초록 ▼

A manufacturing method includes a step of setting prescribed dimensions L and p, a wire feeding step of feeding a wire on a turning base surface by the dimension L, a turning step of turning the wire on the turning base surface to thereby form a first turning portion, a straight first portion, a sec

A manufacturing method includes a step of setting prescribed dimensions L and p, a wire feeding step of feeding a wire on a turning base surface by the dimension L, a turning step of turning the wire on the turning base surface to thereby form a first turning portion, a straight first portion, a second turning portion and a straight second portion, and a pushing step of pushing the straight first portion or the straight second portion so that it goes away from the turning base surface by the dimension p. A manufacturing apparatus that executes the above steps is also disclosed.

대표청구항 ▼

What is claimed is: 1. A manufacturing method of a coil assembly of a rotary electric machine in which the coil assembly includes a plurality of coil members each of which is formed by a winding step of winding a wire so as to form a plurality of first portions, a plurality of second portions, a pl

What is claimed is: 1. A manufacturing method of a coil assembly of a rotary electric machine in which the coil assembly includes a plurality of coil members each of which is formed by a winding step of winding a wire so as to form a plurality of first portions, a plurality of second portions, a plurality of first turning portions each of which connects one of the first portions and one of the second portions that is located on one side of and adjacent to the one of first portions, and a plurality of second turning portions each of which connects one of the first portions and one of the second portions that is located on the other side of and adjacent to the one of first portions, the method comprising: a step of setting a prescribed length L and a prescribed pitch p; a first wire feeding step of feeding the wire onto a turning base surface formed on an end surface of a rotary plate configured to rotate about an axis running perpendicular to the end surface to thereby set a length L for one of the first portions based on the prescribed length L while the turning base surface is stationary; a first turning step of turning, after the first wire feeding step, the wire with the turning base surface to thereby form one of the first turning portions and one of the first portions; a first pushing step of pushing, after the first turning step, the one of first portions along an axial direction of the axis of the rotary plate so that the one of first portions goes away from the turning base surface by the prescribed pitch p while the rotary plate is stationary with respect to the axis running perpendicular to the end surface; a second wire feeding step of feeding, after the first pushing step, the wire onto the turning base surface to thereby set a length L for one of the second portions based on the prescribed length L while the turning base surface is stationary; a second turning step of turning, after the second wire feeding step, the wire with the turning base surface in the same direction as the wire was turned in the first turning step to thereby form one of the second turning portions and form one of the second portions between the one of first turning portions and the one of second turning portions; and a second pushing step of pushing, after the second turning step, the one of second portions along the axial direction of the axis of the rotary plate so that the one of second portions goes away from the turning base surface by the prescribed pitch p while the rotary plate is stationary with respect to the axis running perpendicular to the end surface. 2. The manufacturing method according to claim 1, wherein at least first one of the coil members and second one of the coil members are woven together so that the first portions, the second portions, the first turning portions and the second turning portions of the first one of the coil members are respectively arranged side by side with the first portions, the second portions, the first turning portions and the second turning portions of the second one of the coil members. 3. The manufacturing method according to claim 2, wherein the first one and the second one of the coil members are formed by repeatedly executing the winding step, and are then woven together. 4. The manufacturing method according to claim 2, wherein the second one of the coil members is woven, while being formed by executing the winding step, into the first one of the coil members that has been formed by executing the winding step. 5. The manufacturing method according to claim 2, wherein the first one and the second one of the coil members are woven together while being formed simultaneously by executing the winding step. 6. The manufacturing method according to claim 2, wherein the first one of the coil members and the second one of the coil members are formed on two respective turning base surfaces that are opposed to each other so as to be pushed toward each other, and are woven together. 7. The manufacturing method according to claim 2, wherein the first one of the coil members and the second one of the coil members are formed on two respective turning base surfaces that are opposed to each other so as to be pushed toward each other, and are woven into another coil member that has been formed by executing the winding step. 8. The manufacturing method according to claim 7, wherein the wires for the first one, the second one and the another of the coil members are insulated wires, and wherein insulation coatings are peeled from the insulated wires at prescribed positions while the first one and the second one of the coil members are formed on the turning base surfaces, to enable formation of connection terminals in the insulated wires. 9. The manufacturing method according to claim 2, further comprising a displacing step of displacing the coil members after the coil members have been formed by winding the wires and woven together, wherein in the displacing step, first end portions of the respective first portions and first end portions of the respective second portions of each of the first one and the second one of the coil members are displaced in opposite directions, and second end portions of the respective first portions and second end portions of the respective second portions of each of the first one and the second one of coil members are displaced in opposite directions, whereby first parallel straight portions are formed at the respective first portions and second parallel straight portions are formed at the respective second portions. 10. The manufacturing method according to claim 9, wherein in the displacing step, a plurality of coil combinations are formed each of which is a combination of the first one and the second one of the coil members, and each of the plurality of coil combinations is such that the second parallel straight portions of the second one of coil members are in contact with, from below, the first parallel straight portions of the first one of the coil members, respectively, and that the first parallel straight portions of the second one of the coil members are in contact with, from above, the second parallel straight portions of the first one of the coil members, respectively. 11. The manufacturing method according to claim 10, further comprising an inserting step of inserting the coil assembly into slots of an iron core after the displacing step, wherein in the inserting step, each of the plurality of coil combinations are inserted into the slots that are formed in the iron core at a prescribed pitch in such a manner that each of the first parallel straight portions of the first one of the coil members and each of the second parallel straight portions of the second one of the coil members are inserted into a prescribed slot as a first layer and a second layer, respectively, and each of the first parallel straight portions of the second one of the coil members and each of the second parallel straight portions of the first one of the coil members are inserted into a slot that is distant from the prescribed slot by a prescribed number of pitches as a first layer and a second layer, respectively. 12. The manufacturing method according to claim 11, further comprising a connecting step of connecting ends of the coil members after the inserting step. 13. The manufacturing method according to claim 9, further comprising a pressing step of pressing the coil members so that a first plane where the first portions exist and a second plane where the second portions exist come closer to each other. 14. The manufacturing method according to claim 13, wherein the pressing step is executed after weaving the coil members together and before the displacing step. 15. The manufacturing method according to claim 1, wherein the one of the first portions is pushed parallel the axis of the rotary plate by a pushing member that extends away from a plane of the rotary plate surface.