＤ１方向に搬送し、２番目に成形された斜行部１５Ｂを第２クランプ部２０３と第３クランプ部２０４との間に配置する。その後、図１９に示した場合と同様に、第１クランプ部２０２と第２クランプ部２０３との間に配置される直線部１４に対して、３番目の斜行部１５（斜行部１５Ｃ）を成形する。 After forming the second turn portion 12B, the gripping mechanism 205 further conveys the conductor group 100 in the D1 direction, and the second formed oblique portion 15B is transferred to the second clamp portion 203 and the third clamp portion 204. Place in between. After that, as in the case shown in FIG. 19, the third skew portion 15 (skew portion 15C) with respect to the straight portion 14 arranged between the first clamp portion 202 and the second clamp portion 203. To mold.

これ以降は、導体群１００により成形される波巻コイル１が、ステータコア２０を４周する所定の長さになるまで、上記同様に、２番目の斜行部１５Ｂに対する折り返し工程、４番目の斜行部を成形する斜行部成形工程、３番目の斜行部１５Ｃに対する折り返し工程、・・・が交互に繰り返し実行される。これによって、スロット配置部１１が６本分ずれて２層に重なり合う８層（８ターン）分のシート状の波巻コイル１が成形される。このように、斜行部１５の成形と斜行部１５の折り返しとを交互に繰り返す導体成形装置２００によって成形される波巻コイル１は、コイル線材１０を折り返す際に生じる成形誤差が斜行部１５に蓄積されない。そのため、スロット配置部１１及びターン部１２の成形精度が良好である。 After that, until the corrugated coil 1 formed by the conductor group 100 has a predetermined length around the stator core 20 four times, the second diagonal portion 15B is folded back and the fourth oblique portion is formed in the same manner as described above. The oblique portion forming step of forming the row portion, the folding step for the third oblique portion 15C, and the like are alternately and repeatedly executed. As a result, the sheet-shaped wave winding coil 1 for eight layers (8 turns) in which the slot arrangement portions 11 are displaced by six and overlap the two layers is formed. In this way, in the wave-wound coil 1 formed by the conductor forming apparatus 200 that alternately repeats the forming of the oblique portion 15 and the folding of the oblique portion 15, the forming error that occurs when the coil wire 10 is folded back is the oblique portion. Not accumulated in 15. Therefore, the molding accuracy of the slot arrangement portion 11 and the turn portion 12 is good.

また、本実施形態のように、コイル線材１０が複数本の単位線材１０ａを厚さ方向（Ｙ方向）に並べて構成されるものである場合、斜行部１５を折り返す際に、折り返し前の斜行部１５の延在方向と折り返し方向との角度差により、各単位線材１０ａ間で周長差が発生することが避けられない。従来のように全ての斜行部を先に成形する場合では、折り返しの際に各単位線材１０ａ間で発生する周長差が既に成形済みの斜行部に影響し、成形済みの斜行部の肩曲げ部（斜行部の折り曲げの起点）がずれてしまう問題がある。しかし、本実施形態のように斜行部成形工程と折り返し工程とを交互に行うことにより、折り返しによる単位線材１０ａ間の周長差の影響を、次の斜行部１５の成形によって実質的にキャンセルすることができる。このため、コイル線材１０が複数本の単位線材１０ａを厚さ方向に並べて構成される場合でも、成形精度の良い波巻コイル１を製造することが可能である。 Further, when the coil wire rod 10 is configured by arranging a plurality of unit wire rods 10a in the thickness direction (Y direction) as in the present embodiment, when the skewed portion 15 is folded back, the inclination before folding back is performed. Due to the angle difference between the extending direction and the folding direction of the row portion 15, it is inevitable that a difference in peripheral length will occur between the unit wire rods 10a. When all the skewed portions are molded first as in the conventional case, the difference in peripheral length generated between the unit wire rods 10a at the time of folding back affects the already molded skewed portions, and the molded skewed portions. There is a problem that the shoulder bending portion (starting point of bending of the oblique portion) is displaced. However, by alternately performing the oblique portion forming step and the folding step as in the present embodiment, the influence of the peripheral length difference between the unit wire rods 10a due to the folding is substantially reduced by the next forming of the oblique portion 15. You can cancel. Therefore, even when the coil wire rod 10 is formed by arranging a plurality of unit wire rods 10a in the thickness direction, it is possible to manufacture the wave winding coil 1 having good molding accuracy.

なお、以上により得られるシート状の波巻コイル１は、スロット配置部１１が重なり合った２層構造となり、図１に示したように、ステータコア２０の１周毎にステータコア２０の径方向に層（ターン）が切り替わる層替わり部Ｔａを有する。このような波巻コイル１を成形する場合は、層替わり部Ｔａにおける層間の干渉を避けるため、以下に説明するように、層替わり部Ｔａに対応する折り返し工程において、斜行部１５の折り返し方向を、それまでの折り返し方向（Ｒ１方向）とは逆方向（Ｒ２方向）に折り返してもよい。 The sheet-shaped wave winding coil 1 obtained as described above has a two-layer structure in which the slot arrangement portions 11 are overlapped with each other, and as shown in FIG. 1, a layer (layers in the radial direction of the stator core 20 is provided for each circumference of the stator core 20. It has a layer changing portion Ta at which the turn) is switched. When forming such a wave winding coil 1, in order to avoid interference between layers in the layer changing portion Ta, as described below, in the folding step corresponding to the layer changing portion Ta, the folding direction of the skew portion 15 May be folded back in the direction opposite to the folding direction (R1 direction) up to that point (R2 direction).

図２６に示すように、層替わり部Ｔａに対応する斜行部１５を折り返し線Ｒに沿って折り返す折り返し工程では、それまでの折り返し工程における斜行部１５の折り返し方向（Ｒ１方向）とは逆方向（Ｒ２方向）に斜行部１５を逆折りする。すなわち、本実施形態に示す波巻コイル１の場合、図１に示したように、７層（７Ｔ）と６層（６Ｔ）との間、５層（５Ｔ）と４層（４Ｔ）との間、３層（３Ｔ）と２層（２Ｔ）との間、の計３か所にそれぞれ層替わり部Ｔａが存在するため、これらの層替わり部Ｔａに対応する斜行部１５の折り返し工程のみ、上記のように、斜行部１５を逆折りする。これにより、図２７に示すように、各層替わり部Ｔａにおいて、ターン部１２の厚さ方向（ステータコア２０の径方向、図２７におけるＸ方向）のオフセット方向が逆方向になり、波巻コイル１がステータコア２０に装着された際に、層替わり部Ｔａにおける層間の干渉を避けることができる。 As shown in FIG. 26, in the folding step of folding back the skewed portion 15 corresponding to the layer changing portion Ta along the folding line R, the folding direction (R1 direction) of the skewed portion 15 in the folding process up to that point is opposite. The diagonal portion 15 is folded backward in the direction (R2 direction). That is, in the case of the wave winding coil 1 shown in the present embodiment, as shown in FIG. 1, between the 7th layer (7T) and the 6th layer (6T), the 5th layer (5T) and the 4th layer (4T). Since there are layer changing portions Ta in a total of three places between the three layers (3T) and the two layers (2T), only the folding step of the skew portion 15 corresponding to these layer changing portions Ta is performed. , As described above, the skew portion 15 is folded backward. As a result, as shown in FIG. 27, in each layer changing portion Ta, the offset direction in the thickness direction of the turn portion 12 (the radial direction of the stator core 20 and the X direction in FIG. 27) becomes opposite, and the wave winding coil 1 becomes When mounted on the stator core 20, interference between layers in the layer changing portion Ta can be avoided.

次に、このようにして成形されたシート状の波巻コイル１をステータコア２０のスロット２３に装着する方法の一実施形態について説明する。
シート状に成形された波巻コイル１は、図２８に示すように、巻取り装置３の一対の送りローラ３０，３１間を通過した後、一方の送りローラ３１との間で波巻コイル１を押圧する成形ローラ３２によって、円弧状に成形されながら、巻取り治具３３に向けて送られる。 Next, an embodiment of a method of mounting the sheet-shaped wave winding coil 1 thus formed in the slot 23 of the stator core 20 will be described.
As shown in FIG. 28, the wave winding coil 1 formed in a sheet shape passes between the pair of feed rollers 30 and 31 of the winding device 3, and then is connected to the wave winding coil 1 with one of the feed rollers 31. It is sent toward the winding jig 33 while being formed into an arc shape by the forming roller 32 that presses.

巻取り治具３３の外周側には、巻取り治具３３の略半周に亘って、円弧状のコイルガイド３４が配置されている。コイルガイド３４は、送りローラ３１と成形ローラ３２との間から送り出された波巻コイル１を巻取り治具３３の外周に向けて案内する。コイルガイド３４の終端部近傍には、押込ローラ３５が配置されている。コイルガイド３４に沿って押込ローラ３５まで送られた波巻コイル１は、回転する巻取り治具３３の外周に押込ローラ３５によって押し込まれる。 On the outer peripheral side of the take-up jig 33, an arc-shaped coil guide 34 is arranged over substantially half the circumference of the take-up jig 33. The coil guide 34 guides the wave winding coil 1 fed from between the feed roller 31 and the forming roller 32 toward the outer circumference of the take-up jig 33. A push roller 35 is arranged near the end of the coil guide 34. The wave winding coil 1 sent to the pushing roller 35 along the coil guide 34 is pushed by the pushing roller 35 to the outer circumference of the rotating winding jig 33.

巻取り治具３３は、図２９に示すように、円筒部３３０の外周面に、ステータコア２０のスロット数に対応する７２本ずつのワイヤガイド３３１ａ、３３１ｂが放射状に突出している。ワイヤガイド３３１ａ，３３１ｂは、円筒部３３０の軸方向に、波巻コイル１のスロット配置部１１の長さに略等しい間隔で離間している。このため、波巻コイル１が、回転している巻取り治具３３の外周に押し込まれると、ワイヤガイド３３１ａ，３３１ｂが、波巻コイル１の隣り合うスロット配置部１１，１１の間に順次挿入され、波巻コイル１を巻き付けて保持する。本実施形態の波巻コイル１は、ステータコア２０の４周分の長さを有するため、波巻コイル１は巻取り治具３３の外周を４周した後、ワイヤガイド３３１ａ，３３１ｂによって保持される。 As shown in FIG. 29, in the winding jig 33, 72 wire guides 331a and 331b corresponding to the number of slots of the stator core 20 project radially on the outer peripheral surface of the cylindrical portion 330. The wire guides 331a and 331b are separated from each other in the axial direction of the cylindrical portion 330 at intervals substantially equal to the length of the slot arrangement portion 11 of the wave winding coil 1. Therefore, when the wave winding coil 1 is pushed into the outer periphery of the rotating winding jig 33, the wire guides 331a and 331b are sequentially inserted between the adjacent slot arrangement portions 11 and 11 of the wave winding coil 1. Then, the wave winding coil 1 is wound and held. Since the wave winding coil 1 of the present embodiment has a length equivalent to four turns of the stator core 20, the wave winding coil 1 is held by the wire guides 331a and 331b after making four turns around the outer circumference of the winding jig 33. ..

巻取り治具３３の外周側には、インシュレータ組付装置３６が配置されている。インシュレータ組付装置３６は、押込機構部３６０によって、インシュレータ４を巻取り治具３３の隣り合うワイヤガイド３３１ａ，３３１ａ間及び３３１ｂ，３３１ｂ間に押し込んで組み付ける。本実施形態では２つの押込機構部３６０，３６０が設けられているが、押込機構部３６０の数に制限はない。 An insulator assembling device 36 is arranged on the outer peripheral side of the winding jig 33. The insulator assembling device 36 pushes and assembles the insulator 4 between the adjacent wire guides 331a and 331a and between 331b and 331b of the winding jig 33 by the pushing mechanism unit 360. In the present embodiment, two pushing mechanism units 360 and 360 are provided, but the number of pushing mechanism parts 360 is not limited.

インシュレータ４は、ステータコア２０のスロット２３内に配置される波巻コイル１のスロット配置部１１とステータコア２０との間を絶縁する絶縁体からなる。インシュレータ４は、図３０及び図３１に示すように、一対の側壁板４０，４０と、側壁板４０，４０間をつなぐ底壁板４１と、を有し、底壁板４１と対向する側が開放端４２とされたコ字状に形成される。底壁板４１の上下両端部には、ステータコア２０の軸方向の上下面に対して係止可能なロック爪４３，４３がそれぞれ突設されている。 The insulator 4 is made of an insulator that insulates between the slot arrangement portion 11 of the wave winding coil 1 arranged in the slot 23 of the stator core 20 and the stator core 20. As shown in FIGS. 30 and 31, the insulator 4 has a pair of side wall plates 40, 40 and a bottom wall plate 41 connecting the side wall plates 40, 40, and the side facing the bottom wall plate 41 is open. It is formed in a U shape with the end 42. Lock claws 43 and 43 that can be locked to the upper and lower surfaces of the stator core 20 in the axial direction are projected from the upper and lower ends of the bottom wall plate 41, respectively.

インシュレータ４は、インシュレータ組付装置３６の押込機構部３６０によって、隣り合うワイヤガイド３３１ａ，３３１ａ間及び３３１ｂ，３３１ｂ間に１つずつ押し込まれる。詳しくは、図３２に示すように、インシュレータ４は、隣り合うワイヤガイド３３１ａ，３３１ａ間及び３３１ｂ，３３１ｂ間に配置される８層（８ターン）分のスロット配置部１１を、一対の側壁板４０，４０で挟みながら押し込まれる。 The insulator 4 is pushed one by one between the adjacent wire guides 331a and 331a and between 331b and 331b by the pushing mechanism unit 360 of the insulator assembling device 36. Specifically, as shown in FIG. 32, the insulator 4 has a pair of side wall plates 40 for slot arrangement portions 11 for eight layers (8 turns) arranged between adjacent wire guides 331a and 331a and between 331b and 331b. , 40 while being pushed in.

隣り合う全てのワイヤガイド３３１ａ，３３１ａ間及び３３１ｂ，３３１ｂ間に７２個のインシュレータ４が組み付けられた後、巻取り治具３３に巻回状態の波巻コイル１は、インシュレータ４と共に、図示しない挿入装置を用いて、ステータコア２０の軸孔２１内からスロット２３に挿入される。その結果、図２に示すように、最外層（８Ｔ）から最内層（１Ｔ）に亘ってステータコア２０を４周する８層（８ターン）の波巻コイル１を有するステータ２が得られる。 After 72 insulators 4 are assembled between all the adjacent wire guides 331a and 331a and between 331b and 331b, the wave winding coil 1 in the wound state is inserted into the winding jig 33 together with the insulator 4 (not shown). The device is used to insert the stator core 20 into the slot 23 from inside the shaft hole 21. As a result, as shown in FIG. 2, a stator 2 having eight layers (8 turns) of wave winding coils 1 that circulate the stator core 20 four times from the outermost layer (8T) to the innermost layer (1T) is obtained.

以上説明した波巻コイル１の製造方法において、図７及び図８に示すように、導体群１００の１２本の直線部１４は、ステータコア２０のスロット間隔に対応する均等間隔で平行に並べられ、折り返し工程では、その間隔を維持した状態で斜行部１５が折り返される。しかし、折り返し工程は、導体群１００の斜行部１５を折り返す際に、図３３に示すように、複数のコイル線材１０の直線部１４，１４の間隔を狭くなるように変更してもよい。詳しくは、図３３中の左図に示すように、折り返し前の複数のコイル線材１０の直線部１４，１４の間隔Ｐｔ１に対し、図３３中の右図に示すように、折り返し時の複数のコイル線材１０の直線部１４，１４の間隔Ｐｔ２が狭くなるように、隣り合う直線部１４，１４の間隔が変更される。間隔Ｐｔ１は、ステータコア２０のスロット２３の間隔に略等しい。間隔Ｐｔ２は、ステータコア２０のスロット２３の間隔よりも狭い。 In the method for manufacturing the wave winding coil 1 described above, as shown in FIGS. 7 and 8, the 12 straight portions 14 of the conductor group 100 are arranged in parallel at equal intervals corresponding to the slot intervals of the stator core 20. In the folding step, the skew portion 15 is folded while maintaining the interval. However, the folding step may be changed so that when the diagonal portion 15 of the conductor group 100 is folded back, the intervals between the straight portions 14, 14 of the plurality of coil wires 10 are narrowed, as shown in FIG. 33. Specifically, as shown in the left figure in FIG. 33, with respect to the interval Pt1 of the straight portions 14 and 14 of the plurality of coil wires 10 before folding back, as shown in the right figure in FIG. The spacing between the straight portions 14 and 14 of the coil wire 10 is changed so that the spacing Pt2 between the straight portions 14 and 14 is narrowed. The interval Pt1 is substantially equal to the interval between the slots 23 of the stator core 20. The spacing Pt2 is narrower than the spacing between the slots 23 of the stator core 20.

このように、折り返し工程において直線部１４，１４間の間隔を狭くすることによって、図３４に示すように、折り返し後のターン部１２の頂点部１２ｃの幅をコントロールすることができる。すなわち、隣り合う直線部１４，１４の間隔を変更しない場合に成形されるターン部１２の頂点部１２ｃの幅ｄ１（図３４中の右図）に対し、隣り合う直線部１４，１４の間隔を狭くなるように変更した場合に成形されるターン部１２の頂点部１２ｃの幅ｄ２（図３４中の右図）は狭くなる。 As shown in FIG. 34, the width of the apex portion 12c of the turn portion 12 after the folding can be controlled by narrowing the interval between the straight portions 14 and 14 in the folding step. That is, the distance between the adjacent straight portions 14 and 14 is set with respect to the width d1 (right figure in FIG. 34) of the apex portion 12c of the turn portion 12 formed when the spacing between the adjacent straight portions 14 and 14 is not changed. The width d2 (right figure in FIG. 34) of the apex portion 12c of the turn portion 12 formed when the turn portion 12 is changed to be narrower becomes narrower.

折り返し工程によって成形されるターン部１２の頂点部１２ｃの幅は、隣り合う直線部１４，１４の間隔の狭さを適宜設定することによって調整可能である。頂点部１２ｃの幅が狭くなるように調整されることによって、折り返し後の直線部１４，１４の間隔も狭くなる。一般に、ステータコア２０のスロット２３の間隔は、ステータコア２０の外周側から内周側に向かうに従って次第に狭くなるため、折り返し工程によって直線部１４，１４の間隔が調整されることによって、ステータコア２０のスロット２３に対する装着性の良好な波巻コイル１を容易に製造することができる。 The width of the apex portion 12c of the turn portion 12 formed by the folding step can be adjusted by appropriately setting the narrowness of the interval between the adjacent straight portions 14, 14. By adjusting the width of the apex portion 12c to be narrow, the distance between the straight portions 14 and 14 after folding is also narrowed. In general, the spacing between the slots 23 of the stator core 20 gradually narrows from the outer peripheral side to the inner peripheral side of the stator core 20, so that the spacing between the straight portions 14 and 14 is adjusted by the folding process to adjust the spacing between the slots 23 of the stator core 20. It is possible to easily manufacture the wave winding coil 1 having good mountability on the ground.

このように折り返し工程において直線部１４，１４間の間隔を狭くするための導体成形装置２００の具体的な実施形態について、図３５及び図３６を用いて説明する。図３５及び図３６は、折り返し機構２０７における第２クランプ部２０３及び第３クランプ部２０４の各クランプ部材２０３Ａ，２０３Ｂ、２０４Ａ，２０４Ｂの構造を示している。このクランプ部材は、溝部２３０ａが開閉可能な複数のブロック２３０によって構成される点で、図１１及び図１２に示したクランプ部材の構造と同一である。しかし、このクランプ部材は、直線部１４を、ブロック２３０に一体に設けられる挟着片２３０ｂと、隣り合うブロック２３０，２３０の間に配置される挟着部材２３０ｃとによって挟着するように構成されている点で、図１１及び図１２に示したクランプ部材の構造と相違する。 A specific embodiment of the conductor forming apparatus 200 for narrowing the distance between the straight portions 14 and 14 in the folding step will be described with reference to FIGS. 35 and 36. 35 and 36 show the structures of the clamp members 203A, 203B, 204A, and 204B of the second clamp portion 203 and the third clamp portion 204 in the folding mechanism 207. This clamp member has the same structure as the clamp member shown in FIGS. 11 and 12 in that the groove portion 230a is composed of a plurality of blocks 230 that can be opened and closed. However, this clamp member is configured to sandwich the straight portion 14 by the sandwiching piece 230b integrally provided on the block 230 and the sandwiching member 230c arranged between the adjacent blocks 230 and 230. In that respect, it differs from the structure of the clamp member shown in FIGS. 11 and 12.

図３５において、隣り合うブロック２３０，２３０の間には、相互の間隔を調整可能にするための空隙Ｓが設けられている。図３５は、隣り合う直線部１４，１４の間隔を変更しない場合を示している。このとき、隣り合うブロック２３０，２３０は最も離れ、空隙Ｓは最大の状態となっている。隣り合う直線部１４，１４の間隔Ｐｔ１は、ステータコア２０のスロット２３の間隔に略等しい。各溝部２３０ａには、空隙Ｓが最大の状態で、把持機構２０５によって搬送された導体群１００の各直線部１４が収容される。その後、ブロック２３０及び挟着部材２３０ｃの少なくともいずれか一方が、図示しない移動手段によって移動することによって、図３５に示すように、直線部１４が挟着片２３０ｂと挟着部材２３０ｃとによって挟着される。 In FIG. 35, a gap S is provided between the adjacent blocks 230 and 230 so that the distance between them can be adjusted. FIG. 35 shows a case where the intervals between the adjacent straight lines 14 and 14 are not changed. At this time, the adjacent blocks 230 and 230 are farthest apart, and the gap S is in the maximum state. The distance Pt1 between the adjacent straight portions 14 and 14 is substantially equal to the distance between the slots 23 of the stator core 20. Each groove portion 230a accommodates each straight portion 14 of the conductor group 100 conveyed by the gripping mechanism 205 with the gap S at the maximum. After that, at least one of the block 230 and the sandwiching member 230c is moved by a moving means (not shown), so that the straight line portion 14 is sandwiched between the sandwiching piece 230b and the sandwiching member 230c as shown in FIG. 35. Will be done.

直線部１４を挟着したブロック２３０は、図示しない移動手段によって、空隙Ｓを狭くするように移動可能に構成される。図３６は、空隙Ｓが最も狭くなった状態を示している。このときの隣り合う直線部１４，１４の間隔Ｐｔ２は、ステータコア２０のスロット２３の間隔よりも狭い。隣り合うブロック２３０，２３０の間隔は、図３５に示す空隙Ｓが最大の状態と図３６に示す空隙Ｓが最小の状態との間で任意に調整可能である。したがって、このクランプ部材を有する折り返し機構２０７を用いて、直線部１４，１４の間隔がスロット２３の間隔よりも狭くなるように調整された導体群１００の斜行部１５を折り返すことによって、波巻コイル１のターン部１２の頂点部１２ｃの幅を容易にコントロールすることができる。 The block 230 sandwiching the straight line portion 14 is configured to be movable so as to narrow the gap S by a moving means (not shown). FIG. 36 shows a state in which the void S is the narrowest. The distance Pt2 between the adjacent straight portions 14 and 14 at this time is narrower than the distance between the slots 23 of the stator core 20. The distance between the adjacent blocks 230 and 230 can be arbitrarily adjusted between the state where the gap S shown in FIG. 35 is the maximum and the state where the gap S shown in FIG. 36 is the minimum. Therefore, by using the folding mechanism 207 having the clamp member, the diagonal portion 15 of the conductor group 100 adjusted so that the spacing between the straight portions 14 and 14 is narrower than the spacing between the slots 23 is folded back to wind the wave. The width of the apex portion 12c of the turn portion 12 of the coil 1 can be easily controlled.

以上説明した波巻コイル１の製造方法において、折り返し工程では、斜行部１５におけるターン部１２の頂点部１２ｃに対応する部位を幅方向に挟んだ状態で導体群１００を折り返してもよい。これによって、折り返し時にターン部１２の幅の広がりを抑制することができる。斜行部１５におけるターン部１２の頂点部１２ｃに対応する部位を幅方向に挟む具体的な方法としては、折り返される斜行部１５の内側又は外側で、各コイル線材１０の斜行部１５の頂点部１２ｃに対応する部位をそれぞれ適宜の挟着部材で挟み、頂点部１２ｃの幅方向の広がりを抑制する方法が挙げられる。 In the method of manufacturing the wave winding coil 1 described above, in the folding step, the conductor group 100 may be folded back in a state where the portion corresponding to the apex portion 12c of the turn portion 12 in the skew portion 15 is sandwiched in the width direction. As a result, it is possible to suppress the expansion of the width of the turn portion 12 at the time of turning back. As a specific method of sandwiching the portion corresponding to the apex portion 12c of the turn portion 12 in the skew portion 15 in the width direction, the oblique portion 15 of each coil wire rod 10 is formed inside or outside the diagonal portion 15 to be folded back. Examples thereof include a method in which the portions corresponding to the apex portion 12c are sandwiched between appropriate sandwiching members to suppress the spread of the apex portion 12c in the width direction.

より具体的には、図２０に示すように、折り返し工程において第２クランプ部２０３と第３クランプ部２０４との間に挿入される折り返し治具２２０を用いて、斜行部１５の頂点部１２ｃに対応する部位を挟むようにしてもよい。図３７は、このような折り返し治具２２０の一実施形態を示している。折り返し治具２２０は、鋭角な頂点側の辺縁部２２０ａに、斜行部１５の折り返し部であるターン部１２の頂点部１２ｃに対応する部位をそれぞれ幅方向に挟むように配置される２つずつの突起２２０ｂ，２２０ｂを有している。図３７では、１本のコイル線材１０に対応する２つの突起２２０ｂ，２２０ｂのみが示されている。しかし、導体群１００は６本のコイル線材１０（１２本の斜行部１５）を有するため、折り返し治具２２０の辺縁部２２０ａには、２４本（１２対）の突起２２０ｂが設けられる。 More specifically, as shown in FIG. 20, the apex portion 12c of the skew portion 15 is used by using the folding jig 220 inserted between the second clamp portion 203 and the third clamp portion 204 in the folding step. The part corresponding to the above may be sandwiched. FIG. 37 shows one embodiment of such a folding jig 220. Two folding jigs 220 are arranged on the edge portion 220a on the acute-angled apex side so as to sandwich the portions corresponding to the apex portion 12c of the turn portion 12 which is the folding portion of the oblique portion 15 in the width direction. It has protrusions 220b and 220b, respectively. In FIG. 37, only two protrusions 220b and 220b corresponding to one coil wire 10 are shown. However, since the conductor group 100 has six coil wire rods 10 (12 diagonal portions 15), 24 (12 pairs) protrusions 220b are provided on the edge portion 220a of the folding jig 220.

図３８は、図３７に示す折り返し治具２２０の辺縁部２２０ａを正面視したときの２つの突起２２０ｂ，２２０ｂを示している。１本のコイル線材１０に対応する２つの突起２２０ｂ，２２０ｂは、斜行部１５の頂点部１２ｃに対応する部位を挟み得る間隔をおいて設けられている。各突起２２０ｂ，２２０ｂは、図３８に示すように、折り返し後の斜行部１５の形状に沿うように、斜行部１５と接する面が斜めに形成されている。 FIG. 38 shows two protrusions 220b and 220b when the edge portion 220a of the folding jig 220 shown in FIG. 37 is viewed from the front. The two protrusions 220b and 220b corresponding to one coil wire rod 10 are provided at intervals so as to sandwich a portion corresponding to the apex portion 12c of the skew portion 15. As shown in FIG. 38, each of the protrusions 220b and 220b is formed so as to have a surface in contact with the skewed portion 15 so as to follow the shape of the skewed portion 15 after being folded back.

この折り返し治具２２０は、２つの突起２２０ｂ，２２０ｂが、１本のコイル線材１０の斜行部１５をそれぞれ挟むように、図２０に示すように、第２クランプ部２０３と第３クランプ部２０４との間に挿入される。その後、折り返し工程が実施されることによって、斜行部１５が折り返されてターン部１２が成形される。折り返し時の各コイル線材１０の斜行部１５は、図３９に示すように、２つの突起２２０ｂ，２２０ｂによってそれぞれ幅方向に挟着されるため、折り返し時及び折り返し後の頂点部１２ｃの幅ｄの広がりは抑制される。 As shown in FIG. 20, the folding jig 220 has a second clamp portion 203 and a third clamp portion 204 so that the two protrusions 220b and 220b sandwich the oblique portion 15 of one coil wire rod 10, respectively. It is inserted between and. After that, by carrying out the folding step, the skew portion 15 is folded back and the turn portion 12 is formed. As shown in FIG. 39, the oblique portion 15 of each coil wire rod 10 at the time of folding is sandwiched in the width direction by the two protrusions 220b and 220b, respectively, so that the width d of the apex portion 12c at the time of folding and after folding Spread is suppressed.

以上説明した波巻コイル１は、６本のコイル線材１０を並列させて構成したが、コイル線材１０の並列数は６本に限定されず、適宜増減できる。また、コイル線材１０は、３本の単位線材１０ａを並べて構成したが、単位線材１０ａの本数は３本に限定されず、適宜増減できる。 The wave winding coil 1 described above is configured by arranging six coil wire rods 10 in parallel, but the number of coil wire rods 10 in parallel is not limited to six and can be increased or decreased as appropriate. Further, although the coil wire rod 10 is configured by arranging three unit wire rods 10a, the number of unit wire rods 10a is not limited to three and can be increased or decreased as appropriate.

波巻コイルは、略Ｕ字状のコイル線材１０に対して成形を行うものに限らず、直線状のコイル線材に対して、斜行部成形工程と折り返し工程とを交互に実行することにより波巻コイルを成形するようにしてもよい。 The wave-wound coil is not limited to a coil wire 10 having a substantially U-shape, and a wave is formed by alternately performing a diagonal portion forming process and a folding process on a linear coil wire. The winding coil may be formed.

１ 波巻コイル
１０ コイル線材（導体）
１０ａ 単位線材
１１ スロット配置部
１２ ターン部（折り返し部）
１２ｃ 頂点部
１４ 直線部
１５ 斜行部
２０ ステータコア
２３ スロット
１００ 導体群
２００ 導体成形装置
２０３Ｄ，２０４Ｄ 押圧部材
２０５ 把持機構
２０５Ａ，２０５Ｂ 把持部材
２０６ 斜行部成形機構
２０７ 折り返し機構
２１０ａ 溝部
２２０ 折り返し治具
２２０ａ 辺縁部
２２０ｂ 突起
Ｐ 曲げ起点
Ｒ 折り返し線
１Ｔ〜８Ｔ 層
Ｔａ 層替わり部 1 Wave winding coil 10 Coil wire (conductor)
10a Unit wire 11 Slot arrangement part 12 Turn part (folded part)
12c Apex part 14 Straight part 15 Skew part 20 Stator core 23 Slot 100 Conductor group 200 Conductor molding device 203D, 204D Pressing member 205 Gripping mechanism 205A, 205B Gripping member 206 Diagonal part molding mechanism 207 Folding mechanism 210a Groove 220 Folding jig 220a Margin 220b Protrusion P Bending starting point R Folding line 1T to 8T Layer Ta Layer replacement part

Claims (17)

直線部分を有する複数の導体からなる導体群に対し、複数の斜行部と複数の直線部とを成形し、前記斜行部において前記導体群を厚さ方向に折り返す導体成形装置であって、
前記導体群の前記斜行部を成形する部分を挟んだ両側の部分に対応する前記複数の導体の直線部分を把持し、前記導体群の幅方向に相対的に移動させて前記斜行部を成形する斜行部成形機構と、
成形された前記斜行部を前記導体群の厚さ方向に折り返す折り返し機構と、を有し、
前記折り返し機構で折り返された前記導体群を、次に前記斜行部を成形する部分が前記斜行部成形機構の位置に来るように、前記斜行部成形機構に対して相対的に移動させて、前記斜行部成形機構で前記斜行部を成形する、導体成形装置。 A conductor molding apparatus that forms a plurality of oblique portions and a plurality of straight portions with respect to a conductor group composed of a plurality of conductors having a straight portion, and folds the conductor group in the thickness direction at the skew portion.
The linear portions of the plurality of conductors corresponding to the portions on both sides of the portion forming the oblique portion of the conductor group are grasped and relatively moved in the width direction of the conductor group to move the oblique portion. The diagonal part molding mechanism to be molded and
It has a folding mechanism for folding back the molded diagonal portion in the thickness direction of the conductor group.
The conductor group folded back by the folding mechanism is moved relative to the diagonal portion forming mechanism so that the portion for forming the oblique portion next comes to the position of the oblique portion forming mechanism. A conductor molding apparatus that molds the skewed portion by the skewed portion molding mechanism. 前記導体群の前記直線部を把持して、前記導体群を前記直線部の延在方向に移動可能な把持機構を更に有し、
前記把持機構は、前記直線部を把持した状態で、前記導体群を前記直線部の延在方向に移動させて前記斜行部成形機構又は前記折り返し機構まで搬送し、
前記斜行部成形機構は、前記把持機構によって前記複数の導体が把持された状態で、前記斜行部を成形し、
前記折り返し機構は、前記把持機構によって前記複数の導体が把持された状態で、前記斜行部を折り返す、請求項１に記載の導体成形装置。 Further having a gripping mechanism capable of gripping the straight portion of the conductor group and moving the conductor group in the extending direction of the straight portion.
In the gripping mechanism, while gripping the straight portion, the conductor group is moved in the extending direction of the straight portion and conveyed to the oblique portion forming mechanism or the folding back mechanism.
The slanted portion forming mechanism forms the slanted portion in a state where the plurality of conductors are gripped by the gripping mechanism.
The conductor forming apparatus according to claim 1, wherein the folding mechanism folds the oblique portion in a state where the plurality of conductors are gripped by the gripping mechanism. 前記把持機構は、成形された前記斜行部を挟んだ両側に配置される前記直線部を把持する一対の把持部材を有する、請求項２に記載の導体成形装置。 The conductor molding apparatus according to claim 2, wherein the gripping mechanism has a pair of gripping members for gripping the straight portion arranged on both sides of the molded diagonal portion. 前記折り返し機構及び前記把持機構は、前記複数の導体を収容する溝部を有し、
前記溝部は、前記導体の幅方向に開閉可能に構成され、前記導体を幅方向に把持及び把持解除する、請求項２又は３に記載の導体成形装置。 The folding mechanism and the gripping mechanism have a groove for accommodating the plurality of conductors.
The conductor molding apparatus according to claim 2 or 3, wherein the groove portion is configured to be openable and closable in the width direction of the conductor, and grips and releases the conductor in the width direction. 前記折り返し機構は、前記複数の導体を収容する溝部を有し、
前記溝部の間隔は、前記導体群の前記直線部が収容されるステータコアのスロットの間隔よりも狭い、請求項１〜３のいずれか１項に記載の導体成形装置。 The folding mechanism has a groove for accommodating the plurality of conductors.
The conductor molding apparatus according to any one of claims 1 to 3, wherein the distance between the grooves is narrower than the distance between the slots of the stator core in which the straight portion of the conductor group is housed. 前記斜行部成形機構は、前記斜行部と前記直線部との境界点である曲げ起点を中心とするとともに前記斜行部の長さを半径として、円弧状に移動させることによって前記斜行部を成形する、請求項１〜５のいずれか１項に記載の導体成形装置。 The oblique portion forming mechanism is centered on a bending starting point which is a boundary point between the oblique portion and the straight portion, and is moved in an arc shape with the length of the oblique portion as a radius to perform the oblique portion. The conductor molding apparatus according to any one of claims 1 to 5, wherein the portion is molded. 前記折り返し機構は、折り返した前記導体群の折り返し部を厚さ方向に押圧する押圧部材を有する、請求項１〜６のいずれか１項に記載の導体成形装置。 The conductor molding apparatus according to any one of claims 1 to 6, wherein the folding mechanism has a pressing member that presses the folded portion of the folded conductor group in the thickness direction. 前記折り返し機構は、折り返し完了後に、前記導体群を把持した状態で、前記導体の並び方向に移動させる、請求項１〜７のいずれか１項に記載の導体成形装置。 The conductor forming apparatus according to any one of claims 1 to 7, wherein the folding mechanism moves the conductor group in a state of being gripped in the arrangement direction of the conductors after the folding is completed. 前記折り返し機構は、辺縁部が前記斜行部の折り返し線に沿って挿入される折り返し治具を備える、請求項１〜８のいずれか１項に記載の導体成形装置。 The conductor molding apparatus according to any one of claims 1 to 8, wherein the folding mechanism includes a folding jig in which an edge portion is inserted along a folding line of the diagonal portion. 前記折り返し治具は、前記辺縁部に、前記斜行部の前記折り返し部の頂点部に対応する部位を幅方向に挟むように配置される２つの突起を有する、請求項９に記載の導体成形装置。 The conductor according to claim 9, wherein the folding jig has two protrusions arranged on the edge portion so as to sandwich a portion of the diagonal portion corresponding to the apex portion of the folding portion in the width direction. Molding equipment. コイル線材により成形され、ステータコアのスロットに配置される複数のスロット配置部と、隣り合う前記スロット配置部同士を連結する複数のターン部と、を有する波巻コイルの製造方法であって、
前記コイル線材の直線部を、前記コイル線材の延在する面内において、前記直線部の延在方向と交差する方向にオフセットさせることにより、前記コイル線材に斜行部を成形する斜行部成形工程と、
前記斜行部が成形された前記コイル線材を、前記斜行部における前記ターン部の頂点部に対応する部位において折り返すことにより、折り返された前記斜行部で構成される前記ターン部と、前記斜行部に連続する前記直線部で構成される前記スロット配置部と、を成形する折り返し工程と、を有し、
前記斜行部成形工程と前記折り返し工程とを交互に行うことで、前記波巻コイルを成形する、波巻コイルの製造方法。 A method for manufacturing a wave-wound coil, which comprises a plurality of slot arrangement portions formed of a coil wire and arranged in slots of a stator core, and a plurality of turn portions for connecting adjacent slot arrangement portions.
By offsetting the straight portion of the coil wire rod in a direction intersecting the extending direction of the straight portion in the plane where the coil wire rod extends, an oblique portion forming is formed on the coil wire rod. Process and
By folding back the coil wire rod on which the skewed portion is formed at a portion corresponding to the apex of the turn portion in the skewed portion, the turn portion composed of the folded portion and the turn portion and the said It has the slot arrangement portion formed of the straight portion continuous with the skew portion, and a folding step for forming the slot arrangement portion.
A method for manufacturing a wave-wound coil, which forms the wave-wound coil by alternately performing the skewed portion forming step and the folding step. 前記コイル線材は、複数本の単位線材を前記コイル線材の厚さ方向に並べて構成され、
前記斜行部成形工程及び前記折り返し工程は、前記複数本の単位線材を並べた状態で前記コイル線材を成形する、請求項１１に記載の波巻コイルの製造方法。 The coil wire is composed of a plurality of unit wires arranged in the thickness direction of the coil wire.
The method for manufacturing a wave-wound coil according to claim 11, wherein the diagonal portion forming step and the folding back step form the coil wire in a state where the plurality of unit wires are arranged side by side. 複数本の前記コイル線材から前記波巻コイルを成形し、
前記折り返し工程において、折り返し前の前記複数のコイル線材の前記直線部の間隔を、前記ステータコアの前記スロットの間隔よりも狭くする、請求項１１又は１２に記載の波巻コイルの製造方法。 The wave winding coil is formed from a plurality of the coil wires.
The method for manufacturing a wave-wound coil according to claim 11 or 12, wherein in the folding step, the distance between the straight portions of the plurality of coil wires before folding is narrower than the distance between the slots of the stator core. 前記折り返し工程は、前記ターン部の成形後に、前記ターン部を、前記コイル線材の延在する面に直交する方向に押圧する、請求項１１〜１３のいずれか１項に記載の波巻コイルの製造方法。 The wave winding coil according to any one of claims 11 to 13, wherein in the folding step, after molding the turn portion, the turn portion is pressed in a direction orthogonal to the extending surface of the coil wire rod. Production method. 前記波巻コイルは、前記ステータコアに巻回されて装着されることにより、前記ステータコアの複数周分に対応する複数の層を構成する波巻コイルであり、
前記折り返し工程は、前記層が前記ステータコアの径方向に切り替わる層替わり部において、前記斜行部の折り返し方向を逆にする、請求項１１〜１４のいずれか１項に記載の波巻コイルの製造方法。 The wave-wound coil is a wave-wound coil that is wound around the stator core and mounted to form a plurality of layers corresponding to a plurality of circumferences of the stator core.
The production of the wave winding coil according to any one of claims 11 to 14, wherein in the folding step, the folding direction of the skewed portion is reversed in the layer switching portion in which the layer is switched in the radial direction of the stator core. Method. 前記折り返し工程において、折り返し治具の辺縁部が折り返し線に沿うように、前記斜行部に前記折り返し治具を挿入する、請求項１１〜１５のいずれか１項に記載の波巻コイルの製造方法。 The wave winding coil according to any one of claims 11 to 15, wherein in the folding step, the folding jig is inserted into the diagonal portion so that the edge portion of the folding jig follows the folding line. Production method. 前記折り返し工程において、前記斜行部における前記ターン部の頂点部に対応する部位を幅方向に挟んだ状態で折り返す、請求項１１〜１６のいずれか１項に記載の波巻コイルの製造方法。 The method for manufacturing a wave-wound coil according to any one of claims 11 to 16, wherein in the folding step, the portion corresponding to the apex portion of the turn portion in the skew portion is folded back in a state of being sandwiched in the width direction.
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