Apparatus for manufacturing a rectangular-wire coil

• US 6,216,513 B1
• Filed: 01/27/1999
• Issued: 04/17/2001
• Est. Priority Date: 02/12/1998
• Status: Expired due to Term

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Miura, Tetsuya, Nakamura, Masayuki, Ishimaru, Yasuhiko, Nishioka, Masahiro, Kawabata, Yasutomo, Endo, Katsuhisa
• Primary Examiner(s): Hall, Carl E.
• Application Number:
  US09/238,028
• Time in Patent Office: 811 Days
• Field of Search: 722/24, 722/25, 723/71, 721/46, 721/48, 296/05
• US Class Current: 72/148
• CPC Class Codes: B21B 1/166 Rolling wire into sections or flat ribbons
• CPC Class Codes: B21B 13/12 axes being arranged in different planes
• CPC Class Codes: B21B 2001/383 Cladded or coated products
• CPC Class Codes: H01F 41/077 Deforming the cross section or shape of the winding material while winding
• CPC Class Codes: H02K 15/0031 Shaping or compacting conductors in slots or around salient poles H02K15/005 takes precedence
• CPC Class Codes: H02K 15/095 by laying conductors around salient poles
• CPC Class Codes: H02K 3/18 Windings for salient poles
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49218 with deforming
• CPC Class Codes: Y10T 29/49222 forming array of contacts or terminals
• CPC Class Codes: Y10T 29/5337 including assembly pallet

Abstract

A circular wire with a circular cross section is wound on a coil reel. When a winding-form motor rotates a winding form, the circular wire is pulled and drawn from the coil reel. Rectangular forming rollers press the circular wire, so that a rectangular wire with a rectangular cross section is formed. The rectangular wire is directly wound on the winding form to be formed into a rectangular-wire coil. Because forming rectangular wire and winding on the winding form are carried out in a sequence of contiguous processes, a separate process for removing torsion set of the rectangular wire is unnecessary. The rectangular-wire coil can be formed from inexpensive circular material wire by a simple and low-cost apparatus. It is also possible and preferable to make dimensions and a shape of the rectangular wire variable by controlling clearance widths between the forming rollers and tension acting on the rectangular wire that has passed through the rollers.

Claims

1. An apparatus for manufacturing a rectangular-wire coil, comprising:

feeding means for supplying material wire;

rectangular forming means with rectangular forming rollers for deforming the material wire whereby the material wire provided through the feeding means is deformed to form wire with a rectangular cross section;

coil forming means whereby the rectangular wire is wound on a winding form to form a rectangular-wire coil and the coil forming means includes a winding-form motor for rotating said winding form, wherein forming rectangular wire and winding on the winding form are performed in a sequence of continuous processes which include rotating the winding form using a turning force generated by the winding-form motor, the rectangular wire pulled so as to provide the tension required for extracting the material wire from the rectangular forming rollers and winding on the winding form; and

winding-form motor control means for controlling the winding-form motor in order to vary a rotational speed of the motor according to a rotation angle of the winding form.

2. The apparatus for manufacturing a rectangular-wire coil according to claim 1, wherein

said winding-form motor control means reduces speed of said winding-form motor when the rectangular wire is being wound on a flexion portion of said winding form, and increases speed of said winding-form motor when the rectangular wire is being wound on a flat portion of said winding form.

3. The apparatus for manufacturing a rectangular-wire coil according to claim 1, wherein said feeding means includes

a rotatable material wire reel on which said material wire is wound and

back tension producing means to prevent sag by imparting back tension to a section of the material wire between said material wire reel and said rectangular forming rollers, and wherein

said back tension producing means imparts back tension, related to a difference between a rotational speed of said winding form and that of said material wire reel, and changes said back tension according to a rotational speed of said winding-form motor in conjunction with said winding-form motor control means.

4. The apparatus for manufacturing a rectangular-wire coil according to claim 1, wherein

said coil forming means includes a press roller for pressing the rectangular wire to closely contact with said winding form, and means for controlling roller pressing force by changing the roller pressing force generated by said press roller according to a rotation angle of said winding form, and wherein

said means for controlling roller pressing force decreases said roller pressing force when said press roller is located on a flat portion of said winding form, and increases said roller pressing force when said press roller is located on a flexion portion of said winding form.

5. The apparatus for manufacturing a rectangular-wire coil according to claim 1, wherein said coil forming means includes

a bending tool for pressing a portion of said rectangular wire which is about to be wound on said winding form so that it closely contacts with another portion which has already been wound, and

means for controlling bending tool pressing force exerted by said bending tool according to a rotation angle of said winding form, and wherein

said means for controlling bending tool pressing force decreases said bending tool pressing force when said bending tool is located on a flat portion of said winding form, and increases said bending tool pressing force when said bending tool is located on the flexion portion of said winding form.

6. The apparatus for manufacturing a rectangular wire-coil according to claim 1, comprising:

rectangular forming control means for controlling said rectangular forming means according to target forming dimensions of the rectangular wire, wherein

coils of differing cross-sectional shapes can be manufactured.

7. The apparatus for manufacturing a rectangular-wire coil according to claim 6, wherein

said rectangular forming control means adjusts cross-sectional shapes of said rectangular wire by controlling tension of said rectangular wire.

8. The apparatus for manufacturing a rectangular-wire coil according to claim 1, wherein

insulation adhering means for depositing an insulating material on said rectangular wire is provided to said rectangular forming means or provided between said rectangular forming means and said coil forming means.

9. An apparatus for manufacturing a rectangular-wire coil, comprising:

rectangular forming rollers for deforming a material wire pulled out of a material supplying source in order to form wire with a rectangular cross section;

a winding form to which the rectangular wire formed through said rectangular forming rollers is supplied;

a winding-form motor for rotating said winding form to form a coil by winding the rectangular wire on said winding form; and

winding-form motor control means for controlling the winding-form motor in order to vary a rotational speed of the motor according to a rotation angle of the winding form.