CN117543915A - Method for manufacturing cylindrical air core coil, cylindrical air core coil assembling device, single product coil manufacturing device, and cylindrical air core coil - Google Patents

Abstract

The invention provides a method for manufacturing a cylindrical air core coil, a cylindrical air core coil assembling device, a single product coil manufacturing device and a cylindrical air core coil. The cylindrical air-core coil has a plurality of individual coils which are circumferentially arranged around an axis extending in the axial direction and are located at positions where portions overlap each other in the thickness direction. The method for manufacturing the cylindrical air-core coil comprises the following steps: a loop coil forming step of forming a plurality of loop coils; a ring coil processing step of forming a step portion on the ring coil and bending the step portion to form a single-product coil protruding to one side in the thickness direction; and a single-product coil assembling step of combining the plurality of single-product coils protruding toward one of the thickness directions in a state in which a first portion of the single-product coil is overlapped on an outer surface of a second portion of the single-product coil adjacent to the single-product coil in the circumferential direction, thereby forming a cylindrical air-core coil.

Description

Method for manufacturing cylindrical air core coil, cylindrical air core coil assembling device, single product coil manufacturing device, and cylindrical air core coil

Technical Field

The present invention relates to a method for manufacturing a cylindrical air-core coil, a cylindrical air-core coil assembling apparatus, a single-product coil manufacturing apparatus, and a cylindrical air-core coil.

Background

So-called coreless motors are known, in which the motor has no rotor core or no stator core. As a method for manufacturing an air core coil for a coreless motor, various techniques have been proposed. For example, patent document 1 discloses a winding formed of a plurality of single coils made of a wire. In patent document 1, the single coils overlap each other like overlapping tiles. In addition, in the monocoil of patent document 1, a radially offset portion is provided between one leg and the other leg. Thereby, windings with a high packing density are achieved.

Further, for example, patent document 2 discloses a self-supporting air-core coil composed of at least two formed winding coils. In the air core coil of patent document 2, the shaping winding coils are arranged in a state in which outer peripheral regions overlap each other.

Prior art literature

Patent document 1 Japanese patent laid-open No. 2007-124892

Patent document 2 Japanese patent application laid-open No. 2014-230484

Disclosure of Invention

The single coil described in patent document 1 and the molded wound coil described in patent document 2 have a three-dimensional shape having an offset portion and being curved. As described above, since the coils of patent document 1 and patent document 2 have complex three-dimensional shapes, it is difficult to perform winding of the lead wire with high accuracy. Accordingly, for example, in the structure disclosed in patent document 2, a formed wound coil is manufactured by winding a wire on winding jigs of different diameters. However, even if such a winding jig is used, it is not easy to form a curved three-dimensional winding with good precision.

The purpose of the present invention is to realize a method for manufacturing a cylindrical air-core coil, an assembling device, a single-product coil manufacturing device, and a cylindrical air-core coil, which can form a single-product coil constituting the cylindrical air-core coil with good precision and in a simple manner.

A method of manufacturing a cylindrical air-core coil according to an exemplary embodiment of the present invention is a method of manufacturing a cylindrical air-core coil having a plurality of individual coils that are circumferentially arranged around an axis extending in an axial direction and are located at positions where portions overlap each other in a thickness direction. The method for manufacturing the cylindrical air-core coil comprises the following steps: a loop coil processing step of forming a step between a first portion, which is a portion in the circumferential direction of the loop coil, and a second portion, which is a portion in the circumferential direction of the loop coil, by relatively displacing the first portion in the thickness direction of the loop coil, and performing processing for bending the first portion and the second portion in the same direction in the thickness direction, thereby forming a single coil protruding to one of the thickness directions; and a single-product coil assembling step of positioning each of the convex sides of the plurality of single-product coils protruding to one of the thickness directions, as viewed in the axial direction, outside the radial direction of the axis, and arranging the plurality of single-product coils in the circumferential direction surrounding the axis, and combining the plurality of single-product coils in a state in which a first portion of the single-product coils is overlapped on an outer surface of a second portion of the single-product coil adjacent to the single-product coil in the circumferential direction, thereby forming a cylindrical air-core coil.

An exemplary embodiment of the present invention relates to a cylindrical hollow coil assembly device, comprising: a pin extending in an axial direction; a housing portion that houses a plurality of individual coils protruding to one of the thickness directions at a predetermined position on the outer side in the radial direction with respect to the pin, and that is disposed at a position circumferentially aligned around an axis extending in the axial direction and overlapping each other in the thickness direction; and a plurality of pressing portions that press the plurality of individual coils stored in the storage portion radially inward to form cylindrical air-core coils.

A single-product coil manufacturing apparatus according to an exemplary embodiment of the present invention is an apparatus for manufacturing a plurality of single-product coils that are circumferentially arranged around an axis extending in an axial direction, are located at positions where portions overlap each other in a thickness direction, and respectively constitute a part of cylindrical air-core coils. The single coil manufacturing apparatus includes: a workpiece support fixture having: a first outer peripheral surface having an arc shape with a predetermined diameter, a second outer peripheral surface having an arc shape with a diameter larger than the predetermined diameter, and a support portion located at a boundary between the first outer peripheral surface and the second outer peripheral surface and supporting a wound body around which a wire-shaped coil is wound; a work pressing portion that sandwiches the wound body supported by the support portion of the work support jig on a side opposite to the work support jig, between the work pressing portion and the work support jig; a first pressing portion that is located radially outward of the first outer peripheral surface and moves in a direction approaching the first outer peripheral surface, and presses a part of the wound body supported by the work support jig; and a second pressing portion that is located radially outward of the second outer peripheral surface and moves in a direction approaching the second outer peripheral surface, and presses a part of the wound body supported by the work support jig.

A cylindrical air-core coil according to an exemplary embodiment of the present invention is a cylindrical air-core coil having a plurality of individual coils that are circumferentially arranged around an axis extending in an axial direction and are located at positions where portions overlap each other in a thickness direction. The single product coil has: a first portion which is a part of the circumference of the single-product coil and is bent to the radially inner side; a second portion which is a remaining portion of the single-product coil in the circumferential direction and which is curved to the radially inner side; and a pair of stepped portions between the first portion and the second portion. The pair of stepped portions are displaced relative to each other in the thickness direction of the single-product coil between the first portion and the second portion, the plurality of single-product coils are projected outward in the radial direction of the axis, the plurality of single-product coils are arranged in a circumferential direction surrounding the axis in a posture in which the respective projecting sides are positioned outward in the radial direction of the axis when viewed from the axial direction, and the first portion of the single-product coil is overlapped on an outer surface of the second portion of the single-product coil adjacent to the single-product coil in the circumferential direction.

According to the method for manufacturing a cylindrical air-core coil, the cylindrical air-core coil assembling apparatus, the single-product coil manufacturing apparatus, and the cylindrical air-core coil according to the exemplary embodiment of the present invention, it is possible to form the single-product coil constituting the cylindrical air-core coil with high accuracy and in a simple manner.

Drawings

Fig. 1 is a diagram showing an example of a cylindrical air-core coil according to the embodiment.

Fig. 2 is a flowchart showing an example of a method for manufacturing a cylindrical air-core coil according to the embodiment.

Fig. 3A is a perspective view showing an example of a loop coil used for manufacturing a cylindrical air core coil.

Fig. 3B is a plan view showing an example of the loop coil.

Fig. 3C is a side view showing an example of the loop coil.

Fig. 4A is a perspective view showing an example of a stepped coil in which a stepped portion is formed.

Fig. 4B is a plan view showing an example of a stepped coil.

Fig. 4C is a side view showing an example of a stepped coil.

Fig. 5A is a perspective view showing an example of a single coil subjected to bending.

Fig. 5B is a plan view showing an example of a single coil.

Fig. 5C is a side view showing an example of a single coil.

Fig. 5D is an enlarged cross-sectional view of the VD-VD line shown in fig. 5B.

Fig. 6 is a diagram for explaining a single-product coil assembling process for assembling a single-product coil.

Fig. 7 is a view of the cylindrical air-core coil as seen from the axial direction.

Fig. 8A is a cross-sectional view schematically showing an example of a schematic structure of the step bending device according to the embodiment.

Fig. 8B is an enlarged view of the inside of the frame of the two-dot chain line shown in fig. 8A, and is a diagram for explaining the step bending process of the step bending device.

Fig. 8C is a top view of the step bending device shown in fig. 8B.

Fig. 9A is a side view schematically showing an example of a schematic configuration of the single-product coil manufacturing apparatus according to the embodiment.

Fig. 9B is a plan view of the single-product coil manufacturing apparatus as seen from the direction of arrow D25 shown in fig. 9A.

Fig. 9C is a side view schematically showing a state of bending processing realized by the single-product coil manufacturing apparatus.

Fig. 10A is a side view schematically showing an example of a schematic configuration of the cylindrical hollow coil assembly device according to the embodiment.

Fig. 10B is an enlarged plan view showing an example of a case where a single coil is housed in the cylindrical hollow coil assembly device.

Fig. 10C is a side view showing an example of the cylindrical hollow coil assembly device at the time of pressing.

Fig. 11A is a side view schematically showing an example of a schematic configuration of the cylindrical hollow coil assembly device 40 according to the modification.

Fig. 11B is a side view showing a state of pressing by the cylindrical hollow coil assembly device.

In the figure: 1-cylindrical air core coil, 20-single product coil manufacturing apparatus, 21-work holding jig, 22-first outer peripheral surface, 23-second outer peripheral surface, 24-supporting portion, 25-work pressing portion, 26-first pressing portion, 27-second pressing portion, 30, 40-cylindrical air core coil assembling apparatus, 31-pin, 32-pedestal, 32B-inclined portion, 33A to 33F, 43A, 43B-pressing portion, 42-mounting portion, 44A, 44B-side portion, 50-annular coil, 60-stepped coil, 70-single product coil, 51, 61, 71-first portion, 52, 62, 72-second portion, 63, 73-stepped portion, 75 a-one end portion, 75B-the other end portion, S1-annular coil forming step, S2-annular coil processing step, S3-single product coil assembling step.

Detailed Description

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. The same or corresponding portions in the drawings are denoted by the same reference numerals, and the description thereof will not be repeated. The dimensions of the constituent members in each drawing do not faithfully show the actual dimensions of the constituent members, the ratio of the dimensions of the constituent members, and the like.

In the following description, a direction parallel to the axis P1, which is the central axis of the cylindrical air-core coil, is referred to as an "axial direction", a direction orthogonal to the axis P1 is referred to as a "radial direction", and a direction along an arc centered on the axis P1 is referred to as a "circumferential direction". In the circumferential direction, when the constituent member is viewed from a predetermined direction, the clockwise direction is referred to as "one circumferential direction", and the counterclockwise direction is referred to as "the other circumferential direction". However, there is no intention to limit the orientation of the cylindrical air-core coil of the present invention in use by definition of the direction.

In the following description, the expressions "fixed", "connected" and "attached" include not only the case where the components are directly fixed to each other but also the case where the components are fixed via other components. That is, in the following description, the term "fixing" or the like includes the meaning of directly or indirectly fixing the members to each other.

[ Structure of cylindrical air-core coil ]

Fig. 1 is a diagram showing an example of a cylindrical air-core coil 1 according to the embodiment. The arrow D1 shown in fig. 1 shows the vertical direction of the cylindrical air-core coil 1. The cylindrical air-core coil 1 shown in fig. 1 is a coil assembled in a coreless motor having no iron core of a rotor or a slotless motor having no slot.

As shown in fig. 1, the cylindrical air core coil 1 has six individual coils 70. The six individual coils 70 are circumferentially arranged around an axis P1 extending in the axial direction of the cylindrical air-core coil 1, and are located at positions where portions overlap each other in the thickness direction.

The single coil 70 is a wound body around which a wire-shaped coil is wound. As will be described in detail later, the single coil 70 has a first portion 71, a second portion 72, and a pair of stepped portions 73.

The first portion 71 is a part of the circumference of the single product coil 70, and the second portion 72 is the remaining part of the circumference of the single product coil 70. The first portion 71 and the second portion 72 are bent to one of the thickness directions of the single coil 70. Therefore, the single coil 70 protrudes outward in the radial direction of the axis P1.

A pair of steps 73 is located between the first portion 71 and the second portion 72. At the step 73, the first portion 71 and the second portion 72 are relatively displaced in the thickness direction. The pair of step portions 73 are located at both end portions of the single coil 70 in the axial direction of the cylindrical air core coil 1.

The six individual coils 70 are arranged in a circumferential direction surrounding the axis P1 in a posture in which the convex sides thereof are located outside the radial direction of the axis P1 when viewed in the axial direction. In addition, the first portion 71 of the individual coil 70 is overlapped on the outer surface of the second portion 72 of the individual coil 70 adjacent to the individual coil 70 in the circumferential direction.

As shown in the enlarged view of fig. 1, the single-product coil 70 has one end 75a and the other end 75b of the winding. One end 75a and the other end 75b of the winding are electrically connected to the end of the winding of the other single-product coil 70, a power source, or the like. Thus, the plurality of individual coils 70 are electrically connected, and the plurality of individual coils 70 are electrically connected to the power supply. In other drawings, for convenience of explanation, one end 75a and the other end 75b of the winding of the single coil 70 are not shown.

[ method for manufacturing cylindrical air-core coil ]

A method for manufacturing the cylindrical air-core coil 1 according to the embodiment will be described with reference to fig. 2 to 7. Fig. 2 is a flowchart showing an example of a method for manufacturing the cylindrical air-core coil 1 according to the embodiment. Fig. 3A is a perspective view showing an example of the loop coil 50 used for manufacturing the cylindrical air core coil 1. Fig. 3B is a plan view showing an example of the loop coil 50. Fig. 3C is a side view showing an example of the loop coil 50. Fig. 4A is a perspective view showing an example of the stepped coil 60 formed with the stepped portion 63. Fig. 4B is a plan view showing an example of the stepped coil 60. Fig. 4C is a side view showing an example of the stepped coil 60. Fig. 5A is a perspective view showing an example of the single coil 70 subjected to bending. Fig. 5B is a plan view showing an example of the single coil 70. Fig. 5C is a side view showing an example of the single coil 70. Fig. 5D is an enlarged cross-sectional view of the VD-VD line shown in fig. 5B. Fig. 6 is a diagram for explaining a single-product coil assembling process for assembling the single-product coil 70. Fig. 7 is a view of the cylindrical air-core coil 1 as seen from the axial direction.

(annular coil Forming step)

First, as shown in fig. 2 and 3A to 3C, in the loop coil forming step S1, a linear coil is wound to form a loop coil 50 in a loop shape. In the loop coil forming step S1, six loop coils 50 are formed. In addition, in this specification, the ring shape includes not only a circle and an ellipse but also a rectangle and other polygons. As shown in fig. 3A to 3C, the loop coil 50 has a diamond shape, for example.

(annular coil processing step)

Next, as shown in fig. 2, a loop coil processing step S2 of processing the loop coil 50 formed in the loop coil forming step S1 is performed. Specifically, first, as shown in fig. 3A to 3C, a step bending step is performed to relatively displace the first portion 51, which is a part of the circumferential direction of the annular coil 50, and the second portion 52, which is the rest of the circumferential direction of the annular coil 50, in the thickness direction of the annular coil 50. That is, as shown in fig. 3C, the first portion 51 is relatively displaced in the direction of arrow D51, which is one of the thickness directions, and the second portion 52 is relatively displaced in the direction of arrow D52, which is the other of the thickness directions.

Thus, as shown in fig. 4A to 4C, in the stepped coil 60, a stepped portion 63 is formed between the first portion 61 and the second portion 62.

Next, as shown in fig. 4A to 4C, a bending step of bending the first portion 61 and the second portion 62 in the same direction in the thickness direction is performed. That is, the first portion 61 is bent in the thickness direction, i.e., the direction of arrow D61, and the second portion 62 is bent in the thickness direction, i.e., the direction of arrow D62. In the annular coil processing step S2, when the first portion 61 and the second portion 62 are bent, the bending radius of the first portion 61 is made larger than the bending radius of the second portion 62.

As a result, as shown in fig. 5A to 5D, the single coil 70 protruding to one side in the thickness direction is formed. As shown in fig. 5D in particular, the first portion 71 of the single-product coil 70 is bent with respect to the bending center P70 by a bending radius R1. In addition, the second portion 72 of the single-product coil 70 is bent with a bending radius R2 with reference to the bending center P70. Wherein the bending radius R1 of the first portion 71 of the single product coil 70 is larger than the bending radius R2 of the second portion 72.

According to this structure, in a state in which the first portion 71 of the single-product coil 70 is overlapped on the outer surface of the second portion 72 of the single-product coil 70 adjacent to the single-product coil 70 in the circumferential direction, the size of the gap generated between the first portion 71 and the second portion 72 can be reduced. Therefore, the duty ratio of the cylindrical air-core coil 1 increases.

The above-described six loop coils 50 are subjected to the loop coil processing step S2, respectively, to obtain six individual coils 70 protruding to one side in the thickness direction.

(Single coil Assembly Process)

Next, in the individual coil assembling step S3, the six individual coils 70 obtained in the annular coil processing step S2 are combined.

Specifically, as shown in fig. 6, first, with respect to six individual coils 70 protruding to one of the thickness directions, the protruding sides thereof are positioned radially outward of the axis P1 as viewed from the axial direction, and are arranged in the circumferential direction surrounding the axis P1. The outer surfaces of the first portions 71 of the individual coils 70A to 70F are arranged along the outer peripheral surface T of the cylindrical air-core coil 1 shown by the phantom line of the two-dot chain line in fig. 6.

Then, the six individual coils 70A to 70F are combined, and the first portion 71 of the individual coil 70A is positioned on the outer surface of the second portion 72 of the individual coil 70B adjacent to the individual coil 70A in the circumferential direction. Thereafter, the second portion 72 of the single-product coil 70B is moved in the circumferential direction with respect to the inside of the first portion 71 of the single-product coil 70A, and the axis P1 is viewed from the outside in the radial direction, and the second portion 72 of the single-product coil 70B is positioned at a position overlapping with the first portion 71 of the single-product coil 70A. Thereby, the cylindrical air-core coil 1 shown in fig. 7 and 1 is formed. The outer surfaces of the first portions 71 of the individual coils 70A to 70F constituting the cylindrical air-core coil 1 constitute the outer peripheral surface of the cylindrical air-core coil 1.

As described above, the method for manufacturing the cylindrical air-core coil 1 according to the present embodiment includes the plurality of individual coils 70, and the plurality of individual coils 70 are circumferentially arranged around the axis P1 extending in the axial direction and are located at positions where portions overlap each other in the thickness direction. The method for manufacturing the cylindrical air core coil 1 includes a loop coil forming step S1, a loop coil processing step S2, and a single-product coil assembling step S3. In the loop coil forming step S1, a plurality of loop coils 50 having a loop shape are formed by winding a linear coil. In the annular coil processing step S2, the first portion 51, which is a part of the annular coil 50 in the circumferential direction, and the second portion 52, which is the rest of the annular coil 50 in the circumferential direction, are relatively displaced in the thickness direction of the annular coil 50. Thereby, the stepped coil 60 having the stepped portion 63 formed between the first portion 61 and the second portion 62 is formed. In the annular coil processing step S2, the first portion 61 and the second portion 62 are bent in the same direction in the thickness direction. Thereby, the single coil 70 protruding to one side in the thickness direction is formed. In the individual coil assembling step S3, the plurality of individual coils 70 protruding in one direction in the thickness direction are arranged in the circumferential direction surrounding the axis P1 with their protruding sides positioned outside the radial direction of the axis P1 as viewed from the axial direction, and the plurality of individual coils 70 are assembled in a state where the first portions 71 of the individual coils 70 are overlapped on the outer surfaces of the second portions 72 of the individual coils 70 adjacent to the individual coils 70 in the circumferential direction. Thereby, the cylindrical air-core coil 1 is formed.

In the above-described manufacturing method, in the loop coil forming step S1, the flat loop coil 50 having no step is formed. Such a flat loop coil 50 without steps can be easily manufactured by a simple winding process.

In the annular coil processing step S2, the annular coil 50 is bent while forming the step 63. The step 63 may be formed by a known processing machine, such as a bending process of the loop coil 50. The individual coils 70 obtained in the annular coil processing step S2 constitute a part of the outer peripheral surface of the cylindrical air-core coil 1.

As described above, in the individual coil assembling step S3, the plurality of individual coils 70A having the stepped portion 73 and protruding to one side in the thickness direction are assembled, whereby the cylindrical air-core coil 1 is assembled.

Therefore, according to the method for manufacturing the cylindrical air-core coil 1 of the present embodiment, the single-product coil 70 for assembling the cylindrical air-core coil can be formed with high accuracy and in a simple manner. That is, since the bending of the three-dimensional winding can be avoided, the annular coil can be formed by a simple winding process. Therefore, a method for manufacturing a cylindrical air core coil suitable for mass production can be obtained. In addition, the cylindrical air-core coil 1 having the above-described structure can be efficiently manufactured by the above-described method for manufacturing a cylindrical air-core coil.

The loop coil processing step S2 includes: a step bending step of forming a step 63 between the first portion 51 and the second portion 52 of the loop coil 50; and a bending step of bending the first portion 61 and the second portion 62 of the stepped coil 60 in the same direction in the thickness direction after the step bending step.

According to this configuration, in the annular coil processing step S2, after the step bending step is performed on the annular coil 50, a bending step is performed in which the first portion 61 and the second portion 62 of the stepped coil 60 are bent in the same direction in the thickness direction. Therefore, the annular coil 50 can be processed by a combination of these step bending steps and bending steps.

Therefore, the single-product coil 70 can be easily manufactured as compared with the case where the single-product coil 70 having the stepped portion 73 and protruding to one side in the thickness direction is formed by winding.

Therefore, the takt time when the cylindrical air-core coil 1 is manufactured can be shortened.

[ step bending device ]

Next, a step bending apparatus for performing step bending in the method of manufacturing the cylindrical air-core coil 1 will be described with reference to fig. 8A to 8C.

Fig. 8A is a cross-sectional view schematically showing an example of the schematic structure of the step bending device 10 according to the present embodiment. Fig. 8B is an enlarged view of the inside of the frame of the two-dot chain line shown in fig. 8A, and is a diagram for explaining the step bending processing performed by the step bending device 10. Fig. 8C is a top view of the step bending device 10 shown in fig. 8B. In addition, an arrow D12 shown in fig. 8A shows the up-down direction of the stepped bending device 10.

The step bending device 10 performs a step bending process on the unprocessed loop coil 50.

As shown in fig. 8A, the step bending device 10 has a base portion 11, a pressing portion 12, a work floating pressing portion 13, a stopper portion 14, an abutment portion 15, a fixing pin 16, and a fixing pin handle 17.

The base portion 11 has a stopper portion 14 and an abutment portion 15 on an upper end surface. In addition, the pressing portion 12 and the work floating pressing portion 13 are located above the base portion 11.

The pressing portion 12 is raised upward and lowered downward as indicated by arrow D12, and presses the annular coil 50 as a workpiece.

The work floating pressing portion 13 descends when the pressing portion 12 descends to press the annular coil 50, and presses the annular coil 50 to float.

When the pressing portion 12 is lowered, the stopper 14 restricts the lowering operation of the pressing portion 12. This prevents the annular coil 50 from being crushed by the pressing portion 12 excessively lowering.

The abutment 15 supports the first portion 51 of the annular coil 50 at a predetermined position during the step bending process. That is, in the step bending process, the first portion 51 of the annular coil 50 is located on the upper end surface of the abutting portion 15.

The fixing pin 16 fixes the loop coil 50 at the time of the step bending process. The fixing pin 16 moves in the horizontal direction indicated by the arrow D16 by the operation of the fixing pin handle 17, and presses the first portion 51 in the direction from the inside toward the outside of the loop coil 50. Thereby, the loop coil 50 is fixed to the base portion 11.

When the pressing portion 12 descends downward as indicated by arrow D12, the second portion 52 of the loop coil 50 is pressed down by the lower end surface of the pressing portion 12, while the first portion 51 is supported by the abutment portion 15. Thus, the first portion 51 is located at a position apart from the second portion 52 by the thickness amount of the abutment 15 from the base portion 11 in the up-down direction of the arrow D12.

The step bending process is completed by the lower end surface of the pressing portion 12 being lowered to the upper end surface of the stopper portion 14. As a result, as shown in fig. 8B and 8C, the second portion 62 is located opposite to the first portion 61 of the stepped coil 60 in the thickness direction. Thus, a step 63 is formed between the first portion 61 and the second portion 62.

[ Single coil manufacturing apparatus ]

Next, a single-product coil manufacturing apparatus 20 for performing bending processing in the manufacturing method of the cylindrical air-core coil will be described with reference to fig. 9A and 9B.

Fig. 9A is a side view schematically showing an example of the schematic configuration of the single-product coil manufacturing apparatus 20 according to the embodiment. Fig. 9B is a plan view of the single-product coil manufacturing apparatus 20 as viewed from the direction of arrow D25 shown in fig. 9A. Fig. 9C is a side view schematically showing a state of bending processing performed by the single coil manufacturing apparatus 20.

The single-product coil manufacturing apparatus 20 shown in fig. 9A and 9B is an apparatus for manufacturing a single-product coil 70, and the single-product coil 70 is used for assembling the cylindrical air-core coil 1 by bending the stepped coil 60 having the stepped portion 63.

As shown in fig. 9A and 9B, the single-product coil manufacturing apparatus 20 has a work support jig 21, a work pressing portion 25, a first pressing portion 26, a second pressing portion 27, a third pressing portion 28, and a fourth pressing portion 29.

The workpiece support jig 21 supports a stepped coil 60 as a workpiece. The work support jig 21 has an outer peripheral surface that determines the bending diameter of the bending process. More specifically, the workpiece support jig 21 has a first outer peripheral surface 22, a second outer peripheral surface 23, and a support portion 24.

The first outer peripheral surface 22 has an arc-like shape having a predetermined radius R22 with respect to the center P61.

The second outer peripheral surface 23 has an arc-like shape having a diameter R23 smaller than a predetermined radius R22 with respect to the center P61.

The support portion 24 is located at the boundary between the first outer peripheral surface 22 and the second outer peripheral surface 23, and supports the stepped coil 60 as a wound body around which the wire coil is wound. The stepped coil 60 is supported by the support 24 at the stepped portion 63.

The work pressing portion 25 is located on the opposite side of the work supporting jig 21 with the stepped coil 60 as a wound body supported by the supporting portion 24 of the work supporting jig 21. Further, the work pressing portion 25 moves in the direction of arrow D25 with respect to the work supporting jig 21, sandwiching the stepped coil 60 between it and the work supporting jig 21.

The first pressed portion 26 and the third pressed portion 28 are located radially outward relative to the first outer peripheral surface 22.

The first pressing portion 26 moves in a direction approaching the first outer peripheral surface 22, that is, in a direction of an arrow D26, and presses a part of the stepped coil 60 supported by the work support jig 21. The third pressing portion 28 moves in the direction approaching the first outer peripheral surface 22, i.e., in the direction of arrow D28, and presses the other portion of the stepped coil 60 supported by the work support jig 21. The first press portion 26 and the third press portion 28 have curved surfaces 26a and 28a, respectively, in a shape along a part of the first outer peripheral surface 22 on the radially inner side.

When pressing is performed by the first pressing portion 26, a part of the first portion 61 of the stepped coil 60 is sandwiched by the curved surface 26a of the first pressing portion 26 and a part of the first outer peripheral surface 22. In addition, the other portion of the first portion 61 of the stepped coil 60 is sandwiched by the curved surface 28a of the third pressed portion 28 and a portion of the first outer peripheral surface 22.

The second pressed portion 27 and the fourth pressed portion 29 are located radially outward relative to the second outer peripheral surface 23.

The second pressing portion 27 moves in a direction approaching the second outer peripheral surface 23, that is, in a direction of an arrow D27, and presses a part of the second portion 62 of the stepped coil 60 supported by the work support jig 21. The fourth pressing portion 29 moves in the direction approaching the second outer peripheral surface 23, i.e., in the direction of arrow D29, and presses the other portion of the second portion 62 of the stepped coil 60 supported by the work support jig 21. The second press portion 27 and the fourth press portion 29 have curved surfaces 27a and 29a, respectively, in a shape along a part of the second outer peripheral surface 23 on the radially inner side.

When pressing is performed by the second pressing portion 27, a part of the second portion 62 of the stepped coil 60 is sandwiched by the curved surface 27a of the second pressing portion 27 and a part of the second outer peripheral surface 23. In addition, the other part of the second part 62 of the stepped coil 60 is sandwiched by the curved surface 29a of the fourth pressing portion 29 and a part of the second outer peripheral surface 23.

As described above, the stepped coil 60 sandwiched between the work pressing portion 25 and the work supporting jig 21 is pressed by the first pressing portion 26, the second pressing portion 27, the third pressing portion 28, and the fourth pressing portion 29, thereby completing the bending process. Thereby, as shown in fig. 9C, the single product coil 70 is formed.

As described above, the single-product coil manufacturing apparatus 20 is an apparatus for manufacturing a plurality of single-product coils 70, which are circumferentially arranged around an axis extending in the axial direction, are located at positions where portions overlap each other in the thickness direction, and respectively constitute a part of cylindrical air-core coils. The single-product coil manufacturing apparatus 20 has a work support jig 21, a work pressing portion 25, a first pressing portion 26, a second pressing portion 27, a third pressing portion 28, and a fourth pressing portion 29. The work support jig 21 has: a first outer peripheral surface 22 having a circular arc shape with a predetermined diameter; a second outer peripheral surface 23 having an arc shape with a diameter smaller than the predetermined diameter; and a support portion 24 that is located at a boundary between the first outer peripheral surface 22 and the second outer peripheral surface 23 and supports the stepped coil 60 as a wound body around which the wire coil is wound. The workpiece pressing portion 25 is located on the opposite side of the workpiece support jig 21 with the stepped coil 60 supported by the support portion 24 of the workpiece support jig 21 interposed therebetween, and clamps the stepped coil 60 between the workpiece pressing portion 25 and the workpiece support jig 21. The first pressing portion 26 and the third pressing portion 28 are located radially outward of the first outer peripheral surface 22, and move in a direction approaching the first outer peripheral surface 22, and press a part of the stepped coil 60 supported by the work support jig 21. The second pressing portion 27 and the fourth pressing portion 29 are located radially outward of the second outer peripheral surface 23, and move in a direction approaching the second outer peripheral surface 23, pressing a part of the stepped coil 60 supported by the work support jig 21.

According to this structure, the stepped coil 60 around which the linear coil is wound can be sandwiched and fixed by the work support jig 21 and the work pressing portion 25. In addition, with respect to the fixed stepped coil 60, the first pressing portion 26 presses a part of the stepped coil 60 on the first outer peripheral surface 22 side, and the second pressing portion 27 presses a part of the stepped coil 60 on the second outer peripheral surface 23 side.

That is, according to the single-product coil manufacturing apparatus 20, in a state where the stepped coil 60 as a wound body is stably fixed, a plurality of curved portions having different radii of curvature can be formed on the stepped coil 60 having the stepped portion 63 by the pressing operation of the first pressing portion 26 and the second pressing portion 27.

In this way, the single coil 70 having the plurality of curved portions having different radii of curvature is used for assembling the cylindrical air-core coil 1.

Therefore, the single-product coil 70 for assembling the cylindrical air-core coil 1 can be manufactured with high precision.

[ cylindrical hollow coil Assembly device ]

Next, a cylindrical air-core coil assembling device 30 for assembling a cylindrical air-core coil using a single coil 70 will be described with reference to fig. 10A to 10C.

Fig. 10A is a side view schematically showing an example of the schematic configuration of the cylindrical hollow coil assembly device 30 according to the embodiment. Fig. 10B is an enlarged plan view showing an example of the case where the single coil is housed in the cylindrical hollow coil assembly device 30. Fig. 10C is a side view showing an example of the cylindrical hollow coil assembly device 30 at the time of pressing. Arrow D30 shown in fig. 10A and 10C shows the vertical direction of the cylindrical hollow coil assembly device 30. Arrow D31 shown in fig. 10A and 10C shows the up-down direction of the pin 31.

The cylindrical air core coil assembly device 30 assembles the cylindrical air core coil using a plurality of single product coils 70 having a stepped portion 73 and protruding toward one of the thickness directions of the single product coils 70. That is, the cylindrical air core coil assembly device 30 is a device for manufacturing the cylindrical air core coil 1, and the cylindrical air core coil 1 has a plurality of individual coils 70, and the plurality of individual coils 70 are circumferentially arranged around an axis P1 extending in the axial direction and are located at positions where portions overlap each other in the thickness direction.

As shown in fig. 10A, the cylindrical hollow coil assembly device 30 includes a pin 31, a receiving base 32 as a receiving portion, a plurality of pressing portions 33, and a chute 34.

The pin 31 extends in the direction of an axis P30, and the axis P30 extends in the up-down direction indicated by an arrow D30 as an axial direction. The axis P30 of the pin 31 coincides with the axis P1 of the cylindrical air-core coil. Further, the pin 31 is movable in the up-down direction indicated by an arrow D31. The vertical direction of the pin 31 shown by the arrow D31 is a direction parallel to the vertical direction of the cylindrical hollow coil assembly device 30 shown by the arrow D30.

The receiving base 32 has a receiving portion 32a, and the receiving portion 32a receives lower portions of six individual coils 70 protruding to one of the thickness directions at predetermined positions on the outer side in the radial direction of the pin 31. The receiving portion 32a is a recess located at the center of the upper portion of the pedestal 32. The pedestal 32 has an inclined portion 32b on a side surface of the storage portion 32a, and the inclined portion 32b includes an inclined surface located on an inner peripheral side of the pedestal 32 in a plan view as going toward the bottom. Thus, the pedestal 32 can dispose six individual coils 70 in the housing portion 32a at positions circumferentially aligned around the axis P30 extending in the axial direction and overlapping each other in the thickness direction. That is, the inclined portion 32b of the pedestal 32 supports the plurality of individual coils 70 in an inclined state in which one end 75 in the axial direction is further radially outward away from the pin 31 than the other end 76. With this configuration, the plurality of individual coils 70 can be arranged in a stable posture in the housing portion 32 a. Therefore, the assembly accuracy of the plurality of individual coils 70 can be improved.

The plurality of pressing portions 33 are located above the pedestal 32 and are movable radially inward in the direction indicated by the black arrow D33. The plurality of pressing portions 33 move inward in the radial direction, and press the six individual coils 70 stored in the storage portion 32a of the pedestal 32 inward in the radial direction. In the present embodiment, the plurality of pressing portions 33 are formed of six members. Hereinafter, when it is necessary to distinguish between the plurality of pressing portions 33, the pressing portions 33A to 33F are labeled.

The chute 34 supplies the single coil 70 from above to the housing portion 32a of the pedestal 32 in an inclined state in which one end side in the axial direction is located radially outward of the other end side in the axial direction.

Further, the assembly operation of the cylindrical air core coil in the cylindrical air core coil assembly device 30 will be described with reference to fig. 10A.

First, the chute 34 supplies the individual coil 70 to the housing portion 32a of the pedestal 32 from above. The position of the individual coil 70 fed into the housing portion 32a in the radial direction inside the housing portion 32a is determined by the pin 31. When the pressing portion 33 presses the single-product coil 70, the chute 34 is retracted to a position above the single-product coil 70 supported by the pedestal 32.

As shown in fig. 10B, the pressing portions 33A to 33F moved to the predetermined positions press the individual coils 70 housed in the stand 32 in the inclined state described above, respectively, radially inward. As a result, as shown in fig. 10A, the pressing portions 33A to 33F can bring the positions of the one end portions 75 of the plurality of individual coils 70 close to the pin 31.

The pin 31 moves up and down in response to pressing of the plurality of individual coils 70 by the plurality of pressing portions 33A to 33F.

The operation of the pin 31 will be described more specifically with reference to fig. 10C. In fig. 10C, for convenience of explanation, only the single-product coils 70A and 70B are shown, and the description of the other single-product coils is omitted.

By pressing the plurality of individual coils 70 radially inward by the pressing portions 33A to 33F as described above, the individual coils 70A, 70B move radially inward, and when one end 75 of the individual coils 70A, 70B approaches the axis P30 of the pin 31, the second portion 72 of the individual coil 70B moves radially inward relative to the first portion 71 of the individual coil 70A. At this time, the intermediate portion 72a located at the axial center in the second portion 72 of the single product coil 70B temporarily protrudes radially inward from the radial position in the cylindrical air-core coil 1.

As described above, when the intermediate portion 72a of the single coil 70B protrudes radially inward from the radial position of the cylindrical air core coil 1, the pin 31 is lowered to a position lower than the intermediate portion 72a of the single coil 70B. This prevents the individual coils 70 from interfering with the pins 31 when assembling the plurality of individual coils 70.

When the plurality of individual coils 70 are further pressed radially inward by the pressing portions 33A to 33F, the intermediate portion 72a of the second portion 72 of the individual coil 70B moves radially outward and approaches the radially inner side of the first portion 71 of the individual coil 70A. In this state, the pin 31 is raised to the original position.

Thus, when the second portion 72 of the single coil 70B is moved by the pressing portions 33A to 33F in the direction in which the area overlapping the first portion 71 of the single coil 70A increases, the pins 31 are positioned radially inward of the plurality of single coils 70. Therefore, the pin 31 determines the inner diameter of the cylindrical air-core coil 1.

According to this configuration, when the plurality of individual coils 70 are moved radially inward by pressing, the intermediate portions 72a of the plurality of individual coils 70A, 70B can be prevented from temporarily protruding radially inward to interfere with the pin 31, and dimensional accuracy of the inner diameter of the cylindrical air-core coil 1 can be ensured by the pin 31. Therefore, the assembling accuracy of the cylindrical air-core coil 1 can be improved.

As described above, the cylindrical hollow coil assembly device 30 includes the pin 31, the receiving portion 32a of the receiving base 32, and the plurality of pressing portions 33A to 33F. The pin 31 extends in the axial direction. The housing portion 32a houses a plurality of individual coils 70 protruding to one of the thickness directions at a predetermined position radially outward of the pin 31, and is disposed at a position circumferentially aligned around the axis P30 extending in the axial direction and overlapping each other in the thickness direction. The plurality of pressing portions 33A to 33F press the plurality of individual coils 70 stored in the storage portion 32a radially inward, respectively, to form the cylindrical air-core coil 1.

According to this configuration, the plurality of individual coils 70 stored in the storage portion 32a are pressed radially inward, so that the plurality of individual coils 70 are sandwiched between the pin 31 and the plurality of pressing portions 33A to 33F. Accordingly, the dimensional accuracy of the inner diameter of the cylindrical air-core coil 1 can be ensured by the pin 31, and the dimensional accuracy of the outer diameter of the cylindrical air-core coil 1 can be ensured by the plurality of pressing portions 33A to 33F.

In this way, the cylindrical air core coil 1 can be assembled using the plurality of individual coils 70 by the cylindrical air core coil assembling device 30. Therefore, the plurality of single-product coils 70 having the stepped portion 73 and protruding to one side in the thickness direction are arranged in the circumferential direction in a state of overlapping each other, and the cylindrical air-core coil can be easily assembled.

(modification of cylindrical hollow coil assembling device)

Next, a modification of the cylindrical air core coil assembling device 40 for assembling the cylindrical air core coil will be described with reference to fig. 11A and 11B. Fig. 11A is a side view schematically showing an example of the schematic structure of the cylindrical hollow coil assembly device 40 according to the modification. Fig. 11B is a side view showing a pressed state by the cylindrical hollow coil assembly device. Further, an arrow D40 shown in fig. 11A shows the up-down direction of the cylindrical hollow coil assembly device 40.

As shown in fig. 11A, the cylindrical hollow coil assembly device 40 according to the modification is different from the cylindrical hollow coil assembly device 30 according to the above embodiment in that the pressing portions 43A and 43B have a clamp structure. Hereinafter, the same components as those of the embodiment will be denoted by the same reference numerals, and description thereof will be omitted.

The pressing portions 43A and 43B are L-shaped members when viewed from the side. The end portions of the pressing portions 43A, 43B are supported rotatably with respect to the base 41 about the rotation axis P43A, P B. The rotation of the pressing portions 43A and 43B is synchronized by a synchronization portion such as a link mechanism, not shown. In fig. 11A and 11B, the rotation direction of the pressing portion 43A is shown by an arrow R43A, and the rotation direction of the pressing portion 43B is shown by an arrow R43B.

The pressing portions 43A and 43B have side portions 44A and 44B on the radially inner side of the portion connected to the rotation shaft P43A, P B. The side surfaces 44A and 44B have surfaces extending in the up-down direction in the pressing portions 43A and 43B. When the pressing portions 43A, 43B rotate about the rotation axis P43A, P B, the inclination angle of the side portions 44A, 44B with respect to the axis P40 changes. That is, by the rotation of the pressing portions 43A, 43B, the positions of the side portions 44A, 44B are changed between the inclined position at which the upper end portion is further from the axis P40 than the lower end portion, and the standing position parallel to the axis P.

The side portions 44A, 44B support the single-product coil 70 when located at the inclined positions. That is, the pressing portions 43A and 43B function as a part of the housing portion.

The cylindrical coil assembling device 40 has six pressing portions as in the cylindrical hollow coil assembling device 30, but the other pressing portions have the same structure as the pressing portions 43A and 43B, and therefore illustration and description thereof are omitted.

The cylindrical hollow coil assembly device 40 has a placement portion 42 as a part of the housing portion at a position radially outside the pin 31 on the upper end surface of the base 41.

At the time of pressing, in the cylindrical hollow coil assembly device 40, as shown in fig. 11B, the plurality of pressing portions 43A, 43B are rotated in the upward direction of the arrow R43A, R43B around the rotation axis P43A, P B in synchronization. The plurality of pressing portions 43A and 43B press the plurality of individual coils 70 synchronously by the synchronizing portion.

According to this configuration, the plurality of pressing portions 43A and 43B simultaneously press the plurality of individual coils 70 by the synchronous pressing of the plurality of pressing portions 43A and 43B as described above. Therefore, for example, the individual coils 70 pressed by the pressing portions 43A and 43B can be prevented from interfering with each other.

Further, by the rotation of the pressing portions 43A, 43B, the side portions 44A, 44B of the pressing portions 43A, 43B are positioned at the standing position parallel to the axis P40. Thereby, the upper end portions of the plurality of individual coils 70 can be brought close to the pins 31.

In addition, as in the cylindrical hollow coil assembly device 30 described above, the pin 31 moves in the up-down direction indicated by the arrow D40 in accordance with the upward movement of the side surfaces 44A, 44B of the pressing portions 43A, 43B. This prevents the plurality of individual coils 70 from interfering with the pin 31 when the plurality of individual coils 70 are pushed and moved radially inward.

The pressing portions 43A and 43B have upper limiting portions 45A and 45B protruding radially inward at upper portions. As shown in fig. 11B, at the end of the pressing by the pressing portions 43A, 43B, the pin 31 is positioned in a position in contact with the upper limiting portions 45A, 45B.

By the operation of the pressing portions 43A and 43B, the single coil 70 is sandwiched between the side portions 44A and 44B of the pressing portions 43A and 43B and the pin 31, and the cylindrical air-core coil 1 is formed.

As described above, in the cylindrical hollow coil assembly device 40, at least a part of the housing portion functions as the pressing portion.

According to this configuration, at least a part of the housing portion functioning as the pressing portions 43A, 43B presses the plurality of individual coils 70 housed in the housing portion radially inward. Therefore, the number of components constituting the cylindrical hollow coil assembly device 40 can be reduced.

In the cylindrical hollow coil assembling device 40, the plurality of single coils 70 are housed in the inclined state in which one end 75 in the axial direction is further radially outward from the pin 31 than the other end 76, in the plurality of pressing portions 43A, 43B functioning as a part of the housing portion. The plurality of pressing portions 43A and 43B press the one end portions 75 of the plurality of individual coils 70 radially inward, respectively, so that the one end portions 75 of the plurality of individual coils 70 approach the pins 31.

According to this structure, the plurality of pressing portions 43A, 43B support the plurality of individual coils 70 in an inclined state. Therefore, the plurality of individual coils 70 can be supported in a stable state. In the above configuration, the positions of the one end portions 75 of the plurality of individual coils 70 are brought close to the pins 31 by the pressing of the plurality of pressing portions 43A, 43B.

That is, when the plurality of pressing portions 43A, 43B press the plurality of individual coils 70, the plurality of individual coils 70 are positioned at positions along the up-down direction of the cylindrical hollow coil assembly device 40, respectively. This makes it possible to easily assemble the cylindrical air-core coil 1 in which the plurality of individual coils 70 are arranged in the circumferential direction.

(other embodiments)

While the embodiments of the present invention have been described above, the above embodiments are merely examples for implementing the present invention. Therefore, the present invention is not limited to the above-described embodiments, and can be implemented by appropriately modifying the above-described embodiments within a range not departing from the gist thereof.

In the above embodiment, the cylindrical air core coil 1 has six individual coils 70. The cylindrical air core coil is not limited to this, and may have a plurality of individual coils of five or less or 7 or more.

In the above embodiment, in the loop coil processing step S2, the step bending step and the bending step are sequentially performed. In the annular coil processing step, the first portion and the second portion may be bent in the same direction as the thickness direction, while forming the step. According to this structure, the single-product coil can be manufactured more easily than in the case where the shape of the plurality of single-product coils having the step portion and protruding to one side in the thickness direction is formed by winding. In addition, the number of steps can be reduced as compared with the two steps of the step bending step and the bending step. Therefore, the tact time for manufacturing the cylindrical hollow coil 1 can be shortened.

In the above embodiment, in the annular coil processing step S2, when the first portion 61 and the second portion 62 are bent, the bending radius of the first portion 61 is made larger than the bending radius of the second portion 62. Without being limited thereto, the bending radius of the first portion may also be smaller than the bending radius of the second portion. Further, the bending radius of the first portion may be the same as the bending radius of the second portion.

In the above embodiment, in a state where the first portion 71 of the individual coil 70A is overlapped on the outer surface of the second portion 72 of the individual coil 70B adjacent to the individual coil 70A in the circumferential direction, the six individual coils 70A to 70F are combined. Although not specifically described above, the first portion 71 of the single coil 70A may be overlapped on the outer surface of at least one of the second portions 72 of the single coils 70C to 70F other than the single coil 70B adjacent to the single coil 70A in the circumferential direction.

In the above embodiment, the inclined portion 32b of the pedestal 32 supports the plurality of individual coils 70 in an inclined state in which one end 75 in the axial direction is further radially outward away from the pin 31 than the other end 76. The stand is not limited to this, and may support a plurality of single-product coils in a state where the plurality of single-product coils are housed upright.

In the modification of the cylindrical hollow coil assembly device of the above embodiment, the synchronization section synchronizes the pressing of the plurality of individual coils 70 by the pressing sections 43A, 43B. The pressing portions 43A and 43B may be configured to perform the pressing independently and not in synchronization with each other.

In the modification of the cylindrical hollow coil assembly device of the above embodiment, the pressing portions 43A, 43B are part of the housing portion. The pressing portion and the housing portion may be separate members.

In the above embodiment, the pin 31 moves in the up-down direction according to the operations of the pressing portions 33A to 33F, 43A, 43B. The present invention is not limited to this, and the position of the pin may be fixed during the pressing operation by the pressing portion.

In the above embodiment, in the cylindrical hollow coil assembly device 30, the chute 34 supplies the single coil 70 to the pedestal 32. The single-product coil may be supplied by a robot arm or by manual work.

In the above embodiment, in the single-product coil manufacturing apparatus 20, the stepped coil 60 sandwiched between the work pressing part 25 and the work supporting jig 21 is pressed by the first pressing part 26, the second pressing part 27, the third pressing part 28, and the fourth pressing part 29. The first pressing portion 26 and the third pressing portion 28 may be formed of a single member, or the second pressing portion 27 and the fourth pressing portion 29 may be formed of a single member.

(structural example)

In addition, the present technology may also adopt the following structure.

(1) A method for manufacturing a cylindrical air-core coil having a plurality of individual coils which are arranged circumferentially around an axis extending in an axial direction and are located at positions where portions overlap each other in a thickness direction, the method comprising: a loop coil forming step of forming a plurality of loop coils having a loop shape by winding a linear coil; a loop coil processing step of forming a step between a first portion and a second portion of the loop coil, which is a part of the loop coil in the circumferential direction, by relatively displacing the first portion and the second portion in the circumferential direction of the loop coil in the thickness direction of the loop coil, and performing processing for bending the first portion and the second portion in the same direction in the thickness direction, respectively, to form a single coil protruding in one of the thickness directions; and a single-product coil assembling step of positioning each of the convex sides of the plurality of single-product coils protruding to one of the thickness directions outside the radial direction of the axis line when viewed from the axial direction, and arranging the plurality of single-product coils in the circumferential direction surrounding the axis line, and combining the plurality of single-product coils in a state in which a first portion of the single-product coil is overlapped on an outer surface of a second portion of the single-product coil adjacent to the single-product coil in the circumferential direction, thereby forming a cylindrical air-core coil.

(2) The method for manufacturing a cylindrical hollow coil according to (1), wherein the annular coil processing step includes: a step bending step of forming a step between the first portion and the second portion of the loop coil; and a bending step of bending the first portion and the second portion in the same direction in the thickness direction after the step bending step.

(3) In the method for manufacturing a cylindrical hollow coil according to (1), in the annular coil processing step, the first portion and the second portion are bent in the same direction in the thickness direction while forming the step.

(4) The method for manufacturing a cylindrical hollow coil according to any one of (1) to (3), wherein in the annular coil processing step, the first portion and the second portion are bent such that a bending radius of the first portion is larger than a bending radius of the second portion.

(5) A cylindrical hollow coil assembly device is provided with: a pin extending in an axial direction; a housing portion that houses a plurality of individual coils protruding to one of the thickness directions at a predetermined position on the outer side in the radial direction with respect to the pin, and that is disposed at a position circumferentially aligned around an axis extending in the axial direction and overlapping each other in the thickness direction; and a plurality of pressing portions that press the plurality of individual coils stored in the storage portion radially inward to form cylindrical air-core coils.

(6) The cylindrical hollow coil assembly device according to (5), wherein at least a part of the housing portion functions as the pressing portion.

(7) In the cylindrical hollow coil assembly device according to (6), the plurality of pressing portions press the one end portions of the plurality of individual coils stored in the storage portion radially inward in an inclined state in which the one end portions in the axial direction are separated radially outward from the pin than the other end portions, respectively, so that the one end portions of the plurality of individual coils approach the pin.

(8) The cylindrical hollow coil assembly device according to any one of (5) to (7), further comprising a synchronizing section that causes the plurality of pressing sections to synchronously press the plurality of individual coils.

(9) The cylindrical hollow coil assembly device according to any one of (5) to (8), wherein the housing portion has an inclined portion that supports the plurality of individual coils in an inclined state in which one end portion in the axial direction is further radially outward spaced from the pin than the other end portion.

(10) In the cylindrical hollow coil assembly device according to any one of (5) to (9), the pin moves up and down in accordance with pressing of the plurality of single-product coils by the plurality of pressing portions, respectively.

(11) A single product coil manufacturing apparatus for manufacturing a plurality of single product coils which are circumferentially arranged around an axis extending in an axial direction and are located at positions where portions overlap each other in a thickness direction, respectively constituting a portion of cylindrical air core coils, the single product coil manufacturing apparatus comprising: a workpiece support fixture having: a support portion that is located at a boundary between the first outer peripheral surface and the second outer peripheral surface and that supports a wound body around which a wire-shaped coil is wound, the support portion having an arcuate first outer peripheral surface having a predetermined diameter, an arcuate second outer peripheral surface having a diameter smaller than the predetermined diameter, and an arcuate second outer peripheral surface having a diameter smaller than the predetermined diameter; a work pressing portion that sandwiches the wound body supported by the support portion of the work support jig between the wound body and the work support jig, on a side opposite to the work support jig; a first pressing portion that is located radially outward of the first outer peripheral surface and moves in a direction approaching the first outer peripheral surface, and presses a part of the wound body supported by the work support jig; and a second pressing portion that is located radially outward of the second outer peripheral surface and moves in a direction approaching the second outer peripheral surface, and presses a part of the wound body supported by the work support jig.

(12) A cylindrical air-core coil having a plurality of individual coils which surround an axis extending in an axial direction and are arranged in a circumferential direction and are located at positions where a part thereof overlaps each other in a thickness direction, the individual coils having: a first portion which is a part of the circumference of the single-product coil and is bent to the radially inner side; a second portion which is a remaining portion of the single-product coil in the circumferential direction and which is curved to the radially inner side; and a pair of stepped portions located between the first portion and the second portion, the pair of stepped portions being relatively displaced in the thickness direction of the single-product coil between the first portion and the second portion, the plurality of single-product coils protruding outward in the radial direction of the axis, the plurality of single-product coils being positioned in a circumferential arrangement surrounding the axis in a posture in which the respective protruding sides are located outward in the radial direction of the axis when viewed in the axial direction, the first portion of the single-product coil being overlapped on an outer surface of the second portion of the single-product coil adjacent in the circumferential direction.

Industrial applicability the following is applicable.

The present invention can be used for a method of manufacturing a cylindrical air-core coil, a cylindrical air-core coil assembling apparatus, a single-product coil manufacturing apparatus, and a cylindrical air-core coil manufactured by the method of manufacturing a cylindrical air-core coil and the cylindrical air-core coil assembling apparatus.

Claims (12)

1. A method for manufacturing a cylindrical air-core coil having a plurality of single-element coils circumferentially arranged around an axis extending in an axial direction and located at positions where portions overlap each other in a thickness direction, characterized in that,

the device comprises:

a loop coil forming step of forming a loop coil having a loop shape by winding a linear coil;

a loop coil processing step of forming a step between a first portion, which is a part of a circumferential direction of the loop coil, and a second portion, which is a part of a circumferential direction of the loop coil, by relatively displacing the first portion in a thickness direction of the loop coil, and performing processing of bending the first portion and the second portion in the same direction in the thickness direction, thereby forming a single coil protruding to one side in the thickness direction; and

and a single-element coil assembling step of assembling the plurality of single-element coils, each of which protrudes in one direction in the thickness direction, by positioning the protruding sides of the single-element coils outside the axis in the radial direction as viewed in the axial direction, and arranging the single-element coils in the circumferential direction around the axis, and combining the plurality of single-element coils in a state in which a first portion of the single-element coils is overlapped on an outer surface of a second portion of the single-element coils adjacent to the single-element coils in the circumferential direction.

2. The method of manufacturing a cylindrical air core coil according to claim 1, wherein,

the annular coil processing step includes:

a step bending step of forming a step between the first portion and the second portion of the loop coil; and

and a bending step of bending the first portion and the second portion in the same direction in the thickness direction after the step bending step.

3. The method of manufacturing a cylindrical air core coil according to claim 1, wherein,

in the processing step of the annular coil, the annular coil is formed,

the first portion and the second portion are bent in the same direction in the thickness direction while the step portion is formed.

4. The method for manufacturing a cylindrical air-core coil according to any one of claims 1 to 3, wherein,

in the annular coil processing step, the first portion and the second portion are bent such that a bending radius of the first portion is larger than a bending radius of the second portion.

5. A cylindrical hollow coil assembly device is characterized in that,

the device comprises:

a pin extending in an axial direction;

a housing portion that houses a plurality of individual coils protruding to one of the thickness directions at a predetermined position on the outer side in the radial direction with respect to the pin, and that is disposed at a position circumferentially aligned around an axis extending in the axial direction and overlapping each other in the thickness direction; and

And a plurality of pressing portions that press the plurality of individual coils stored in the storage portion radially inward to form cylindrical air-core coils.

6. The cylindrical hollow coil assembly device according to claim 5, wherein,

at least a part of the housing portion functions as the pressing portion.

7. The cylindrical hollow coil assembly device according to claim 6, wherein,

the plurality of pressing portions press the one end portions of the plurality of individual coils stored in the storage portion radially inward in an inclined state in which the one end portion in the axial direction is separated radially outward from the pin than the other end portion, respectively, so that the one end portions of the plurality of individual coils approach the pin.

8. The cylindrical hollow coil assembly device according to claim 5, wherein,

the coil pressing device further comprises a synchronizing part which enables the pressing parts to synchronously press the single-product coils.

9. The cylindrical hollow coil assembly device according to claim 5, wherein,

the housing portion has an inclined portion that supports the plurality of individual coils in an inclined state in which one end portion in the axial direction is further radially outward away from the pin than the other end portion.

10. The cylindrical hollow coil assembly device according to any one of claims 5 to 9, wherein,

the pin moves up and down according to pressing of the plurality of single-product coils by the plurality of pressing portions, respectively.

11. A single-product coil manufacturing apparatus for manufacturing a plurality of single-product coils which are circumferentially arranged around an axis extending in an axial direction and which are located at positions where parts overlap each other in a thickness direction, respectively, constitute parts of cylindrical air-core coils, characterized in that,

the device comprises:

a workpiece support fixture having: a first outer peripheral surface having a circular arc shape with a predetermined diameter; a second outer peripheral surface having an arc shape with a diameter smaller than the predetermined diameter; and a support portion that is located at a boundary between the first outer peripheral surface and the second outer peripheral surface and that supports a wound body around which a wire-like coil is wound;

a work pressing portion located on the opposite side of the work supporting jig with the wound body supported by the supporting portion of the work supporting jig interposed therebetween, the wound body being sandwiched between the work pressing portion and the work supporting jig;

A first pressing portion that is located radially outward of the first outer peripheral surface and moves in a direction approaching the first outer peripheral surface, and presses a part of the wound body supported by the work support jig; and

and a second pressing portion that is located radially outward of the second outer peripheral surface and moves in a direction approaching the second outer peripheral surface, and presses a part of the wound body supported by the work support jig.

12. A cylindrical air-core coil having a plurality of individual coils which are circumferentially arranged around an axis extending in an axial direction and which are located at positions where a part of the individual coils overlap each other in a thickness direction, characterized in that,

the single product coil has:

a first portion which is a part of the circumference of the single-product coil and is bent to the radially inner side;

a second portion which is a remaining portion of the single-product coil in the circumferential direction and which is curved to the radially inner side; and

a pair of steps between the first portion and the second portion,

the pair of step portions are relatively displaced in the thickness direction of the single product coil between the first portion and the second portion,

The plurality of individual coils are arranged in a circumferential direction surrounding the axis in such a manner that each of the individual coils protrudes outward in the radial direction of the axis when viewed in the axial direction,

the first portion of the single-product coil overlaps an outer surface of the second portion of the single-product coil circumferentially adjacent to the single-product coil.