Segmented-coil manufacturing method and apparatus

Patent metadata

Field	Value
Publication number	US-9613750-B2
Application number	US-201114346409-A
Country	US
Kind code	B2
Filing date	Sep 27, 2011
Priority date	Sep 27, 2011
Publication date	Apr 4, 2017
Grant date	Apr 4, 2017

Abstract

In a segment coil manufacturing method for manufacturing a segmented coil by bending a flat rectangular conductor using a forming die so that the segmented coil has a circular arc section, a crank section, and a protrusion-shaped section, the forming die includes an outer peripheral surface forming upper die, an inner peripheral surface forming upper die, an inner peripheral surface forming lower die, and an outer peripheral surface forming lower die, and the method includes forming the circular arc section, the crank section, and the protrusion-shaped section while holding at least two surfaces of the outer peripheral surfaces of the flat rectangular conductor by the outer peripheral surface forming upper die, the inner peripheral surface forming upper die, the inner peripheral surface forming lower die, and the outer peripheral surface forming lower die.

First claim

The invention claimed is:

1. A segment coil manufacturing method for manufacturing a segment coil by bending a flat rectangular conductor by use of a forming die, the segment coil including a circular-arc shaped section, a crank-shaped section, and a protrusion section at a coil end,
the forming die includes a first forming die and a second forming die,
the method includes forming the circular-arc shaped section, the crank-shaped section, and the protrusion section while holding at least two surfaces of outer surfaces of the flat rectangular conductor by the first forming die and the second forming die without opening the first forming die and the second forming die, and
wherein
the method includes holding the flat rectangular conductor by a holding mechanism between the first forming die and the second forming die in a direction intersecting with a moving direction of the first forming die while the first and second forming dies are in a die open state.

2. The method for manufacturing a segment coil according to claim 1 , wherein the method includes moving a shoulder forming die along a side face of the forming die to bend the flat rectangular conductor in the edgewise direction.

3. The method for manufacturing a segment coil according to claim 1 , wherein
after the circular-arc shaped section and the crank-shaped section are formed in the flat rectangular conductor,
the method includes forming a shift section in a crank shape by bending the flat rectangular conductor in the flatwise direction by a shift section forming die while holding the flat rectangular conductor by the forming die.

4. The method for manufacturing a segment coil according to claim 1 , wherein
circular-arc shaped section forming faces to form the circular-arc shaped section and crank-shaped section forming faces to form the crank-shaped section are provided along the moving direction of the first forming die,
the method includes:
bending the flat rectangular conductor in a flatwise direction by the circular-arc shaped section forming faces formed in the first forming die and the second forming die to form the circular-arc shaped section, and
bending a part of the circular-arc shaped section in the flatwise direction into a crank shape by the crank-shaped section forming faces formed in the first forming die and the second forming die to form the crank-shaped section, and
deforming the flat rectangular conductor in an edgewise direction by protrusion section forming faces formed in the first forming die and the second forming die to form the protrusion section.

5. A segment coil manufacturing method for manufacturing a segment coil by bending a flat rectangular conductor by use of a forming die, the segment coil including a circular-arc shaped section, a crank-shaped section, and a protrusion section at a coil end,
the forming die includes a first forming die and a second forming die,
the method includes forming the circular-arc shaped section, the crank-shaped section, and the protrusion section while holding at least two surfaces of outer surfaces of the flat rectangular conductor by the first forming die and the second forming die without opening the first forming die and the second forming die,
wherein
circular-arc shaped section forming faces to form the circular-arc shaped section and crank-shaped section forming faces to form the crank-shaped section are provided along the moving direction of the first forming die,
the method includes:
bending the flat rectangular conductor in a flatwise direction by the circular-arc shaped section forming faces formed in the first forming die and the second forming die to form the circular-arc shaped section, and
bending a part of the circular-arc shaped section in the flatwise direction into a crank shape by the crank-shaped section forming faces formed in the first forming die and the second forming die to form the crank-shaped section, and
deforming the flat rectangular conductor in an edgewise direction by protrusion section forming faces formed in the first forming die and the second forming die to form the protrusion section.

6. The method for manufacturing a segment coil according to claim 5 , wherein
the forming die further include a third forming die and a fourth forming die,
the first forming die, the second forming die, the third forming die, and the fourth forming die are placed in positions facing each other,
the method includes moving a set of the first forming die and the fourth forming die and a set of the second forming die and the third forming die in a direction coming close to each other
to form an outer periphery of the circular-arc shaped section by the circular-arc shaped section forming faces of the first forming die and the third forming die and an inner periphery of the circular-arc shaped section by the circular-arc shaped section forming faces of the second forming die and the fourth forming die,
to form the crank-shaped section in the flat rectangular conductor by the crank-shaped section forming faces of the first forming die and the second forming die and the crank-shaped section forming faces of the third forming die and the fourth forming die, the crank-shaped section forming faces being provided so that centers of circular-arcs defining the crank-shaped section forming faces are different from each other, and
to form an outer surface of the protrusion section by the protrusion section forming faces of the first forming die and the fourth forming die and an inner surface of the protrusion section is formed by the protrusion section forming faces of the second forming die and the third forming die.

7. A segment coil manufacturing method for manufacturing a segment coil by bending a flat rectangular conductor by use of a forming die, the segment coil including a circular-arc shaped section, a crank-shaped section, and a protrusion section at a coil end,
the forming die includes a first forming die and a second forming die,
the method includes forming the circular-arc shaped section, the crank-shaped section, and the protrusion section while holding at least two surfaces of outer surfaces of the flat rectangular conductor by the first forming die and the second forming die without opening the first forming die and the second forming die,
wherein
the forming die further include a third forming die and a fourth forming die,
the first forming die, the second forming die, the third forming die, and the fourth forming die are placed in positions facing each other,
the method includes moving a set of the first forming die, and the fourth forming die and a set of the second forming die and the third forming die in a direction coming close to each other
to form an outer periphery of the circular-arc shaped section by the circular-arc shaped section forming faces of the first forming die and the third forming die and an inner periphery of the circular-arc shaped section by a circular-arc shaped section forming faces of the second forming die and the fourth forming die,
to form the crank-shaped section in the flat rectangular conductor by the crank-shaped section forming faces of the first forming die and the second forming die and the crank-shaped section forming faces of the third forming die and the fourth forming die, the crank-shaped section forming faces being provided so that centers of circular-arcs defining the crank-shaped section forming faces are different from each other, and
to form an outer surface of the protrusion section by the protrusion section forming faces of the first forming die and the fourth forming die and an inner surface of the protrusion section is formed by the protrusion section forming faces of the second forming die and the third forming die.

8. The meth

Assignees

• Watanabe Atsushi
• Kitamura Manabu
• Watanabe Hajime
• Hashimoto Shingo
• Oota Takanori
• Toyota Motor Co Ltd
• Aisin Aw Co

Inventors

• Watanabe Atsushi
• Kitamura Manabu
• Watanabe Hajime
• Hashimoto Shingo
• Oota Takanori

Classifications

• H02K3/12

  arranged in slots · CPC title

• Y10T29/4902

  Electromagnet, transformer or inductor · CPC title

• H01F41/04 Primary

  for manufacturing coils {(coils for transformer or inductances H01F27/28)} · CPC title

• H02K15/0421 Primary

  and consisting of single conductors, e.g. hairpins · CPC title