JP2005247562A - Coil winding method and coil winding device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce a winding swelling of a wire member wound on a slender core in the orthogonal direction to the magnetizing direction. <P>SOLUTION: A top roller 34 is rotatably supported via a support shaft 34a by a tip part projecting in the radial direction of a revolving flyer 30. The wire member 63 supplied by being guided by its outer peripheral part, is wound on the slender core 61 in the orthogonal direction to the magnetizing direction B. The top roller is inclined to a plane P including the rotational axis and a part for supporting the top roller of a tip part of the flyer so that a rotational central surface S orthogonal to its support shaft passes through the rear side of the rotational axis O1 of the flyer in the revolving direction of the flyer. The top roller is also rotatably supported around the second axis O2 parallel to the rotational axis O1. An inclination of the rotational central surface S of the top roller to the plane including both axes, may be reciprocally switched, and may also be controlled so as to periodically change in response to a revolving angle of the flyer. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a coil winding method and a coil winding device for winding on a core, and more particularly to a coil winding method and a coil winding device suitable for winding an elongated core in a direction orthogonal to the magnetization direction.

  For example, in an electric power steering device or the like, an elongated electric motor is used to move a rack shaft (see, for example, Patent Document 1). The stator of such an electric motor is obtained by connecting teeth assemblies wound around a plurality of elongated cores divided in a circumferential direction in a cylindrical shape, and fixed to the inner peripheral surface of the yoke housing by shrink fitting or the like. Is magnetized in the direction of the center line, that is, in the direction perpendicular to the longitudinal direction.

In addition, as a technique for winding a wire member around the core, a top roller is rotatably provided on a support shaft fixed to a distal end projecting in the radial direction of a flyer turning around the rotation axis, and the core is placed on an extension line of the rotation axis. There is a technique in which a wire member guided and supplied by the outer peripheral portion of the top roller is wound around a core by rotating the flyer. In the technique of this Patent Document 2, the rotation center plane of the top roller orthogonal to the support shaft includes the rotation axis of the flyer.
Japanese Patent Laying-Open No. 2003-306154 (paragraph [0041], FIGS. 2 and 3). JP 2002-27714 A (paragraphs [0011], [0018], FIGS. 1 to 4).

  FIG. 6 is a front view showing the flyer 1, the core 61, and the insulator 62 placed on the outside thereof when the technique shown in Patent Document 2 is applied to winding the elongated core in a direction orthogonal to the magnetization direction. A wire member 63 guided and supplied by a V-groove formed on the outer peripheral portion of the top roller 2 provided at the tip of the flyer 1 is wound around a core 61 (hereinafter simply referred to as a core 61) covered with an insulator 62. The teeth assembly 5 is formed. However, the wire member 63 wound around the core 61 in this way is bulged as shown in the longitudinal and lateral enlarged sectional views of the tooth assembly 5 shown in FIGS. 7 and 8. This winding bulge is usually maximum near the center in the longitudinal direction of the core 61, and a part of the wire member 6 wound outward is protruded outward from the inside of the concave groove 61 c of the core 61. This winding swelling is particularly remarkable when the wire member 63 is thick.

  The plurality of teeth assemblies 5 wound around the core 61 are alternately arranged in the winding direction and connected in a cylindrical shape to form the stator of the electric motor. When a part of the line member 6 protrudes from the inside of the groove 61c, as shown in FIG. 9, the line members 6 protruding from the recessed groove 61c of the adjacent teeth assembly 5 interfere with each other, and the base 61a of the core 61 is formed. It cannot be brought into close contact, and cannot be inserted and fixed on the inner peripheral surface of a yoke housing or the like of the electric power steering device as it is. For this reason, conventionally, since the wire member 6 wound around the core 61 is compressed from the side by a press or the like and set in a state where the wire member 6 is pushed into the concave groove 61c, an assembling work is increased. In addition, the defect rate due to breakage of the insulator 62 due to compression at the time of correction increases, so that there is a problem that the manufacturing cost increases.

  The cause of such bulging is not always clear. However, the wire member 63 that is guided to the top roller 2 rotatably provided at the tip of the flyer 1 via the support shaft 3 and is wound around the core 61 is twisted every time the flyer 1 is rotated. At this time, in a state where the top roller 2 is at a position greatly inclined from the longitudinal direction of the elongated core 61 in a direction orthogonal to the magnetization direction, the line member 63 supplied from the top roller 2 to the core 61 is moved in the radial direction of the flyer 1. On the other hand, since it is pulled out in the direction of the rear side in the turning direction, it is bent in the direction of the rear side in the turning direction of the flyer 1 at a position away from the top roller 2 (see FIG. 6). It is possible that Therefore, the inventor passes the top roller 2 through the center of the top roller 2 on the center surface of rotation (plane passing through the center in the width direction of the V groove formed on the outer periphery of the top roller 2 and orthogonal to the support shaft 3). A plane that includes a portion that is rotatably mounted by a support shaft 3 at a plurality of positions rotated around a diameter extending in parallel with one rotation axis O1 and that supports the top roller 2 at the tip of the rotation axis O1 and the flyer 1. The effect of the inclination angle of the rotation center plane of the top roller 2 on the bulge was experimentally measured.

  The winding swelling is indicated by the value of the maximum coil width W of the wound wire member 63 at each of the positions A to E obtained by equally dividing the space between the end surface on the winding start line 6a side and the opposite end surface of the core 61 into four. did. The width and length of the portion of the core 61 covered with the insulator 62 around which the wire member 63 is wound are 6.1 mm and 68 mm, respectively, the radius from the rotation axis O1 of the flyer 1 to the support shaft 3 of the top roller 2 is 130 mm, and the wire member 63 is a copper wire having a wire diameter of 1.56 mm and an insulating coating by enamel. Further, the inclination angle of the rotation center plane of the top roller 2 is inclined so that the rotation center plane passes the rear side of the rotation axis O1 in the turning direction of the flyer 1 with reference to the plane including the rotation axis O1. The coil width was not measured at the position where the rotation center plane was inclined in the opposite direction.

  The experimental results are shown in FIG. The experiment is performed at each position where the tilt angle of the top roller is 0 degree, 3 degrees, 6 degrees, and 10 degrees with respect to the plane including the rotation axis O1 and the portion supporting the top roller 2 at the tip of the flyer 1; ◆ ■ ▲ XX indicates the measured value of the actual coil width at each position A to E. A solid line, a broken line (two types), a one-dot chain line, and a two-dot chain line are curves indicated by a polynomial obtained by calculating the relationship of the coil width at each position with respect to the inclination angle of the top roller based on each measured value using the least square method. is there. As can be seen from this curve, the coil width with respect to each inclination angle of the top roller has the maximum value at the position B when each inclination angle of the top roller is about 4 degrees or less, and when it exceeds that, the value at the position C becomes maximum. . Since this maximum value is minimum when the inclination angle of the top roller is around 4 degrees, it can be seen that the bulge can be minimized by selecting such an inclination angle.

  An object of the present invention is to solve the above-described problem of the swollen bulge based on such knowledge.

  For this purpose, the coil winding method according to the present invention arranges an elongated core in a direction perpendicular to the magnetization direction on an extension of the rotation axis of the swirling flyer so that its longitudinal direction is perpendicular to the rotation axis. In the coil winding method in which a wire member that is guided by an outer peripheral portion of a top roller that is rotatably supported around a spindle orthogonal to the rotation axis is wound around a core at a tip portion that protrudes in the direction, the top roller The center of rotation perpendicular to the support shaft is inclined with respect to the plane including the rotation axis and the plane supporting the top roller at the tip of the flyer so that it passes the rear side of the rotation axis of the flyer in the turning direction of the flyer. It is what.

  In the coil winding method according to claim 1, the inclination angle of the top roller may be constant.

  In the coil winding method according to claim 1, the top roller supports the flyer so as to be rotatable about a second axis substantially parallel to the rotation axis and includes the rotation axis and the second axis. It is preferable to control the inclination angle of the rotation center plane of the top roller with respect to the plane to be opposite to each other according to the turning direction of the flyer.

  4. The coil winding method according to claim 3, wherein the inclination angle of the rotation center plane of the top roller with respect to a plane including the rotation axis and the second axis is controlled so as to periodically change according to the turning angle of the flyer. Is preferred.

  The coil winding method according to claim 3 or 4, wherein the second axis is disposed so as to be a tangent to a portion of the outer periphery of the top roller to which the line member is guided away from the rotation axis of the flyer. preferable.

  In the coil winding method according to claim 1, the top roller is a second roller extending substantially parallel to the rotation axis at a tangent line of the outer periphery of the top roller to which the line member is guided away from the rotation axis of the flyer. You may make it also rotatably support also around an axis line.

  Further, the coil winding device according to the present invention includes a flyer that revolves around a rotation axis, a top roller that is rotatably supported around a support shaft that is orthogonal to the rotation axis at a tip portion that protrudes in the radial direction of the flyer, Provided with a core support device that supports an elongated core in a direction orthogonal to the magnetization direction on an extension line of the rotation axis so that the longitudinal direction is orthogonal to the rotation axis, and is guided and supplied by the outer periphery of the top roller In the coil winding apparatus in which the wire member is wound around the core by turning the flyer, the top roller has the rotation axis and the flyer so that the rotation center plane orthogonal to the support shaft passes behind the rotation axis of the flyer in the turning direction of the flyer. It is characterized in that it is inclined with respect to a plane including a portion that supports the top roller at the tip portion.

  The coil winding apparatus according to claim 7, wherein the inclination angle of the top roller is preferably constant.

  The coil winding device according to claim 7, wherein the rotating member is rotatably supported around the second axis substantially parallel to the rotation axis at the tip of the flyer and supports the top roller via the support shaft. A top roller angle adjusting mechanism for controlling the rotation of the rotation member so that the inclination angle of the rotation center plane of the top roller with respect to the plane including the rotation axis and the second axis is opposite to each other according to the turning direction of the flyer It is preferable to further comprise.

  10. The coil winding device according to claim 9, wherein the top roller angle adjusting mechanism is configured such that the inclination angle of the rotation center plane of the top roller with respect to a plane including the rotation axis and the second axis is periodically changed according to the turning angle of the flyer. It is preferable to further control the rotation of the rotation member so as to change.

  The coil winding device according to claim 9 or 10, wherein the second axis is disposed so as to be a tangent to a portion away from the rotation axis of the flyer on the outer peripheral portion of the top roller through which the line member is guided, It is preferable that a through hole is formed coaxially in the rotating member, and the wire member is guided to the outer peripheral portion of the top roller through the through hole.

  Further, in the coil winding apparatus according to claim 7, a rotating member having a through hole coaxially formed by being rotatably supported around the second axis substantially parallel to the rotation axis at the tip of the flyer. Further, the top roller is supported by the rotating member via the support shaft so that the tangent of the outer peripheral portion of the top roller, to which the line member is guided, is located on the extension of the second axis line. The wire member may be led to the outer periphery of the top roller through the through hole.

  As described above, according to the coil winding method of the present invention, the top roller has the rotation axis and the flyer so that the rotation center plane orthogonal to the support shaft passes the rear side of the rotation axis of the flyer in the turning direction of the flyer. Since the tip portion is inclined with respect to the plane including the portion that supports the top roller, as shown in the experimental results described above with reference to FIG. Is smaller than that of the prior art in which the angle is zero. Therefore, it is possible to assemble a plurality of wound cores as a cylindrical shape of a predetermined dimension to a counterpart part without the need for a correction process of compressing the wire member wound around the core from the side using a press or the like, or the correction process Even if necessary, the amount of correction is small, correction is easy, and the defect rate due to breakage of the insulator is reduced, so that the manufacturing cost can be reduced.

  According to the invention of claim 2 in which the inclination angle of the top roller is constant, the structure of the apparatus necessary for the implementation is simplified, so that the equipment cost can be reduced.

  The top roller also supports the flyer so as to be rotatable about a second axis substantially parallel to the rotation axis, and the inclination angle of the rotation center plane of the top roller with respect to the plane including the rotation axis and the second axis is the flyer. According to the invention of claim 3 controlled so as to be opposite to each other in accordance with the turning direction, the cores in which the winding directions of the wire members are opposite to each other can be manufactured by the same apparatus.

  In the case of a core that is elongated in the direction perpendicular to the magnetization direction, the linear member supplied from the top roller to the core is drawn with an inclination toward the rear side in the turning direction with respect to the radial direction of the flyer. It changes periodically according to the turning angle. Therefore, according to the invention of claim 4, wherein the inclination angle of the rotation center plane of the top roller with respect to the plane including the rotation axis and the second axis is controlled to periodically change according to the turning angle of the flyer. Since the bending of the wire member at the distant position can always be reduced, the winding swelling is further reduced. Accordingly, the necessity of the correction process is reduced and the amount of correction when it is necessary is also reduced, so that the manufacturing cost can be further reduced.

  According to the invention of claim 5, wherein the second axis is arranged so as to be a tangent to a portion of the outer periphery of the top roller to which the line member is guided away from the rotation axis of the flyer, the line member is along the second axis. Therefore, even if the inclination angle of the top roller changes, the position of the line member guided to the top roller does not change, and stable winding can be performed.

  7. The top roller is also supported so as to be rotatable about a second axis extending substantially parallel to the rotation axis at a tangent line away from the rotation axis of the fryer on the outer periphery of the top roller to which the line member is guided. According to this invention, even if the inclination angle of the top roller is not actively controlled, the inclination angle is automatically oriented in the drawing direction of the line member supplied to the core, and the inclination angle of the top roller is Even if it changes, the position of the line member guided to the top roller will not change. Accordingly, since the structure of the apparatus necessary for the implementation is simplified, the equipment cost can be reduced and stable winding can be performed.

  Further, according to the coil winding apparatus of the present invention, the top roller has the rotation axis and the tip of the flyer so that the rotation center plane orthogonal to the support shaft passes behind the rotation axis of the flyer in the turning direction of the flyer. As shown in the experimental results described above with reference to FIG. 10, the winding bulge of the wire member wound on the elongated core is the angle of inclination described above. Is smaller than the prior art in which is zero. Therefore, it is possible to assemble a plurality of wound cores as a cylindrical shape of a predetermined dimension to a counterpart part without the need for a correction process of compressing the wire member wound around the core from the side using a press or the like, or the correction process Even if necessary, the amount of correction is small, correction is easy, and the defect rate due to breakage of the insulator is reduced, so that the manufacturing cost can be reduced.

  According to the invention of claim 8 in which the inclination angle of the top roller is constant, the structure of the coil winding device is simplified, so that the equipment cost can be reduced.

  A rotating member that is rotatably supported around a second axis substantially parallel to the rotational axis at the tip of the flyer and supports the top roller via a support shaft, and a top with respect to a plane including the rotational axis and the second axis According to the invention of claim 9, further comprising a top roller angle adjusting mechanism for controlling the rotation of the rotation member so that the inclination angle of the rotation center plane of the rollers is opposite to each other according to the turning direction of the flyer. Cores in which the winding directions of the wire members are opposite to each other can be manufactured by the same coil winding device.

  In the case of a core that is elongated in the direction perpendicular to the magnetization direction, the linear member supplied from the top roller to the core is drawn with an inclination toward the rear side in the turning direction with respect to the radial direction of the flyer. It changes periodically according to the turning angle. Therefore, the top roller angle adjusting mechanism rotates the rotating member so that the inclination angle of the rotation center plane of the top roller with respect to the plane including the rotation axis and the second axis periodically changes according to the turning angle of the flyer. Further, according to the controlled invention of claim 10, the bending of the wire member at the position away from the top roller can always be reduced, so that the winding bulge is further reduced. Accordingly, the necessity of the correction process is reduced and the amount of correction when it is necessary is also reduced, so that the manufacturing cost can be further reduced.

  The second axis is disposed so as to be a tangent to a part of the outer periphery of the top roller to which the line member is guided away from the rotation axis of the flyer, and a through hole is coaxially formed in the rotation member. According to the invention of claim 11, the position of the line member guided to the top roller does not change even if the inclination angle of the top roller changes, and the line member is always Since it is guided through a through-hole formed coaxially with the second axis, the operation of the coil winding device becomes stable.

  The top roller further includes a rotation member that is rotatably supported around a second axis substantially parallel to the rotation axis at the tip of the flyer and has a through-hole formed coaxially, and the top roller is a top roller to which the line member is guided The outer peripheral part of the top roller is supported by the rotating member via a support shaft so that the tangent of the part away from the rotation axis of the flyer is located on the extension of the second axis, and the linear member passes through the through hole and the outer peripheral part of the top roller According to the twelfth aspect of the present invention, the inclination angle of the top roller is automatically adjusted in the drawing direction of the line member supplied to the core without actively controlling the inclination angle of the top roller by the top roller angle adjusting mechanism. In addition, even if the inclination angle of the top roller changes, the position of the line member guided to the top roller does not change, and always passes through the vicinity of the center of the through-hole formed coaxially with the second axis. guided by . Accordingly, since the structure of the coil winding device is simplified, the equipment cost can be reduced, and the operation of the coil winding device can be stabilized.

  Hereinafter, the best mode of the coil winding method and the coil winding apparatus according to the present invention will be described with reference to FIGS.

  First, the tooth assembly manufactured by this embodiment will be described. As shown in FIGS. 3 and 4, the teeth assembly is formed by covering an insulator 62 on the outer side of an elongated core 61 in a direction orthogonal to the magnetization direction B, and winding a wire member 63 around the both 61 and 62. . The elongated core 61 is formed by stacking a large number of plates having a constant cross-sectional shape made of a magnetic material in the longitudinal direction (see FIG. 7), and includes a base portion 61a, a salient pole portion 61b projecting from a central portion on one side thereof, It has a shape formed by a protruding portion that protrudes on both sides from the tip of the pole portion 61b, and a concave groove 61c is formed on both sides. The back surface of the base portion 61a opposite to the salient pole portion 61b and the tip surface of the salient pole portion 61b are formed in a concentric convex arc shape and a concave arc shape. The elongated core 61 is covered with an insulator 62 made of a synthetic resin molded product having the same shape from both end faces to the center in the longitudinal direction, and the both end faces and the concave grooves 61c on both sides are covered. Hereinafter, unless otherwise specified, the core 61 covered with the insulator 62 is simply referred to as the core 61, and the concave groove 61 c of the core 61 means a concave groove formed by the outer surface of the insulator 62. Note that the central angle of the core 61 of this embodiment is 30 degrees.

  In the tooth assembly 60A shown in FIGS. 3 and 4, the wire member 63 wound around the core 61 has a thick wire diameter of 1.56 mm, and each layer is composed of three layers starting with the winding start wire 63a and ending with the connecting wire 63b. There are 4 rolls. The first layer to be wound first is wound from the base 61a side of the core 61 toward the tip end side of the salient pole portion 61b, and the wire member 63 forming each winding has portions located in the concave grooves 61c on both sides. Parallel to the longitudinal axis of the core 61, pairs of the same winding such as the first winding and the second winding are aligned on a plane orthogonal to the magnetization direction B (hereinafter simply referred to as an orthogonal plane). Each part of the wire member 63 located in the concave groove 61c has a semicircular arc-like line member in which the same windings are aligned on an orthogonal plane at the beginning of winding and the end opposite to the connecting wires 63a and 63b. 63, and at the beginning of winding and at the end of the connecting wires 63a and 63b, the wire is connected to the next winding by a semicircular arc-shaped line member 63 intersecting the orthogonal plane. The first layer is thus wound on the core 61.

  The second layer is wound from the tip end side of the salient pole portion 61b toward the base portion 61a side, and the portions located in the concave grooves 61c on both sides of the wire member 63 forming each winding are the longitudinal axis of the core 61 and They are stacked in parallel so as to be placed between the wire members 63 of the first layer. This second layer is connected to the end of the first layer by a semicircular arc-shaped line member 63 whose start end intersects the orthogonal plane, and the end of each part located in each concave groove 61c is the first layer Like the layer, the semi-arc-shaped line member 63 aligned on the orthogonal plane and the semi-arc-shaped line member 63 intersecting the orthogonal plane (the direction of the intersection is opposite to that of the first layer) are connected. Wrapped on the first layer. The third layer is the same as the first layer except that the portions located in the concave grooves 61c on both sides of the line member 63 are stacked so that they are placed between the line members 63 of the second layer. It is wound on the second layer.

  The teeth assembly 60B disposed adjacent to the teeth assembly 60A is the same as the teeth assembly 60A except that the winding direction of the wire member 63 is reversed and starts at the connecting wire 63b and ends at the winding end wire 63c. It is. The pair of cores 61 that form both the tooth assemblies 60A and 60B are attached to the sub-pallet 55 diagonally back to back and wound continuously.

  Next, an embodiment of the coil winding apparatus according to the present invention will be described with reference to FIGS. The coil winding device of this embodiment is configured to wind in a reverse direction continuously to a pair of cores 61 attached diagonally back to back on the sub-pallet 55 as described above. Mainly, the main frame 11 and the top roller The flyer 30 provided with 34, the top roller angle adjusting mechanism 40, and the core support device 50.

  As shown mainly in FIG. 1, the main frame 11 of this embodiment has an L-shaped cross section, and can reciprocate horizontally in a horizontal direction on a bed 10 of a coil winding device via a guide rail device (not shown). Is supported by guidance. The main frame 11 is connected via a feed mechanism 15 including a ball screw shaft 15a supported at both ends by a bracket 18 and a bearing block 19 provided on the bed 10 and a ball nut 15b fixed to the lower portion of the main frame 11. It is reciprocated by a frame feed servo motor 16 attached to the bracket 18. An upper frame 12 extending rearward is fixed to the upper portion of the main frame 11, and a cylindrical support member 13 having a central axis parallel to the moving direction of the main frame 11 is fixed to the middle portion in the vertical direction.

  A rotating member 20 is supported on the support member 13 via a ball bearing 25 so as to be rotatable coaxially. A driven pulley 22 is coaxially fixed to the rear portion of the rotating member 20, and between the drive pulley 21 and the driven pulley 22 fixed to the output shaft of the servo motor 24 attached to the main frame 11 via the plate 24 a. A belt 23 is stretched. As a result, the rotating member 20 is driven to rotate around the rotation axis O 1 that coincides with the central axis of the support member 13 by the servo motor 24. A first guide hole 20 a is coaxially formed in the rear protrusion of the rotating member 20. A second guide hole 26a having the same diameter as the first guide hole 20a of the rotating member 20 is formed on the flyer shaft 26 coaxially fixed to the front side of the rotating member 20, and the second guide hole 26a. A slit 26b is formed in the radial direction with a width that is considerably narrower than the diameter of the first guide hole 26a. The plate-like support block 27 inserted into the slit 26b is fixed to the flyer shaft 26 so as to protrude into the second guide hole 26a, and the deep receiving groove 27a formed in the support block 27 has a second receiving groove 27a. One intermediate roller 28 is rotatably supported around an axis perpendicular to the rotation axis O1.

  As shown in FIGS. 1 and 2, a flyer 30 extending in the radial direction in opposite directions is fixed to the front end of the flyer shaft 26. A shaft portion 35a of the rotation member 35 is rotatably supported around a second axis O2 parallel to the rotation axis O1 at a tip portion protruding in the radial direction of the flyer shaft 26. A top roller 34 is rotatably supported between a pair of plate-like brackets 33 fixed to the front side via a support shaft 34a orthogonal to the second axis O2. A through hole 35b is coaxially formed in the rotation member 35 passing through the flyer 30 in the axial direction, and a line guided by a V groove on the outer periphery of the top roller 34 so as to surround the front side of the top roller 34 in the bracket 33. A stopper 36 for preventing the member 63 (described later) from coming off is provided.

  On the rear side of the flyer 30 corresponding to the top roller 34, a second intermediate roller 32 is supported via a fixed bracket 31 so as to be rotatable about an axis perpendicular to the rotation axis O1. The three intermediate rollers 28, 32, and 34 have substantially the same shape, and a V-groove for guiding the wire member 63 is formed on the outer periphery. In this embodiment, the outer peripheral part of each roller 28, 32, 34 to which the line member 63 is guided means the circumference through which the center line of the line member 63 guided along the groove bottom of the V groove passes. Substantially, it means the circumference along the groove bottom of the V-groove. A portion of the outer peripheral portion of the top roller 34 and the second intermediate roller 32 that is led away from the rotation axis O1 (indicated by reference numeral 34y for the top roller 34) is in contact with the second axis O2, in other words. It is a tangent to the top roller 34 in the portion 34y. Further, the portion of the outer peripheral portion of the first intermediate roller 28 on the side of the rotation axis O1 is in contact with the rotation axis O1. A thin pipe 29 is fixed coaxially with the rotation axis O1 at the rear end of the support block 27 and extends rearward.

  Next, the top roller angle adjustment mechanism 40 that controls the rotation angle of the top roller 34 and the rotation member 35 around the second axis O2 will be described. An advance / retreat shaft 41 is slidably inserted into the first guide hole 20a of the rotating member 20, and a slit of the flyer shaft 26 is provided at the tip of the advance / retreat shaft 41 inserted into the second guide hole 26a of the flyer shaft 26. A groove 41a that is slidably engaged with the support block 27 is formed with the same width as 26b. The tip of one arm of a bell crank 47 pivotally supported in the slit 26 b at the tip of the flyer shaft 26 is connected to the tip of the advance / retreat shaft 41 via a link 48. The tip of the other arm of the bell crank 47 protrudes forward from a window hole 30a formed in the flyer 30, and is provided so as to be orthogonal to a plane P connecting the two axes O1 and O2 to the tip as shown in FIG. The pin 47a and a pin 35d provided substantially parallel to the pin 47a on the arm portion 35c projecting laterally from the rotating member 35 are connected by a tie rod 49 provided with ball joints at both ends. A through-hole through which the above-described thin pipe 29 is inserted is coaxially formed in the advance / retreat shaft 41 on the rear side of the groove 41a.

  Below the upper frame 12 provided in the main frame 11, a ball screw shaft 42a whose both ends are supported by bearing blocks 12b and 12c so as to be parallel to the rotation axis O1 and a rear end portion of the advance / retreat shaft 41 are provided. A feed mechanism 42 comprising a ball nut 42b rotatably connected via a ball bearing 41b is provided. The advance / retreat shaft 41 is reciprocated by rotationally driving the ball screw shaft 42a by a servo motor 46 attached to the upper frame 12 via the plate 12a via the drive pulley 43, the belt 45 and the driven pulley 44. When the advance / retreat shaft 41 is advanced and retracted in this way, the rotation member 35 and the top roller 34 are rotated about the second axis O2 via the link 48, the bell crank 47, the tie rod 49, and the arm portion 35c. . In this embodiment, the top roller angle adjustment mechanism 40 is based on a command from a control device (not shown) that controls the operation of the entire coil winding device, as shown in FIG. 2, according to the turning direction of the flyer 30. The rotation center plane S of the top roller 34 (a plane orthogonal to the support shaft 34a passing through the center in the width direction of the V groove formed on the outer periphery of the top roller 34) passes the rear side of the rotation axis O1 in the turning direction of the flyer 30. The inclination angle α with respect to the plane P connecting the two axes O1 and O2 is switched so as to be oriented, but the absolute value of the inclination angle α is set to a constant value regardless of the turning angle of the flyer 30.

  The wire member 63 is, for example, a copper wire having a wire diameter of 1.56 mm and an insulating coating with enamel. The wire member 63 pulled out from the bobbin and applied with an appropriate tension by the tension applying device is inserted from the rear end of the pipe 29 and is first guided outward in the radial direction by the V groove on the outer peripheral portion of the first intermediate roller 28. The second intermediate roller 32 is guided in the direction parallel to the rotation axis O1 by the V-groove at the outer peripheral portion of the second intermediate roller 32, passes through the through hole 35b of the rotating member 35, and is guided by the V-groove at the outer peripheral portion of the top roller 34. It is supplied to the core 61 disposed on the extension line of the opposing rotation axis O <b> 1, and is wound around the core 61 by the turning of the flyer 30.

  The core support device 50 is configured to rotate a rotating table 52 provided on a base 51 fixed on the bed 10 so as to be rotatable about a vertical axis by a servo motor (not shown) via a shaft 52a. In the center of the turntable 52, a support stand 53 is provided upright. As described above, the sub-pallet 55 having the pair of cores 61 attached diagonally back to back is mounted on the upper end of the support base 53 so that the longitudinal direction of each core 61 is in the vertical direction perpendicular to the rotation axis O1. Yes. The core support device 50 indexes each core 61 on the extension line of the rotation axis O1 facing the flyer 30 based on a command from a control device (not shown) that controls the operation of the entire coil winding device. Each core 61 is rotated according to the turning, and the wound wire member 63 is controlled to have a predetermined shape as described below.

  Next, the coil winding method in the case of winding around the core 61 by the above-described coil winding apparatus will be described. The wire member 63 drawn out from the bobbin (not shown) is inserted in advance from the rear end of the pipe 29 through a tension applying device, and drawn out to the core support device 50 side through the outer peripheral portions of the rollers 28, 32, and 34. Then, a sub-pallet 55 having a pair of cores 61 attached diagonally back to back is mounted on the upper end of the support base 53, and one of the cores 61 serving as the teeth assembly 60A is indexed on an extension line of the rotation axis O1 facing the flyer 30. The tip of the wire member 63 led out from the outer peripheral portion of the top roller 34 is locked at a predetermined position of the one core 61 described above.

  If the operation device is operated in this state to start the operation of the coil winding device, the control device first turns the rotating member 20, the flyer shaft 26, the flyer 30 and the advance / retreat shaft 41 in a predetermined direction by the servo motor 24. As the flyer 30 turns, the wire member 63 guided by the outer peripheral portion of the top roller 34 is supplied to the core 61 and starts to be wound. At the same time, the control device switches the forward / backward inclination angle α of the rotation center plane S of the top roller 34 with respect to the plane P including the two axes O 1 and O 2 by the top roller angle adjusting mechanism 40, and the servo motor 24 controls the flyer 30. The position is controlled to advance and retreat, and the subpallet 55 is controlled to rotate around the vertical axis by a servo motor (not shown). The forward / reverse switching of the inclination angle α of the rotation center plane S of the top roller 34 by the top roller angle adjustment mechanism 40 is a direction in which the rotation center plane S of the top roller 34 passes the rear side of the rotation axis O1 in the turning direction of the flyer 30. (See FIG. 2). For the advance / retreat control of the position of the flyer 30 by the servo motor 24 and the rotation control of the sub-pallet 55 around the vertical axis by the servo motor (not shown), the line member 63 wound around the core 61 is provided with concave grooves 61c on both sides of the core 61. At the end opposite to the inner and winding start and connecting wires 63a and 63b (or the connecting and winding end wires 63b and 63c), they are aligned on an orthogonal plane (a plane orthogonal to the magnetization direction B), and the winding start and connecting wires At the end portion of the core 61 on the 63a, 63b (same as above) side, a semi-arc-shaped line member 63 intersecting the orthogonal plane is connected to the next winding.

  When the wire member 63 is wound a predetermined number of times around one core 61 that becomes the tooth assembly 60A and the winding is finished, the control device rotates the turntable 52 by a servo motor, and the other core that becomes the teeth assembly 60B. The core 61 is indexed on the extension line of the rotation axis O1 facing the flyer 30, and the wire member 63 is wound around the other core 61 in the same manner as described above. However, in this case, the flyer 30 is swung in the opposite direction to the case of the one core 61 described above, and the rotation center plane S of the top roller 34 is in the direction passing the rear side of the rotation axis O1 in this swiveling direction. Further, the top roller angle adjusting mechanism 40 switches the inclination angle α of the rotation center plane S of the top roller 34 with respect to the plane P connecting the rotation axis O1 and the second axis O2 to the opposite side, thereby performing winding.

  According to the embodiment described above, the rotation center plane of the top roller 34 so that the rotation center plane S of the top roller 34 orthogonal to the support shaft 34 a passes through the rear side of the rotation axis O <b> 1 of the flyer 30 in the turning direction of the flyer 30. Since S is inclined by an angle α with respect to the plane P connecting the rotation axis O1 and the second axis O2, the line member wound around the elongated core 61 as shown in the experimental results described above with reference to FIG. The winding bulge 63 is smaller than that of the prior art in which the inclination angle is zero. Therefore, even if the wire member 6 wound around the core 61 is not corrected by being compressed from the side by a press or the like, a part of the wire member 63 does not protrude from the recessed groove 61c of the core 61. Accordingly, as shown in FIG. 5, a pair of adjacent tooth assemblies 60A and 60B can be brought into close contact with each other, and a plurality of pairs (for example, 6 pairs) of such tooth assemblies 60A and 60B are brought into close contact with each other. Since it can be cylindrical, it can be assembled by shrink fitting or the like on the inner peripheral surface of the yoke housing of the electric power steering apparatus. Thus, the labor required for assembly can be reduced, and an increase in the defect rate due to breakage of the insulator 62 is eliminated, so that the manufacturing cost can be reduced. Alternatively, even when the winding bulge needs to be corrected, the amount of correction is small and the correction becomes easy, and the defect rate due to breakage of the insulator 62 is reduced, so that the manufacturing cost can be reduced.

  In the embodiment described above, the rotation member 35 is provided at the tip of the flyer 30 so as to be rotatable around the second axis O2 substantially parallel to the rotation axis O1, and the top of the rotation member 35 is supported via the support shaft 34a. The roller 34 is supported, and the inclination angle α of the top roller 34 is opposite to the plane P connecting the rotation axis O1 and the second axis O2 in accordance with the turning direction of the flyer 30. By doing so, the core 61 in which the winding direction of the wire member 63 is opposite to each other can be manufactured by the same coil winding device. However, the present invention is not limited to this, and the inclination angle α of the top roller 34 can be implemented as a fixed value. Even in such a case, a defect due to omission / simplification of the compression process and damage to the insulator 62 is possible. The above-described effects such as a reduction in the rate can be obtained, and the top roller angle adjusting mechanism 40 is not necessary, and the bracket 33 that supports the top roller 34 only needs to be fixed to the tip of the flyer 30. The equipment cost can be reduced.

  In the above-described embodiment, the absolute value of the inclination angle α of the top roller 34 is constant, and in this way, the structure of the top roller angle adjusting mechanism 40 can be simplified, so that the equipment cost is reduced. Can do. However, the present invention is not limited to this, and the tilt angle α of the top roller 34 may be controlled to be periodically changed according to the turning angle of the flyer 30. In the case of the core 61 that is elongated in the direction perpendicular to the magnetization direction B, the line member 63 supplied from the top roller 34 to the core 61 is pulled out with an inclination toward the rear side in the turning direction with respect to the radial direction of the flyer 30. The inclination angle changes periodically according to the turning angle of the flyer 30. Therefore, if the inclination angle α of the top roller 34 is periodically changed according to the turning angle of the flyer 30 so as to be interlocked with the change of the inclination angle, the bending of the line member 63 at the position away from the top roller 34 is always maintained. Since it can be made smaller, the winding bulge can be further reduced. In this manner, the necessity for correction is reduced and the amount of correction when it is required is also reduced, so that the manufacturing cost of the stator in which the tooth assemblies 60A and 60B are combined can be further reduced.

  In the above-described embodiment, the second axis O2 of the rotating member 35 that pivotally supports the top roller 34 via the support shaft 34a is the rotation axis of the flyer 30 at the outer periphery of the top roller 34 to which the line member 63 is guided. The line member 63 is arranged so as to be a tangent at the portion 34y farthest from O1, and in this way, the line member 63 passes through the through hole 35b formed coaxially with the second axis O2, and the outer peripheral portion of the top roller 34. Therefore, even if the inclination angle of the top roller 34 changes, the position of the line member 63 guided to the top roller 34 does not change, and therefore there is no possibility that the line member 63 contacts the inner surface of the through hole 35b. The operation of the coil winding device becomes more stable. However, the present invention is not limited to this, and the position of the second axis O2 is almost parallel to the rotation axis O1 and near the extension of the rotation center plane S of the rotation member 35. Takes a sufficient margin around the line member 63 guided to the outer periphery of the top roller 34, and the line member 63 guided to the outer periphery of the top roller 34 moves by the rotation of the top roller 34 around the second axis O2. Even so, it is only necessary to prevent contact with surrounding members.

  Further, in the above-described embodiment, the rotation of the rotation member 35 that supports the top roller 34 around the second axis O2 is positively performed by the top roller angle adjustment mechanism 40, but the present invention is limited to this. Instead, the position of the second axis O2 that rotatably supports the rotating member 35 is located near the portion 34y of the outer peripheral portion of the top roller 34 away from the rotation axis O1 of the flyer 30 or further away from the rotation axis O1. If so, the top roller angle adjusting mechanism 40 may be omitted. In this case, the top roller 34 is rotated around the second axis O2 by the tension of the line member 63 drawn from the top roller 34 toward the core 61, and the inclination angle with respect to both the axes O1 and O2 is supplied to the core 61. In the direction in which the line member 63 is pulled out, that is, in the turning direction of the flyer 30, it automatically passes through the rear side of the rotational axis O1 of the flyer 30. Thereby, the structure of the coil winding apparatus which can wind the wire member 63 without winding up the elongate core 61 in the direction orthogonal to the magnetization direction B can be simplified.

It is a longitudinal section showing the whole structure of one embodiment of a coil winding device by the present invention. It is 2-2 sectional drawing of FIG. It is a side view of the teeth assembly wound by the coil winding apparatus shown in FIG.1 and FIG.2. FIG. 4 is a cross-sectional view of a pair of teeth assemblies shown in FIG. 3 attached to a subpallet. It is a cross-sectional view which shows the state which removed the pair of teeth assembly shown in FIG. 4 from the subpallet, and was joined tightly. It is sectional drawing equivalent to FIG. 2 of an example of the coil winding apparatus by a prior art. It is longitudinal direction sectional drawing of the teeth assembly wound by the coil winding apparatus shown in FIG. It is a cross-sectional view of the teeth assembly shown in FIG. FIG. 9 is a cross-sectional view illustrating a state in which a pair of teeth assemblies illustrated in FIGS. 7 and 8 are joined. It is a figure which shows the relationship between the inclination angle of the top roller in a coil winding apparatus, and the coil width of the wound teeth assembly.

Explanation of symbols

DESCRIPTION OF SYMBOLS 30 ... Flyer, 34 ... Top roller, 34a ... Spindle, 34y ... part, 35 ... Turning member, 35b ... Through-hole, 40 ... Top roller angle adjustment mechanism, 50 ... Core support apparatus, 61 ... Core, 63 ... Line Member, B ... magnetization direction, O1 ... rotation axis, O2 ... second axis, P ... plane, S ... rotation center plane.

Claims (12)

An elongated core is disposed on an extension line of the rotation axis of the rotating flyer in a direction orthogonal to the magnetization direction so that the longitudinal direction thereof is orthogonal to the rotation axis, and the rotation axis and the distal end projecting in the radial direction of the flyer In the coil winding method of winding a wire member guided by an outer peripheral portion of a top roller supported rotatably around an orthogonal support shaft around the core, the top roller has a rotation center orthogonal to the support shaft. The surface is inclined with respect to a plane including a portion supporting the top roller at the tip of the flyer and the tip of the flyer so that the surface passes the rear side of the flyer's axis of rotation in the turning direction of the flyer. Coil winding method. 2. The coil winding method according to claim 1, wherein the inclination angle is constant. 2. The coil winding method according to claim 1, wherein the top roller is rotatably supported around a second axis substantially parallel to the rotation axis with respect to the flyer, and the rotation axis and the second A coil winding method, wherein an inclination angle of a rotation center plane of the top roller with respect to a plane including an axis is controlled to be opposite to each other according to a turning direction of the flyer. 4. The coil winding method according to claim 3, wherein an inclination angle of a rotation center plane of the top roller with respect to a plane including the rotation axis and the second axis is periodically changed according to a turning angle of the flyer. A coil winding method characterized by being controlled. 5. The coil winding method according to claim 3, wherein the second axis is a tangent to a portion of the outer peripheral portion of the top roller to which the line member is guided away from the rotation axis of the flyer. A coil winding method characterized by being arranged. 2. The coil winding method according to claim 1, wherein the top roller extends substantially parallel to the rotation axis at a tangential line of a portion away from the rotation axis of the fryer at an outer peripheral portion of the top roller to which the line member is guided. A coil winding method, wherein the coil winding method is also supported rotatably around a second axis. A flyer that revolves around a rotation axis, a top roller that is supported by a tip portion that protrudes in the radial direction of the flyer so as to be rotatable about a support shaft that is orthogonal to the rotation axis, and an elongated core that is orthogonal to the magnetization direction. A core support device is provided that supports the extension of the rotation axis so that its longitudinal direction is perpendicular to the rotation axis, and the line member guided and supplied by the outer periphery of the top roller is rotated by the flyer. In the coil winding apparatus wound around the core, the top roller has a rotation center plane orthogonal to the support shaft passing through a rear side of the rotation axis of the flyer in a turning direction of the flyer. A coil winding device, wherein the coil winding device is inclined with respect to a plane including a portion supporting the top roller at the tip. 8. The coil winding apparatus according to claim 7, wherein the inclination angle is constant. 8. The coil winding apparatus according to claim 7, wherein the top end of the flyer is rotatably supported around a second axis substantially parallel to the rotation axis and supports the top roller via the support shaft. The rotation member is rotated so that the inclination angle of the rotation center plane of the top roller with respect to the plane including the moving axis and the rotation axis and the second axis is opposite to each other according to the turning direction of the flyer. A coil winding apparatus, further comprising a top roller angle adjusting mechanism to be controlled. 10. The coil winding device according to claim 9, wherein the top roller angle adjusting mechanism is configured such that an inclination angle of a rotation center plane of the top roller with respect to a plane including the rotation axis and the second axis corresponds to a turning angle of the flyer. The coil winding device further controls the rotation of the rotating member so as to periodically change. 11. The coil winding apparatus according to claim 9, wherein the second axis is a tangent to a portion of the outer periphery of the top roller to which the wire member is guided away from the rotation axis of the flyer. A coil winding apparatus characterized in that the rotating member is coaxially formed with a through hole, and the wire member is guided to the outer peripheral portion of the top roller through the through hole. 8. The coil winding device according to claim 7, wherein a rotary member is coaxially formed with a through hole coaxially supported by a tip end portion of the flyer so as to be rotatable about a second axis substantially parallel to the rotation axis. The top roller further includes the support shaft so that a tangent of a portion of the outer periphery of the top roller, to which the linear member is guided, away from the rotation axis of the flyer is positioned on an extension of the second axis. The coil winding device is supported by the rotating member, and the wire member is guided to the outer peripheral portion of the top roller through the through hole.

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