CN101443860A - Coil and coil shaping method - Google Patents
Coil and coil shaping method Download PDFInfo
- Publication number
- CN101443860A CN101443860A CNA2007800171130A CN200780017113A CN101443860A CN 101443860 A CN101443860 A CN 101443860A CN A2007800171130 A CNA2007800171130 A CN A2007800171130A CN 200780017113 A CN200780017113 A CN 200780017113A CN 101443860 A CN101443860 A CN 101443860A
- Authority
- CN
- China
- Prior art keywords
- coil part
- coil
- rectangular wire
- winding
- coiling
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Images
Abstract
To simplify the production work of a coil and to miniaturize a reactor, or the like, by reducing the occupation space as much as possible. [MEANS FOR SOLVING PROBLEMS] A reactor coil (12) consists of a first coil element (121) and a second coil element (122) formed by winding one flat type wire (17) rectangularly edgewise thereby stacking it in rectangular tube shape. At the end-of-winding of the first coil element (121), the flat type wire (17) is bent by about 90 DEG in the direction reverse to the winding direction of the first coil element (121), and wound rectangularly edgewise in the direction reverse to the winding direction of the first coil element (121) so that it is stacked in the direction reverse to the stacking direction of the first coil element (121) thus shaping the coil in such a state as the first coil element (121) and the second coil element (122) are arranged continuously in parallel at the moment in time when winding of the second coil element (122) is ended.
Description
Technical field
The present invention relates to a kind of coil as electronic unit, and a kind of method that is used to form this coil, and relate more specifically to the method that is suitable for use as the coil of reactor winding and is used to form this coil.
Background technology
Usually, the core that reactor has winding for example and made by magnetisable material, and this winding reels around core, and to constitute the coil of reactor, this makes it possible to obtain inductance.Traditionally, reactor is used in booster circuit, inverter circuit, the active filter circuit etc., and, in a lot of situations, this reactor has structure like this, being the core and the coil of reeling around this core is housed inside in the shell of being made by metal etc. (referring to, for example, patent reference 1) with other insulating component etc.
For the reactor that in vehicle-mounted booster circuit, uses, used coil with structure like this, be that each all has predetermined winding diameter and can provide two single coil elements of the number of windings of high inductance numerical value to be formed parallel to each other and connection (connection) each other in high galvanic areas, thus opposite each other by the mobile sense of current of these two coils.
First conventional example of this coil has structure like this, be that in above-mentioned two single coil elements each forms by each winding, and by on the end via the connection side that is communicated with terminal of winding, welding, these two single coil elements be connected to each other (referring to, for example, patent reference 2).
Second conventional example of this coil has structure like this, promptly by using one section vertical coiling of rectangular wire to form placement parallel to each other and by two single coil elements of reeling along equidirectional, and, by along and the Width of longitudinal direction quadrature will be in the joining part doubling of the rectangular wire between above two single coil elements connected to one another, formed coil is accommodated in the external shape that the end surfaces by two coil parts forms (referring to above-mentioned patent reference 2).
Patent reference 1: Japanese Patent Application Laid-Open No.2003-124039
Patent reference 2: Japan Patent No.3737461
Summary of the invention
Problem to be solved by this invention
Yet, in above-mentioned first conventional coil, the winding that is used to form two coil parts connects via being communicated with terminal, and therefore, as described in the above patent reference 2, end on the connection side of this connection terminal and each winding highlights from the profile that the end surfaces by two coil parts forms, thereby cause when coil being contained in the above-mentioned shell, the space that is occupied by coil increases, particularly, it is bigger that shell sizes becomes, and therefore causes the size of whole reactor to become big.
In addition, in first conventional example of above coil, need further process, wherein the coating on end on each winding and in the connection side of each winding is stripped from, and be used to connect two coil parts and be communicated with terminal, and, after this, weld on these parts, the result causes the manufacturing step of coil very complicated.And then, in above first conventional example, each these two coil part of making by each winding is by welding and be electrically connected to each other via being communicated with terminal, and, therefore, reliability in the welding portion becomes a problem inevitably, and produces another problem, and promptly electrology characteristic is according to changing of how welding.
Carry one in passing,, require the pin-point accuracy of these two coils to arrange because for example the core of general toroidal is inserted in two coil parts that constitute reactor.Yet, in the situation of first conventional example of coil, via being communicated with terminal the end on the connection side of two coil parts is connect each other, and therefore, the layout of these two coil parts changes easily, and this causes in some cases core being inserted becoming impossible.
On the other hand, in above-mentioned second conventional coil, form this two coil parts by using identical winding, and therefore, it is dispensable to be communicated with terminal, and this makes it be easy to joining part is contained in the external shape that the end surfaces by two coil parts forms.Yet, joining part forms on the end of two coil parts in such a manner, and promptly joining part is folded in half, and the result, folded part is outstanding on the end side of these two coil parts inevitably, and therefore causing is increased by the space that coil occupies in the mode corresponding to this folded part.In this case, if worry to make that the thickness of folded part reduces, then winding, promptly, the curvature influence of the electrology characteristic of coil is subjected to having done very for a short time this folded part.In addition, can not deny, have possibility like this, that is, electrology characteristic according to joining part by changing of how folding.And then, although it is unnecessary to make that the process of welding between two coil parts and connection terminal becomes, also requiring to be used for the above-mentioned other step of folding joining part, this proposes another problem, that is and, it is complicated that manufacture process becomes.
First purpose of the present invention is to provide the technology that can reduce as much as possible by the occupied space of the coil of the parts that are used as reactor, to realize the further miniaturization of reactor.
Second purpose of the present invention is to be provided for the technology of the coil that is made of the complex coil element, weld between coil part and the needs of the process of folding joining part by eliminating, this technology can be eliminated the variation of coil characteristics and high reliability is provided.
The 3rd purpose of the present invention is to be provided for the technology of the coil that is made of coil part, welds between coil part and the needs of the process of folding joining part by eliminating, and this technology can be simplified the process of making coil.
The 4th purpose of the present invention is to be provided for the technology of the coil that is made of coil part, and by making the accuracy of layout of a plurality of coil parts uprise, this technology can be inserted core in each coil part reliably.
The method that is used to deal with problems
The present inventor has been found that a kind of coil and a kind of method that is used to form this coil, this coil has new structure, wherein form a plurality of coil parts, thereby these a plurality of coil parts are placed on the same side, so that eliminate the needs that joining part is turned back, thereby and the sense of current that flows by these a plurality of coils be opposite.
Promptly, in order to realize first to the 3rd above purpose, coil of the present invention is by carrying out vertical to one section rectangular wire in one way and the rectangle coiling, in described mode, the rectangular wire of being reeled becomes rectangle and cylindricality ground to pile up in such a manner, promptly at least the first coil part and second coil part in continuous state, aim in parallel with each other and the coiling direction of rectangular wire opposite each other, it is characterized in that, by the mode that becomes rectangle and cylindricality ground to pile up with the rectangular wire of wherein being reeled rectangular wire is being carried out coiling termination end points place vertical and first coil part that the rectangle coiling forms, rectangular wire is bent roughly 90 degree along the direction opposite with the coiling direction of first coil part, thereby rectangular wire is stacked along the direction opposite with the stacking direction of first coil part, and reel along vertical ground of the direction opposite and one-tenth rectangular area with the coiling direction of first coil part, to form second coil part, and, at the coiling termination end points place of second coil part, first coil part and second coil part are arranged parallel to each other in continuous state.
By as above constructing, do not need to be used for welding portion and folded part that coil part is interconnected, and therefore, by being reduced as much as possible as the occupied space of the coil of parts, this makes it possible to realize the further miniaturization of reactor etc.And, do not need to be used for the welding that coil part is connect each other and/or turn back to be used for, and therefore the coil that can acquired character does not change and have high reliability with the turning back of coil part parallel alignment.In addition, eliminated welding job and/or the needs that turn back, and therefore, can simplify manufacturing work.
In order to realize above first to the 3rd purpose, a kind of coil formation method of the present invention is provided, be used to form by in one way one section rectangular wire being carried out coil vertical and that rectangle is reeled and constructed, in described mode, the rectangular wire of being reeled becomes rectangle and cylindricality ground to pile up, and, at least the first coil part and second coil part in continuous state, aim in parallel with each other and the coiling direction of rectangular wire opposite each other, and be used to use first winding head and form first and second coil parts with predetermined space separates installation from first winding head second winding head from one section rectangular wire, this method comprises:
The first rectangular wire feeding process, be used to prepare to have reel to form the rectangular wire of the required length of first coil part and second coil part, and from the second winding head side to first this rectangular wire of winding head side feeding, rectangular wire being placed first winding head, and the end of rectangular wire is set at the state that goes out around head process from the first volume with predetermined length;
The first coil part winding process is used for by using the first winding head coiling rectangular wire to reach the regulation numerical value that is used to form first coil part until the number of windings of first coil part;
The second rectangular wire feeding process is used for once more from the second winding head side to the first winding head side feeding rectangular wire, forms first coil part in the end of described rectangular wire;
The first coil part forming process is used for by with the whole first coil part bending 90 degree and first coil part is set at the state with regulation attitude roughly;
The 3rd rectangular wire feeding process is used for rectangular wire further is fed into the first winding head side from the second winding head side, to guarantee to be used for the winding part of second coil part; With
The second coil part winding process is used for by using the second winding head coiling rectangular wire to reach the regulation numerical value that is used to form second coil part until the number of windings of first coil part.
By as above constructing, can obtain to be used to form the method for coil, the needs that weld and turn back for coil part is connect have each other been eliminated thus, and therefore, by being reduced as much as possible as the occupied space of the coil of parts, this makes that reactor etc. can miniaturization and need not weld for coil part is connect each other and/or in order to turn back in parallel with each other alignment line coil element and turning back, and therefore, can realize there is not characteristic variations and have the coil formation method of high reliability.In addition, eliminated welding job and/or the needs that turn back, and therefore, can simplify manufacturing work.
And in the second rectangular wire feeding process, rectangular wire is with the feeding excessively of coil spacing length quilt, to guarantee the interval between first coil part and second coil part.
By as above constructing, be easy to guarantee in advance the predetermined coil gap length between first coil part and second coil part, and therefore, can eliminate the variation in the coil part between first coil part and second coil part, this can strengthen the reliability of formed coil.And the 3rd rectangular wire feeding process can comprise the process of cutting rectangular wire, be used for predetermined length rectangular wire being released cutting, thereby the terminal of the rectangular wire that forms by cutting constitutes the end of second coil part.
By as above constructing, make the coiling of second coil part carry out easily, can simplify manufacturing work thus.
On the other hand, in order to realize first to the 4th purpose, a kind of coil is provided, this coil has first coil part and second coil part at least, by the mode that becomes rectangle and cylindricality ground to pile up with the rectangular wire of wherein being reeled rectangular wire is carried out vertical the coiling with rectangle and form described first coil part, and in the mode of wherein piling up rectangular wire along the direction opposite with the stacking direction of first coil part at the coiling termination end points place of first coil part, along the direction opposite rectangular wire is carried out vertical the coiling with rectangle and form described second coil part with the stacking direction of first coil part, it is characterized in that, sentence continuation mode by using rectangular wire to be offset to reel based on the certain deviation amount at the coiling destination node of second coil part and be formed parallel to each other described first coil part and second coil part, concern and obtain described side-play amount by measuring position between second coil part and first coil part.
By as above constructing, the accumulation of the wire rod feeding error that produces when forming each side of second coil part during the winding process of reeling by skew can be cancelled, and therefore, can make the layout pin-point accuracy of first and second coil parts, and the core of general toroidal can insert reliably in each of first and second coil parts.In addition, do not need to be used for welding portion and folded part that coil part is connect each other, and therefore, can obtain the coil that does not have characteristic variations and have high reliability.In addition, eliminated welding job and/or the needs that turn back, and therefore, can simplify manufacturing work.
And, in order to realize first to the 4th purpose, a kind of coil formation method is provided, be used to form this coil and be used to use first winding head and form first and second coil parts from one section rectangular wire with predetermined space separates installation from first winding head second winding head, construct described coil by in one way one section rectangular wire being carried out vertical the coiling with rectangle, in described mode, the rectangular wire of being reeled becomes rectangle and cylindricality ground to pile up, and, at least the first coil part and second coil part in continuous state, aim in parallel with each other and the coiling direction of rectangular wire opposite each other, this method comprises:
The first rectangular wire feeding process, be used to prepare to have reel to form the rectangular wire of the required length of first coil part and second coil part, and from the second winding head side to first this rectangular wire of winding head side feeding, rectangular wire being placed first winding head, and the end of rectangular wire is set at the state that goes out around head process from the first volume with predetermined length;
The first coil part winding process is used for by using the first winding head coiling rectangular wire to reach the regulation numerical value that is used to form first coil part until the number of windings of first coil part;
The second rectangular wire feeding process is used for once more from the second winding head side to the first winding head side feeding rectangular wire, forms first coil part in the end of this rectangular wire;
The first coil part forming process is used for by be set at the state with regulation attitude with whole first coil part bending and with first coil part;
The 3rd rectangular wire feeding process is used for rectangular wire further is fed into the first winding head side from the winding head side, to guarantee to be used for the winding part of second coil part; With
The second coil part winding process, be used for by using the second winding head coiling rectangular wire to reach predetermined value until the number of windings of second coil part, and concerning and calculating side-play amount by measuring position between second coil part and first coil part during the winding process, and forming second coil part by being offset based on the side-play amount that is obtained to reel.
By as above constructing, the accumulation of the wire rod feeding error that produces when forming each side of second coil part during the winding process of reeling by skew can be cancelled, and therefore, can make the layout pin-point accuracy of first and second coil parts, and the core of general toroidal can insert reliably in each of first and second coil parts.In addition, do not need to be used for welding portion and folded part that coil part is connect each other, and therefore, can obtain the coil that does not have characteristic variations and have high reliability.And, eliminated welding job and/or the needs that turn back, and therefore, can simplify manufacturing work.
And in the second rectangular wire feeding process, rectangular wire is with the feeding excessively of coil spacing length quilt, to guarantee the interval between first coil part and second coil part.
By as above constructing, be easy to guarantee in advance the predetermined coil gap length between first coil part and second coil part, and therefore, can eliminate the variation in the coil part between first coil part and second coil part, this can strengthen the reliability of formed coil.
In this coil part winding process, obtain side-play amount to guarantee that the distance between the axle core of the axle core of first coil part and second coil part is the length of regulation.
By as above constructing, can eliminate the variable in distance between the axle core of axle core and second coil part of first coil part, thus, for example, the core of general toroidal can insert in each coil part reliably, and therefore can further strengthen reliability.
Effect of the present invention
According to the present invention, the end on the connection side of connection terminal and each winding is outstanding from the profile that the end surfaces by two coil parts forms, and the occupied space of coil does not increase.In addition, do not need the fold back portion that is used to connect, this can prevent that member etc. is side-prominent and can reduce the space that is occupied by coil towards the end surfaces of two coil parts, and therefore, when coil of the present invention is applied to electronic unit etc., coil is housed inside in the shell in this electronic unit, might make shell have small size, therefore realizes the miniaturization of whole electronic unit.
In addition, aspect reliability, cause problem without any welding portion, and do not have according to how the possibility of coil being turned back and in the electrology characteristic of coil, changing, can be formed in the coil that the electrology characteristic aspect has high reliability and fail safe thus.
And, need and not be communicated with the process of welding and turning back between the terminal at two coil parts, simplify the manufacturing work of coil thus.
And then, based in that offset calculated is offset coiling by measuring the position relation between second coil part and first coil part during the winding process, and therefore, the accumulation of the wire rod feeding error that takes place when forming each side of second coil part during winding process can be cancelled, and can make the layout pin-point accuracy of first coil part and second coil part.This makes that for example the core of general toroidal can insert in each coil part reliably, is provided at the coil that the electrology characteristic aspect has high reliability and fail safe thus.
Embodiment
By being described in detail with reference to the attached drawings the coil of the first embodiment of the present invention.According to first embodiment, coil of the present invention is applied to the coil (hereinafter, being called reactor winding) of reactor.Fig. 1 is the perspective view as the reactor of an example that comprises reactor winding of the present invention.Reactor 10 shown in Figure 1 is used to the circuit in a kind of equipment, this equipment for example has forced cooling device, and be configured to make after the reactor winding 12 that forms by the rectangular metal silk 17 of reeling around reactor core 9 is housed inside in the heat conduction shell 1, thereby filler 8 is injected wherein constant reactance device coil 12, between rectangular metal silk 17 and reactor winding 12, be inserted with coil holder (bobbin) (Fig. 1 is not shown).And, as described with reference to figure 3 after a while, the reactor winding 12 of first embodiment comprises first coil part 121 and second coil part 122, first coil part 121 and second coil part 122 each all carry out vertical to rectangular metal silk 17 and rectangle is reeled and formed by this way, and the rectangular metal silk 17 of promptly being reeled is become rectangles and cylindricality ground to pile up.In addition, in the lead portion 121L and 122L of the end that forms first coil part 121 and 122 respectively, coating is peeled off and the conductor of the rectangular metal silk 17 that exhumes out from rectangular metal silk 17, and the sub-(not shown) of pressure connecting terminal is mounted to be electrically connected to other electrical components.The reactor fixing hole 13 that use forms at the place, four bights of heat conduction shell 1, its each all be used as and be used for reactor winding 12 is fixed to the screw hole of for example forcing cooled enclosure etc.
Fig. 2 is the decomposition diagram of reactor 10 shown in Figure 1.Reactor 10 comprises that heat passes
Next, be to form among the winding part 4b after the reactor winding 12, from the two ends assembling partitioned portion 4a of coiling frame part 4b.Then, reactor core 9 is inserted among the coiling frame part 4b.Reactor core 9 is made of a plurality of block 3a and 3b and sheet members 6, and each block is made by magnetisable material, and sheet members 6 is inserted between the block 3b as magnetic gap.In this embodiment, reactor core 9 is made of two block 3a, 6 block 3b and 8 sheet members 6.Each of reactor core 9 all has the shape of general toroidal, and each block 3b and sheet members 6 of making by magnetisable material are inserted among the coiling frame part 4b all block 3b and thin slice 6 formation straight line portioies.Reactor core 9 has two straight line portioies and reactor winding 12 forms in each straight line portion, and here, coiling frame part 4b is inserted into wherein to obtain the electrology characteristic of regulation.The block 3a that is made by magnetisable material is connected to each straight line portion, therefore, forms the reactor core 9 with general toroidal shape.In addition, after the block 3b that is made by magnetisable material and sheet members 4 were inserted into the coiling frame part 4b of coil holder 4, block 3a was incorporated into sheet members 6, and therefore, block 3a is configured to not separated.
By above process, form reactor core 9 and reactor winding 12.Afterwards, after the thin slice 7 that will insulate/dispel the heat placed on the bottom surface of heat conduction shell 1, reactor core 9 and reactor winding 12 were accommodated in the heat conduction shell 1.Next, filler 8 is injected in the heat conduction shell 1, so that reactor core 9 and reactor winding 12 are fixed in the heat conduction shell 1.Insulation/heat radiation thin slice 7 is placed between reactor winding 12 and the heat conduction shell 1, thinks that the two provides insulation.In addition, the insulation of this embodiment/heat radiation thin slice 7 use have than around the thin slice of the higher thermal conductivity of the thermal conductivity of filler 8, and therefore, can be effectively with the heat transferred that produces from reactor winding 12 to heat conduction shell 1.Thus, dissipate the heat that produces from reactor winding 12 efficiently from the heat conduction shell 1 of forcing cooling.
As mentioned above, the reactor winding 12 of this embodiment comprises first coil part 121 and second coil part 122, first coil part 121 and second coil part 122 each all carry out vertical to rectangular metal silk 17 and rectangle is reeled and formed by this way, and the rectangular metal silk 17 of promptly being reeled is become rectangles and cylindricality ground to pile up.Therefore, first coil part 121 and second coil part 122 are so formed, be that the bottom surface is the plane and contacts with heat conduction shell 1, wherein insulation/heat radiation thin slice 7 is inserted between them, and therefore, compare with the stacked situation of cylindricality mode with coil part wherein, the heat dissipation characteristics of reactor winding 12 is fine.Equally, similarly, when comparing with the stacked situation of cylindricality mode with coil part wherein, the idle space in the heat conduction shell 1 is reduced, therefore make reactor winding 12 to be housed inside and have in the shell that reduces volume that this is used to make that whole reactor has little size.In addition, the reactor winding 12 of this embodiment forms first coil part 121 and second coil part 122 by vertical ground (vertically) crooked rectangle wire 17, and therefore, compare, can make the voltage between coil less with the situation that rectangular metal silk 17 is wherein reeled in a horizontal manner.Therefore, even, also might guarantee high reliability applying to it in reactor winding of 1000 volts of big voltages.
Fig. 3 is the perspective view that the reactor winding 12 of this embodiment is shown.As shown in Figure 3, the reactor winding 12 of this embodiment constitutes by first coil part 121 with second coil part 122, its each all carry out vertical to one section rectangular metal silk 17 by this way and rectangle is reeled and formed, the rectangular metal silk 17 of promptly being reeled is become rectangles and cylindricality ground to pile up.First coil part 121 and second coil part 122 are so formed, thereby thereby parallel to each other in a continuous manner and its coiling direction is opposite each other.Reactor winding 12 is characterised in that, among the coiling termination end 121E of first coil part 121 that forms rectangular metal silk 17 being carried out vertical the coiling by the mode that becomes rectangle and cylindricality ground to pile up with rectangle with the rectangular metal silk 17 of wherein being reeled, rectangular metal silk 17 is bent roughly 90 degree along the direction opposite with the coiling direction of first coil part 121, thereby rectangular metal silk 17 is piled up along the direction opposite with the stacking direction of first coil part (among Fig. 3 shown in the arrow A) (among Fig. 3 shown in the arrow B), and carried out vertical along the direction opposite and the rectangle coiling with the coiling direction of first coil part 121, and, the result, in the coiling termination end points of second coil part 122, first coil part 121 and second coil part 122 are arranged parallel to each other in a continuous manner.Here, term " vertical coiling " refers to a kind of winding method, and by this mode, rectangular metal silk 17 is reeled vertically.Equally, term " rectangle coiling " refers to a kind of winding method, and by this mode, coil is become rectangular area to reel, and this term forms contrast with " circular roll around ".In addition, the lead portion 122L of the lead portion 121L of first coil part 121 and second coil part 122 is placed on each the same side of first coil part 121 and second coil part 122, and therefore, even when the terminal of not illustrating is installed to each marginal portion of lead portion 121L and lead portion 122L, also might aligned with terminal.
Carry one in passing, by described the method for the reactor winding 12 that is used to form this embodiment with reference to figure 4,5 and 6.In the method for the reactor winding 12 that is used to form this embodiment, to shown in Fig. 6 (1), the winding head 100 that is used for first coil part by use is reeled with the winding head 200 that is used for second coil part as Fig. 4 (a).In the winding head 100 and 200 each all has two termination parts, and each termination parts all is provided with in such a manner, promptly faces with each other with predetermined interval.At first, shown in Fig. 4 (a), be fed to the position (first process of feeding rectangular wire 170) of regulation as a kind of rectangular metal silk (hereinafter, being known as rectangular wire 170) of wire rod.Promptly, as the winding that will be used to first coil part 121 and second coil part 122, prepare sufficiently long rectangular wire 170 and then rectangular wire 170 is fed into winding head 100 sides from winding head 200 sides, promptly, direction shown in the arrow A in Fig. 4 (a), pass through the position of winding head 100 so that rectangular wire 170 is pulled, thereby the top 170f of rectangular wire 170 is outstanding from the winding head 100 with predetermined length with setting rectangular wire 170.Form rectangular wire 170 by utilizing coating to cover so-called rectangular conductor.In addition, as describing after a while, the top 170f of rectangular wire 170 constitutes the end 121a of first coil part 121.
Then, shown in Fig. 4 (b), reel to form first coil part 121 (winding process of first coil part) by using winding head 100.In this case, reel to form first coil part 121 until reaching the predetermined number of windings (, so same) for second coil part 122.Towards centering on second coil part, 122 coiling rectangular wires 170 by the direction shown in the arrow B among Fig. 4 (b).Shown in Fig. 4 (b) and after a while other accompanying drawing, first coil part 121 (perhaps second coil part 122) is formed along having the size of regulation with the direction (along the above-below direction of accompanying drawing paper) of accompanying drawing paper quadrature.
After forming first coil part 121, shown in Fig. 4 (c), feeding rectangular wire 170 (the second feeding process of rectangular wire) once more.That is the top 170f of direction feeding rectangular wire 170 shown in the arrow C in Fig. 4 (c).At this moment, in order to guarantee the interval between first coil part 121 and second coil part 122, with predetermined coil spacing length T feeding rectangular wire 170 excessively.
Shown in Fig. 4 (d), form (bending) whole first coil part 121 with 90 degree.That is, forming (bending) rectangular wires 170, the first coil parts 121 by direction shown in the arrow D in Fig. 4 (d) with 90 degree is set to and takes predetermined attitude.In this case, at rectangular wire 170 with the coil spacing length T from the outstanding position of winding head 100, by using winding head 100 with rectangular wire 170 crooked 90 degree.That is, spend crooked rectangular wire 170 with the position of the coil spacing length T displacement of regulation with 90 at rectangular wire 170, form whole first coil part 121 by using winding head 100.
Then, shown in Fig. 5 (e), rectangular wire 170 is by further feeding (the 3rd feeding process of rectangular wire).Direction shown in the arrow E of the top 170f of rectangular wire 170 in Fig. 5 (e) is by further feeding.This process is a big feature of method that forms the reactor winding 12 of this embodiment, and, for the length of second coil part, the 122 needed wire rods that guarantee to be used to reel, rectangular wire 170 is fed until first coil part 121 and rectangular wire 170 and surpasses quite long length from winding head 100 is outstanding.In addition, according to this embodiment, by after its source of supply is released enough length, rectangular wire 170 is cut at rectangular wire 170, and constitutes the top 122a of second coil part 122 by the terminal 170b that cuts the rectangular wire 170 that forms.
Next, shown in Fig. 5 (f), reel to form second coil part 122 (winding process of second coil part) by using winding head 200.In this case, reel to form second coil part 122 until reaching the predetermined number of windings (, so same) for first coil part 121.At this moment on the point, shown in Fig. 5 (f), form rectangular wire 170 along the direction opposite, reel to form second coil part 122 with first coil part 121 by using winding head 200.That is, form (bending) rectangular wire 170 with 90 degree, begin to reel to form second coil part 122 by direction shown in the arrow F in Fig. 5 (f).Correspondingly, the coiling by using part that between the winding head 200 of rectangular wire 170 and winding head 100, exists as Fig. 5 (f) shown in and the part shown in Fig. 5 (e) to be used to form second coil part 122 from winding head 100 releases.That is, when rectangular wire 170 was formed (bending) 90 and spends, the bending direction of rectangular wire 170 changed (bending direction is reversed 180 degree).
Therefore, shown in Fig. 5 (e) and 5 (f), after finishing the coiling that is used to form first coil part 121, with rectangular wire 170 feedings be used to reel with form second coil part, 122 needed length and then rectangular wire 170 reeled once more to be used to form the coiling of second coil part 122 along opposite direction.This method that forms reactor winding is a big feature of present embodiment.
Like this, shown in Fig. 5 (g), because in order to form the coiling of second coil part 122, first coil part 121 is moved to winding head 200 sides, that is, and and direction shown in the arrow G in Fig. 5 (g).That is, this means that coil part 121 and 122 beginnings are close to each other.
In addition, shown in Fig. 6 (h), the coiling that is used to form second coil part 122 is proceeded, and the result, and coil part 121 and 122 is more close each other.At this moment, shown in Fig. 6 (h), first coil part 121 separate with winding head 100 and the arrow H in Fig. 6 (h) shown in direction near second coil part 122.Therefore, thus expectation reactor winding 12 has and promotes the mechanism that first coil part, 121 first coil parts and winding head 100 upwards separate.
Shown in Fig. 6 (i), state from second coil part 122 shown in Fig. 6 (h), coiling continues to the state of coiling quadrant (90 degree), finished the formation of second coil part 122 thus, and therefore make the coiling of two coil parts 121 and 122 all be done, this has finished the formation of reactor winding 12.Finish therein in this state of coiling, the end 122a (the end 170b of rectangular wire 170) of the end 121a of first coil part (the top 170f of rectangular wire 170) and second coil part aims in the mode of extending along the same direction shown in Fig. 6 (i).In addition, be necessary and separate with winding head 200 by the reactor winding 12 that first coil part 121 and second coil part 122 constitute, and therefore, thus expectation is provided for promoting two coil parts 121 and 122 coil parts 121 and 122 mechanisms that upwards are removed.
By using above formation method, as shown in Figure 3, can obtain not have the reactor winding 12 of the part of recoiling.Promptly, the method that is used to form reactor winding according to this embodiment, the attitude of coil part of being finished 121 and each of 122 all is in as shown in Figure 3 the state, and therefore, can save two coil parts 121 of welding (connection) and 122 and the process of recoiling rectangular wire 170.Be unlike in the situation of the first traditional example of coil like that, wherein reel respectively to form each coil part, and connect two coil parts by welding, in the present embodiment, on both sides,, do not need the member and a plurality of man-hour that are used to connect thus continuously by rectangular wire two coil parts 121 of 170 coilings and 122.In tradition second example of coil, do not need the parts that are used to connect and man-hour number, yet, in the situation of traditional second example, need recoil, this coil that causes being finished has the part of recoil and this requires the recoil process.According to reactor winding of present embodiment and forming method thereof, as in the situation of (rectangle coiling) common reactor winding of reeling, only require to carry out bending with 90 degree roughly, and the coil of being finished do not have the recoil part, it is unnecessary to make that thus the recoil process becomes.Promptly, term " recoil " refer to as in the second traditional situation with about 180 degree rectangular wire that integrally curls, and term " bending " refer to as in the situation of (rectangle coilings) common reactor winding of reeling with the curling rectangular wire of about 90 degree.In other words, in tradition second example of coil, the joining part of the rectangular wire between coil part connected to one another is folded in half along the Width with the longitudinal direction quadrature of rectangular wire, yet, according to present embodiment, along the direction opposite with the coiling direction of first coil part, from the displacing part of first coil part, 121 to second coil parts 122, rectangular wire 170 is bent about 90 degree.That is, the thickness direction from the displacing part of first coil part, 121 to second coil parts 122 along rectangular wire 170 of rectangular wire 170 is bent about 90 degree.
Like this, the reactor winding of present embodiment and the method that is used to form this reactor winding are characterised in that the mode that connects between two coil parts 121 and 122.In tradition first example of coil, be necessary to provide member and zone, for example be communicated with terminal and not as the welding portion of the winding of coil part, they only are used to connect between two coil parts.And, in second conventional example of coil, being necessary the zone that is provided for recoiling, this zone only is used for connecting between two coil parts, and not as the winding part.Unlike first and second conventional example, reactor and the method that is used to form coil according to present embodiment, as shown in Figure 3, thereby in fact the winding part of first coil part 121 is bent the winding part that 90 degree are coupled to second coil part 122, and therefore, need not to prepare only to be used to any member or the zone that connect, this can provide the epoch-making loop construction of not wasting.In other words, except sweep, all parts of rectangular wire 170 are all as the part of first coil part 121 or the part of second coil part 122 (as the part as the coil that produces inductance).
As mentioned above, the method feature of this embodiment and coil of the present invention and formation coil is, only by crooked rectangular wire 170 directly and do not use unnecessary portions for example to be used to terminal that welds or the fold back portion that is used to connect, just might realize two connections between the coil part.Therefore, unlike first conventional example, comprising that the end on the connection side that is communicated with terminal is not projected into the outside from the profile that the end surfaces by two coil parts forms, this does not cause the occupied space of coil to increase.In addition,, do not need the fold back portion that is used to connect, and therefore,, do not exist in member outstanding on the end surfaces of two coil parts etc. as clearly visible from Fig. 3 unlike tradition second example of coil.As a result, when comparing, because fold back portion with the situation of tradition second example of coil, the space that is occupied by coil is reduced, and therefore, when coil is housed inside in the above-mentioned heat conduction shell, especially, can make shell have little size, and reactor integral body can be miniaturized.
In addition, unlike tradition first example of coil, in the present embodiment, do not having problems aspect the reliability of welding portion.Unlike tradition second example of coil, the possibility that does not exist electrology characteristic to change according to the coil that how to turn back.Correspondingly, can form coil with high reliability and stable electrology characteristic.In addition, there is very big advantage, that is, need and be communicated with and welds between the terminal or, simplify manufacturing work thus the process that coil turns back at two coil parts.
Connect down, be described in detail with reference to the attached drawings the coil of the second embodiment of the present invention.Fig. 7 is the perspective view of the reactor winding 12 of the second embodiment of the present invention.As shown in Figure 7, as in the situation of first embodiment, the reactor winding of second embodiment comprises first coil part 121 and second coil part 122, its each all by being carried out vertical by the mode that becomes rectangles and cylindricality ground to pile up to one section rectangular wire 170 with the rectangular wire 170 of wherein being reeled and rectangle is reeled and formed.First coil part 121 and second coil part 122 are so formed, thereby thereby parallel to each other in a continuous manner and its coiling direction is opposite each other.Reactor winding 12 is characterised in that, among the coiling termination end points 121E of first coil part 121 that forms being used rectangular wire 170 to carry out vertical the coiling by the mode that becomes rectangle and cylindricality ground to pile up with rectangle with the rectangular wire 170 of wherein being reeled, rectangular wire 170 is bent roughly 90 degree along the direction opposite with the coiling direction of first coil part 121, thereby rectangular wire 170 is piled up along the direction opposite with the stacking direction of first coil part (among Fig. 7 shown in the arrow B) (among Fig. 7 shown in the arrow A), and carried out vertical along the direction opposite and the rectangle coiling with the coiling direction of first coil part 121, and, the result, in the coiling termination end points of second coil part 122, first coil part 121 and second coil part 122 are arranged parallel to each other in a continuous manner.
Therefore, the reactor winding 12 of second embodiment is coils that the duplex of so formation connects, promptly, after the rectangle that is used to form first coil part 121 is reeled end, feeding in advance has in order to reeling forming the rectangular wire 170 of the required length of second coil part 122, and uses wire rod to carry out rectangle on first coil part, 121 non-existent sides and reel to form second coil part 122.The result, what worry is, the accumulation of the wire rod feeding error that produces when forming each side during the rectangle winding process that is being used to form second coil part 122 occurs as the variable in distance between the axle core of the axle core of first coil part 121 and second coil part 122.As mentioned above, two straight line portioies of looping reactor core 9 are inserted in first coil part 121 and second coil part 122, and therefore, between the axle core of axle core and second coil part 122 of first coil part 121 apart from aspect, need high dimensional accuracy.According to second embodiment, in order to offset the accumulation of wire rod feeding error, on second coil part 122 that exists near the joining part between first coil part 121 and second coil part 122, reel as the Offset portion 123 enterprising line displacement of excess length part.
Because reel by skew, the accumulation of the wire rod feeding error that produces when forming each side during the winding process that is being used to form second coil part 122 can be cancelled, might arrange first coil part 121 and second coil part 122 in pin-point accuracy ground, and two line parts of the reactor core 9 of formation general toroidal can insert reliably in each of first and second coil parts 121 and 122.In addition, do not need to be used for the welding that coil part 121 and 122 is connect each other and be used for turning back that first and second coil parts 121 and 122 are aimed in parallel with each other, and therefore, the coil that can obtain to have unconverted characteristic and high reliability is provided.In addition, do not need the welding job and/or the work of turning back, simplify manufacture process thus.
Fig. 8,9 and 10 is figure that the method that is used to form reactor winding 12 is shown.In the method that forms reactor winding 12, to shown in 10 (i), reel by using winding head 100 that forms first coil part 121 and the winding head 200 that forms second coil part 122 as Fig. 8 (a).In winding head 100 and the winding head 200 each includes two pulley-like tip member that the mode that faces with each other with predetermined distance is provided with.
At first, shown in Fig. 8 (a), the rectangular wire 170 that is used as wire rod is fed to precalculated position (first process of feeding rectangular wire).Promptly, as the operating winding that is used to form first coil part 121 and second coil part 122, prepare sufficiently long rectangular wire 170, and rectangular wire 170 is fed into winding head 100 sides from winding head 200 sides then, promptly, direction shown in the arrow A in Fig. 8 (a), so that rectangular wire 170 pulled by winding head 100 setting the position of rectangular wire 170, thereby the top 170f of rectangular wire 170 is outstanding from the winding head 100 with predetermined length.Form rectangular wire 170 by utilizing coating to cover so-called rectangular conductor.In addition, as describing after a while, the top 170f of rectangular wire 170 constitutes the end 121a of first coil part 121.
Then, shown in Fig. 8 (b), reel to form first coil part 121 (winding process of first coil part) by using winding head 100.In this case, reel continuously to form first coil part 121 until reaching the predetermined number of windings.Towards centering on second coil part, 122 coiling rectangular wires 170 by the direction shown in the arrow B among Fig. 8 (b).Shown in Fig. 8 (b) and after a while other accompanying drawing, first coil part 121 is formed along having the size of regulation with the direction (along the above-below direction of accompanying drawing paper) of accompanying drawing paper quadrature.
After forming first coil part 121, shown in Fig. 8 (c), feeding rectangular wire 170 (the second feeding process of rectangular wire) once more.That is the top 170f of direction feeding rectangular wire 170 shown in the arrow C in Fig. 8 (c).At this moment, in order to guarantee the interval between first coil part 121 and second coil part 122, with predetermined coil spacing length T feeding rectangular wire 170 excessively, shown in the Fig. 8 (d) that describes after a while.
Shown in Fig. 8 (d), form (bending) whole first coil part 121 with 90 degree.That is, forming (bending) rectangular wires 170, the first coil parts 121 by direction shown in the arrow D in Fig. 8 (d) with 90 degree is set to and takes predetermined attitude.In this case, at rectangular wire 170 with the coil spacing length T from the outstanding position of winding head 100, by using winding head 100 with rectangular wire 170 crooked 90 degree.That is, spend crooked rectangular wire 170 with the position of the coil spacing length T displacement of regulation with 90 at rectangular wire 170, form whole first coil part 121 by using winding head 100.
Then, shown in Fig. 9 (e), rectangular wire 170 is by further feeding (the 3rd feeding process of rectangular wire).Direction shown in the arrow E of the top 170f of rectangular wire 170 in Fig. 9 (e) is by further feeding.This process is a big feature of method that forms the reactor winding 12 of this embodiment, and, in order to guarantee to be used to reel to form the length of second coil part, 122 needed wire rods, rectangular wire 170 is fed until first coil part 121 and rectangular wire 170 outstanding above quite long length from winding head 100.In addition, according to this embodiment, by after its source of supply is released enough length, rectangular wire 170 is cut at rectangular wire 170, and the terminal 170b of the rectangular wire 170 that forms by cutting process constitutes the top 122a of second coil part 122.
Next, shown in Fig. 9 (f), reel to form second coil part 122 (being used to form the winding process of second coil part) by using winding head 200.At this moment, shown in Fig. 9 (f),, reel to form second coil part 122 by using winding head 200 along the direction coiling rectangular wire 170 opposite with first coil part 121.That is, with 90 degree coiling rectangular wires 170, begin to reel to form second coil part 122 by direction shown in the arrow F in Fig. 9 (f).Correspondingly, the coiling by using part that between the winding head 200 of rectangular wire 170 and winding head 100, exists as Fig. 9 (f) shown in and the part shown in Fig. 9 (e) to be used to form second coil part 122 by from winding head 100 releases.
Therefore, shown in Fig. 9 (e) and 9 (f), after finishing the coiling that is used to form first coil part 121, rectangular wire 170 feedings are used for reeling forming second coil part, 122 needed length, and rectangular wire 170 is reeled in the opposite direction once more to be used to form the coiling of second coil part 122 then.This method that forms reactor winding is a big feature of present embodiment.Like this, shown in Fig. 9 (g), because in order to form the coiling of second coil part 122, first coil part 121 is moved to winding head 200 sides, that is, and and direction shown in the arrow G in Fig. 9 (g).This means that coil part 121 and 122 beginnings are close to each other.
Then, shown in Figure 10 (f), when the coiling that is used to form second coil part proceed and first coil part 121 and second coil part 122 further when close to each other, for example, before finishing coiling, when winding is set in the have 2 times state of (twice coiling), utilize distance between sensor measurement first and second coil parts 121 and 122 and the data that record to be stored in the memory of control section.Distance between two coil parts 121 and 122 can be the limited distance between two coil parts 121 and 122, shown in Figure 10 (h), for example comprise distance between the axle core of the axle core of the distance L 1 between the center of a side 122h of the center of a side 121h of first coil part 121 that faces with each other and second coil part 122, first coil part 121 and second coil part 122 etc.In addition, as the transducer that in above measurement, uses, can use any transducer, as long as it can measuring distance, comprise existing sensors, for example optical pickocff, mechanical pick-up device etc., and, further, after vision measurement, the numerical value that records can be input in the control section of up-coiler etc.
Then, based on the distance that records between two coil parts 121 and 122, calculate side-play amount F, thereby the distance L 1 between the axle core W2 of the axle core W1 of first coil part 121 of the reactor winding 12 with the final structure shown in its Figure 10 (i) and second coil part 122 becomes the predetermined length with wire rod amount of feeding feeding rectangular wire 170, and the wire rod amount of feeding that adds common by the side-play amount that will calculate obtains the described wire rod amount of feeding.Therefore, have predetermined length by the distance L 1 between the axle core W2 of axle core W1 and second coil part 122 of first coil part 121 is set for, making two straight line portioies with the reactor core 9 of general toroidal insert becomes possibility.The coiling that is used to form second coil part 122 is proceeded until because further coiling quadrant (90 degree), and the state shown in its Figure 10 (h) is changed the state shown in Figure 10 (f) into it.Can calculate side-play amount F from equation (1):
F＝(L1-a)/2+(b+r)…(1)
Wherein " L1 " refers to the distance between a side 122h of the side 121h of first coil part 121 that faces with each other and second coil part 122 in the memory of the control section that is stored in up-coiler, " a " refers to the length (distance between the center of rectangular wire 170) of a side 121h of first coil part 121 in the memory of the control section that is stored in up-coiler in advance, " b " refers to the width of rectangular wire 170, and " r " refers to the diameter of winding head 200.In addition, shown in Figure 10 (h), first coil part 121 separate with winding head 100 and the arrow H in Figure 10 (h) shown in direction near until second coil part 122.Therefore, thus the mechanism that expectation provides a kind of lifting first coil part 121 first coil parts 121 and winding head 100 upwards to separate.
Then, shown in Figure 10 (i), by with common wire rod amount of feeding feeding rectangular wire 170 and the coiling that is used to form second coil part 122 until because further coiling quadrant (90 degree), state shown in its Figure 10 (i) is changed and is the state shown in Figure 10 (j), finished the formation of second coil part 122, and the operating winding that is used to form two coil parts 121 and 122 is finished, and therefore causes forming the reactor winding 12 of this embodiment.On second coil part, 122 sides that exist near the joining part between first coil part 121 and second coil part 122, reel as the Offset portion 123 enterprising line displacement of excess length part, and therefore, the accumulation of wire rod feeding error can be cancelled.In addition, aspect the wire rod feeding accumulation of error, though can in the Offset portion on second coil part, 122 sides that exist near the joining part between first coil part 121 and second coil part 122, expectation obtain optimum efficiency, the part that wherein is offset coiling is not limited to top, and can select any part to form first coil part 121 or second coil part 122.
In addition, finished therein in the state of coiling, the end 122a (the end 170b of rectangular wire 170) of the end 121a of first coil part 121 (the top 170f of rectangular wire 170) and second coil part 122 aims in the extension mode along the equidirectional shown in Figure 10 (i).Requirement will be separated with winding head 220 with 122 reactor windings that constitute 12 by two coil parts 121, and therefore, and it is a kind of with two coil parts 121 and 122 mechanisms that upwards separate with winding head 200 that expectation provides.
According to above formation method, as shown in Figure 7, the accumulation of wire rod feeding error and the reactor winding 12 that does not have fold back portion can have been obtained to eliminate.Promptly, in the method for the reactor winding 12 that is used to form this embodiment, formed coil part 121 and 122 each attitude are in the state shown in Figure 7, and therefore, two straight line portioies of the reactor core 9 of general toroidal can insert in coil part 121 and 122, allow to save two coil parts 121 of welding (connection) and 122 the process and the process of turning back thus.
Therefore, this formation method is characterised in that and makes it possible to two coil parts 121 and 122 are carried out the bind mode that pin-point accuracy is arranged.In tradition first example of coil, need as the coil winding part only be used to the member or the zone that connect for example be communicated with terminal and/or welding portion.And, in second conventional example of coil, need and be not used in coil coiling only be used to the zone that connects, for example fold back portion.Unlike conventional example, at the reactor winding of this embodiment be used to form in the method for reactor winding, as shown in Figure 7, in fact the winding part of first coil part 121 is bent 90 degree to be attached to the winding part of second coil part 122, and therefore, need not to prepare only to be used to any member or the zone that connect, this can provide the epoch-making loop construction of not wasting.In other words, except sweep, all parts of rectangular wire 170 are all as the part of first coil part 121 or the part of second coil part 122 (as the part as the coil that produces inductance).
Obviously, the invention is not restricted to above embodiment, but under the situation that does not depart from scope and spirit of the present invention, can change and revise.
Industrial usability
The present invention can not only be applied to the coil of reactor widely, but also is used for other electricity As long as the coil of the electronic unit of son such as transformer etc. is at least by using in one way square Reel to form coil part forms described line to the shape wire rod vertically and orthogonally The circle, in described mode, the rectangular wire that is wound be stacked and coil part parallel to each other The coiling direction of ground aligning and coil part is opposite each other.
Description of drawings
Fig. 1 is the perspective view of an example with reactor of coil according to an embodiment of the invention;
Fig. 2 is the decomposition diagram of the reactor of Fig. 1;
Fig. 3 is the perspective view according to the reactor winding of the first embodiment of the present invention;
Fig. 4 is first figure of explanation according to the method for the formation reactor winding of the first embodiment of the present invention;
Fig. 5 is second figure of explanation according to the method for the formation reactor winding of the first embodiment of the present invention;
Fig. 6 is three figure of explanation according to the method for the formation reactor winding of the first embodiment of the present invention;
Fig. 7 is the perspective view of reactor winding according to a second embodiment of the present invention;
Fig. 8 is first figure that the method for formation reactor winding according to a second embodiment of the present invention is described;
Fig. 9 is second figure that the method for formation reactor winding according to a second embodiment of the present invention is described;
Figure 10 is the 3rd figure that the method for formation reactor winding according to a second embodiment of the present invention is described.
To letter or digital explanation
1: the heat conduction shell
4: coil holder
7: insulation/heat radiation thin slice
8: filler;
10: reactor;
12: reactor winding;
13: the reactor fixing hole;
17: the rectangular metal silk;
121L, 122L: lead portion
121: the first coil parts;
122: the second coil parts;
123: Offset portion;
100: winding head
200: winding head
170: rectangular wire
Claims (8)
1. coil, this coil carries out vertical by the mode that becomes rectangle and cylindricality ground to pile up with the rectangular wire of being reeled as follows to one section rectangular wire and rectangle is reeled forms, promptly at least the first coil part and second coil part in continuous state, aim in parallel with each other and the coiling direction of described rectangular wire opposite each other, it is characterized in that, by the mode that becomes rectangle and cylindricality ground to pile up described rectangular wire is being carried out coiling termination end points place vertical and described first coil part that the rectangle coiling forms by the rectangular wire of being reeled with quilt, described rectangular wire is bent roughly 90 degree along the direction opposite with the coiling direction of described first coil part, thereby described rectangular wire is stacked along the direction opposite with the stacking direction of described first coil part, and vertical and one-tenth rectangular area coiling along the direction opposite with the coiling direction of described first coil part, to form second coil part, and, at the coiling termination end points place of described second coil part, described first coil part and second coil part are arranged parallel to each other in a continuous manner.
2. coil formation method, this method is used to form described coil, and be used to use first winding head and separate second winding head that predetermined space installs and form first coil part and second coil part from one section rectangular wire with described first winding head, construct described coil by as follows one section rectangular wire being carried out vertical the coiling with rectangle, promptly the rectangular wire of being reeled is become rectangle and cylindricality ground to pile up, and at least the first coil part and second coil part are aimed in continuous state in parallel with each other and the coiling direction of described rectangular wire is opposite each other, and described method comprises:
The first rectangular wire feeding process, provide to have and reel to form the rectangular wire of the required length of described first coil part and second coil part, and from the described second winding head side to the described rectangular wire of the described first winding head side feeding, described rectangular wire being placed described first winding head, and the end of described rectangular wire is set at the state that goes out around head process from the described first volume with predetermined length;
The first coil part winding process by using the described first winding head described rectangular wire of reeling, reaches the regulation numerical value that is used to form described first coil part until the number of windings of described first coil part;
The second rectangular wire feeding process, again from the described second winding head side to the described rectangular wire of the described first winding head side feeding, form first coil part at an end place of described rectangular wire;
The first coil part forming process by with the whole first coil part bending 90 degree roughly, and is set at the state with regulation attitude with described first coil part;
The 3rd rectangular wire feeding process further is fed into described first winding head with described rectangular wire from the described second winding head side, to guarantee to be used for the winding part of described second coil part; With
The second coil part winding process by using the described second winding head described rectangular wire of reeling, reaches the regulation numerical value that is used to form described second coil part until the number of windings of described first coil part.
3. according to the coil formation method of claim 2, wherein, in the described second rectangular wire feeding process, described rectangular wire with coil spacing length by feeding excessively, so that guarantee interval between described first coil part and described second coil part.
4. according to the coil formation method of claim 2 or claim 3, wherein, described the 3rd rectangular wire feeding process comprises the process of cutting described rectangular wire, be used for described rectangular wire being released cutting, thereby an end of the described rectangular wire that forms by cutting constitutes the end of described second coil part with predetermined length.
5. coil, this coil has first coil part and second coil part at least, form described first coil part by as follows described rectangular wire being carried out vertical the coiling with rectangle, promptly the rectangular wire of being reeled is become rectangle and cylindricality ground to pile up; And, coiling termination end points place at described first coil part, to pile up the mode of described rectangular wire along the direction opposite with the stacking direction of described first coil part, carry out vertical to described rectangular wire and the rectangle coiling along the direction opposite with the stacking direction of described first coil part, form described second coil part, it is characterized in that, by using described rectangular wire to be offset coiling based on a side-play amount, and be formed parallel to each other described first coil part and second coil part in a continuous manner at the coiling destination node place of described second coil part, by before the coiling termination of described second coil part, concerning and obtain above-mentioned side-play amount measuring position between described second coil part and described first coil part during the winding process.
6. coil formation method, this method is used to form described coil, and be used to use first winding head and separate second winding head that predetermined space installs and form first coil part and second coil part from one section rectangular wire with described first winding head, construct described coil by as follows described one section rectangular wire being carried out vertical the coiling with rectangle, promptly the rectangular wire of being reeled is become rectangle and cylindricality ground to pile up, and, at least the first coil part and second coil part in continuous state, aim in parallel with each other and the coiling direction of described rectangular wire opposite each other, described method comprises:
The first rectangular wire feeding process, preparation has reels to form the rectangular wire of the required length of described first coil part and second coil part, and from the described second winding head side to the described rectangular wire of the described first winding head side feeding, described rectangular wire being placed described first winding head, and the end of described rectangular wire is set at the state that goes out around head process from the described first volume with predetermined length;
The first coil part winding process by using the described first winding head described rectangular wire of reeling, reaches the regulation numerical value that is used to form described first coil part until the number of windings of described first coil part;
The second rectangular wire feeding process, again from the described second winding head side to the described rectangular wire of the described first winding head side feeding, form described first coil part at an end place of described rectangular wire;
The first coil part forming process by making the whole first coil part bending, and is set at the state with regulation attitude with described first coil part;
The 3rd rectangular wire feeding process further is fed into the described first winding head side from described winding head side with described rectangular wire, to guarantee to be used for the winding part of described second coil part; With
The second coil part winding process, the described rectangular wire of reeling, until reaching predetermined value by the number of windings of using described second coil part of described second winding head, and concerning and calculating side-play amount by measuring position between described second coil part and described first coil part during the winding process, and forming described second coil part by being offset based on the side-play amount that is obtained to reel.
7. according to the coil formation method of claim 6, wherein, in the described second rectangular wire feeding process, described rectangular wire with coil spacing length by feeding excessively, so that guarantee interval between described coil part and described second coil part.
8. according to the coil formation method of claim 6 or claim 7, wherein, in described coil part winding process, obtain described side-play amount, be the length of regulation with the distance between the axle core of axle core and described second coil part of guaranteeing described first coil part.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2006133041A JP4951272B2 (en) | 2006-05-11 | 2006-05-11 | Coil and coil forming method |
| JP133041/2006 | 2006-05-11 | ||
| JP018828/2007 | 2007-01-30 | ||
| JP2007018828A JP4812641B2 (en) | 2007-01-30 | 2007-01-30 | Coil and coil forming method |
| PCT/JP2007/000507 WO2007132558A1 (en) | 2006-05-11 | 2007-05-11 | Coil and coil shaping method |
Related Child Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2011104027989A Division CN102592794A (en) | 2006-05-11 | 2007-05-11 | Coil and method for forming coil |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN101443860A true CN101443860A (en) | 2009-05-27 |
| CN101443860B CN101443860B (en) | 2012-02-01 |
Family
ID=38839475
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2007800171130A Active CN101443860B (en) | 2006-05-11 | 2007-05-11 | Coil and coil shaping method |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JP4951272B2 (en) |
| CN (1) | CN101443860B (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102110525A (en) * | 2010-12-23 | 2011-06-29 | 株洲南方机电制造有限公司 | Method for forming coil with flat coiling machine |
| CN102315000A (en) * | 2010-05-14 | 2012-01-11 | 株式会社丰田自动织机 | The method of coil component, reactor and formation coil component |
| CN103189942A (en) * | 2010-11-19 | 2013-07-03 | 住友电气工业株式会社 | Reactor |
| CN103650080A (en) * | 2011-05-19 | 2014-03-19 | 株式会社昌星 | Production method for a figure-of-eight-shaped laminated coil |
| CN104143418A (en) * | 2014-07-04 | 2014-11-12 | 苏州腾冉电气设备有限公司 | Coil winding for iron-silicon reactor |
Families Citing this family (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4997074B2 (en) * | 2007-11-20 | 2012-08-08 | 株式会社タムラ製作所 | Connecting coil forming method and connecting coil forming apparatus |
| JP4760825B2 (en) * | 2007-12-26 | 2011-08-31 | トヨタ自動車株式会社 | Edgewise winding method and edgewise winding apparatus |
| JP5142339B2 (en) | 2008-02-29 | 2013-02-13 | 株式会社タムラ製作所 | Connecting coil forming apparatus and connecting coil forming method |
| JP5105079B2 (en) * | 2008-03-31 | 2012-12-19 | 住友電気工業株式会社 | Reactor and reactor bobbins |
| JP4278700B1 (en) * | 2008-06-12 | 2009-06-17 | 日特エンジニアリング株式会社 | Winding method and winding apparatus for edgewise coil |
| JP5234422B2 (en) * | 2009-03-04 | 2013-07-10 | 住友電気工業株式会社 | Reactor coil member, manufacturing method thereof, and reactor |
| JP5353813B2 (en) * | 2010-05-14 | 2013-11-27 | 株式会社豊田自動織機 | Coil parts, reactor, and method for forming coil parts |
| JP5915588B2 (en) * | 2013-05-10 | 2016-05-11 | 株式会社豊田自動織機 | Coil and coil manufacturing method |
| JP6519437B2 (en) * | 2015-10-16 | 2019-05-29 | スミダコーポレーション株式会社 | Coil component and method of forming coil component |
| JP6780578B2 (en) * | 2017-05-12 | 2020-11-04 | 株式会社村田製作所 | Taping Electronic Components Ren |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5527236Y2 (en) * | 1977-10-20 | 1980-06-30 | ||
| JP3413244B2 (en) * | 1993-06-04 | 2003-06-03 | 明電ケミカル株式会社 | Impedance bond |
| JP3398855B2 (en) * | 1996-12-13 | 2003-04-21 | 東京精電株式会社 | Manufacturing method of coil parts |
| JP2000195725A (en) * | 1998-12-25 | 2000-07-14 | Tdk Corp | Line filter coil |
| JP3640207B2 (en) * | 2001-10-25 | 2005-04-20 | Ｔｄｋ株式会社 | Manufacturing method and apparatus for rectangular coil |
| JP3737461B2 (en) * | 2002-07-22 | 2006-01-18 | 株式会社東郷製作所 | Coil component and method for forming coil component |
| JP2005057113A (en) * | 2003-08-06 | 2005-03-03 | Matsushita Electric Ind Co Ltd | Rectangular wire series coil and coil components using the same |
| JP4355547B2 (en) * | 2003-09-19 | 2009-11-04 | パナソニック株式会社 | Manufacturing method and manufacturing apparatus of rectangular coil using flat conductive wire |
| JPWO2006016554A1 (en) * | 2004-08-10 | 2008-05-01 | 株式会社タムラ製作所 | Reactor |
-
2006
- 2006-05-11 JP JP2006133041A patent/JP4951272B2/en active Active
-
2007
- 2007-05-11 CN CN2007800171130A patent/CN101443860B/en active Active
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102315000A (en) * | 2010-05-14 | 2012-01-11 | 株式会社丰田自动织机 | The method of coil component, reactor and formation coil component |
| CN102315000B (en) * | 2010-05-14 | 2014-12-03 | 株式会社丰田自动织机 | Coil component, reactor, and method for forming coil component |
| CN103189942A (en) * | 2010-11-19 | 2013-07-03 | 住友电气工业株式会社 | Reactor |
| US9099236B2 (en) | 2010-11-19 | 2015-08-04 | Sumitomo Electric Industries, Ltd. | Reactor |
| CN103189942B (en) * | 2010-11-19 | 2016-02-03 | 住友电气工业株式会社 | Reactor |
| CN102110525A (en) * | 2010-12-23 | 2011-06-29 | 株洲南方机电制造有限公司 | Method for forming coil with flat coiling machine |
| CN102110525B (en) * | 2010-12-23 | 2012-07-11 | 株洲南方机电制造有限公司 | Method for forming coil with flat coiling machine |
| CN103650080A (en) * | 2011-05-19 | 2014-03-19 | 株式会社昌星 | Production method for a figure-of-eight-shaped laminated coil |
| CN104143418A (en) * | 2014-07-04 | 2014-11-12 | 苏州腾冉电气设备有限公司 | Coil winding for iron-silicon reactor |
Also Published As
| Publication number | Publication date |
|---|---|
| CN101443860B (en) | 2012-02-01 |
| JP2007305803A (en) | 2007-11-22 |
| JP4951272B2 (en) | 2012-06-13 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN101443860B (en) | Coil and coil shaping method | |
| CN102592794A (en) | Coil and method for forming coil | |
| US8056212B2 (en) | Coil and method of forming the coil | |
| CN1862723B (en) | Ignition coil apparatus for an internal combustion engine | |
| JP4845199B2 (en) | Trance | |
| JP4812641B2 (en) | Coil and coil forming method | |
| KR102273354B1 (en) | Electromagnetic induction apparatus and method of producing the same | |
| US20220172882A1 (en) | Coil component and manufacturing method of coil component | |
| US20090071454A1 (en) | Ignition coil having compressed powder core | |
| JP2012033955A (en) | Coil and coil formation method | |
| US20150145631A1 (en) | Coil winding method and transformer | |
| CN101946294A (en) | Reactor | |
| JP2958972B2 (en) | Transformer for high pressure generation | |
| JP3619812B2 (en) | Low profile transformer | |
| US9287037B2 (en) | Transformer-bobbin and transformer | |
| JPH0462807A (en) | Transformer | |
| JP3109241B2 (en) | Deflection coil and method of manufacturing the same | |
| JP2022164084A (en) | Terminal block | |
| JP2022164083A (en) | Bobbin and coil device | |
| JPH0410647Y2 (en) | ||
| JP2004031517A (en) | Wire winding method | |
| JP2001217117A (en) | Coil bobbin and wiring method of lead wire using the same | |
| JPH0582369A (en) | Transformer | |
| JPH03138915A (en) | Transformer for high-voltage generation | |
| JPH08279425A (en) | Flyback transformer |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant |