EP3074989B1 - Device, and method for winding a wire for an inductive component - Google Patents

Device, and method for winding a wire for an inductive component Download PDF

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Publication number
EP3074989B1
EP3074989B1 EP14805542.9A EP14805542A EP3074989B1 EP 3074989 B1 EP3074989 B1 EP 3074989B1 EP 14805542 A EP14805542 A EP 14805542A EP 3074989 B1 EP3074989 B1 EP 3074989B1
Authority
EP
European Patent Office
Prior art keywords
arrangement
wire
shaping
bending
pitch
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.)
Active
Application number
EP14805542.9A
Other languages
German (de)
French (fr)
Other versions
EP3074989A1 (en
Inventor
Karsten Frey
Jürgen Frey
Wolfgang PORISCH
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
TDK Electronics AG
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TDK Electronics AG
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Publication date
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Publication of EP3074989A1 publication Critical patent/EP3074989A1/en
Application granted granted Critical
Publication of EP3074989B1 publication Critical patent/EP3074989B1/en
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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06Coil winding
    • H01F41/061Winding flat conductive wires or sheets
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2847Sheets; Strips
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D7/00Bending rods, profiles, or tubes
    • B21D7/02Bending rods, profiles, or tubes over a stationary forming member; by use of a swinging forming member or abutment
    • B21D7/024Bending rods, profiles, or tubes over a stationary forming member; by use of a swinging forming member or abutment by a swinging forming member
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2823Wires
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2895Windings disposed upon ring cores
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06Coil winding
    • H01F41/077Deforming the cross section or shape of the winding material while winding
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06Coil winding
    • H01F41/08Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06Coil winding
    • H01F41/082Devices for guiding or positioning the winding material on the former
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D7/00Bending rods, profiles, or tubes
    • B21D7/08Bending rods, profiles, or tubes by passing between rollers or through a curved die
    • B21D7/085Bending rods, profiles, or tubes by passing between rollers or through a curved die by passing through a curved die

Definitions

  • the invention relates to a device for winding a wire which can be used, for example, as an air-core coil or as part of an inductive component, in particular as the winding of a transformer.
  • inductive components for example an air-core coil or a transformer
  • the wire For example, to produce an air core coil, the wire must be wound in a helical shape.
  • To manufacture a transformer it is necessary to wrap the wire around one leg of the transformer. If the transformer has a closed core, an automated, direct winding of the closed core is a particular challenge.
  • transformers that have a closed core and in which flat wires with a rectangular cross-section (rectangular wires) are used for the winding instead of round wires.
  • This type of transformer enables currents with high amperage to be carried with high inductance of the component due to the high number of turns that can be achieved.
  • the application of a rectangular or flat wire to a closed core can usually no longer be carried out in an automated manner and is therefore generally very time-consuming.
  • the pamphlets US 2009/065623 A1 , JP 2004-327461 A , U.S. 5,331,729 A and JP 2004-158653 A describe devices and methods for winding a coil around a magnetic core.
  • a device for winding a wire with which it is possible to automatically wind a wire, in particular a rectangular or flat wire, as an air-core coil or to wind it around a closed core of a transformer.
  • a method for winding a wire is to be specified with which it is possible to automatically wind a wire, in particular a rectangular or flat wire, as an air-core coil or to wind it around a closed core of a transformer.
  • the device and the method can also be used to wind a round wire.
  • such a device is for Winding a wire indicated.
  • the device comprises a feed device for displacing the wire, a shaping device and a pitch transmitter device for bending the wire.
  • the shaping device is used to bend the wire in one plane and the pitch transmitter device for bending the wire with a slope out of the plane.
  • the pitch transmitter device is arranged behind the shaping device.
  • the pitch generating device can also be integrated into the shaping device, so that the wire also experiences a pitch during circular bending in the shaping device.
  • the shaping device and the pitch transmitter device are arranged in such a way that the wire is introduced into the shaping device and the pitch transmitter device when it is displaced by the feed device.
  • the shaping device and the pitch transmitter device are designed in such a way that the wire is bent helically during displacement in the shaping device and the pitch transmitter device.
  • a method for winding a wire is specified.
  • the method provides for the provision of a device, in particular the device specified above, for winding the wire.
  • the wire is displaced in the device in such a way that the wire is fed to a shaping device and a pitch transmitter device.
  • the wire is bent in a helical shape.
  • the wire is bent in the plane when it is passed through the shaping device and bent out of the plane with an incline when it is passed through the incline transmitter device.
  • any cross-sections, preferably thick and therefore very stiff cross-sections, of a wire, in particular a rectangular or flat wire, can be applied very quickly and directly to closed core cross-sections be wound up automatically.
  • the compressed "compression spring" of the winding is retained.
  • the core can be wound almost completely without mechanical stresses being generated in the winding direction and thus with almost no mechanical forces acting on the core.
  • the device for winding the wire can contain a guide device for guiding the wire in the plane, the guide device having a straight course in the plane.
  • the wire is placed in the guide device and, by means of the feed device, is pushed into the shaping device which is arranged behind the guide device in the feed direction of the wire.
  • the feed device can be designed, for example, as an eccentric lifting press. The device thus provides a type of “push wire technique” with which very high push forces can be introduced onto the wire guided in the guide device and the shaping device.
  • the shaping device can be designed as a recess in a plate.
  • the wire can then be bent in the plane of the plate by the deformation device.
  • the shaping device has a bottom surface for supporting the wire and a curved side wall.
  • the side wall can be bent in a semicircle so that the wire is bent in a circle.
  • the wire is bent out of the plane of the plate by the pitch transmitter device, so that a helical turn of the wire is created from the circular bend.
  • the shape of the wire can also be called "helical” or "spiral" in the sense of a cylindrical spiral.
  • the device is particularly suitable for bending a flat wire, the flat wire resting with its larger side surface on the bottom surface of the forming device and with its smaller side surface resting on the side wall of the forming device.
  • the side of the recess which is opposite the bottom surface and which is open can be covered by a sliding cover device. This special shape prevents the wire from tipping over when it is bent.
  • the incline sensor device causes the wire to incline, so that after one turn it exceeds its own height and is bent over a section of the wire lying underneath.
  • the device can have a receiving device for positioning a core, in particular a closed core, of an inductive component, for example a transformer.
  • the shaping device and the pitch transmitter device are arranged around the receiving device in such a way that the wire can be wound helically around a leg of the closed core when it is moved by the shaping device and the pitch transmitter device, without the sensitive lacquer of the wire, for example an enamelled copper wire, or the insulation coating of the core to damage.
  • An otherwise customary winding mandrel is not required.
  • flat or rectangular wires with a width of, for example, 5 mm and a thickness of 1 mm to 2 mm can be bent helically as an air-core coil or helically around one Bend the legs of a closed frame core of a transformer.
  • an end section of the wire can be pre-bent by a pre-bending device of the device.
  • the wire is clamped in the feed device in such a way that the end section of the wire to be bent protrudes from the device on the side on which the guide device or the shaping device is arranged.
  • the end section of the wire is bent in such a way that the wire can then be inserted into the upwardly open depression of the forming device.
  • the further bending of the wire takes place, as described above, in an automated manner by moving the wire through the shaping device and the pitch transmitter device.
  • an inductive component is specified.
  • the component is preferably produced by the method described above.
  • the wire is wound circularly with a pitch, i.e., helically.
  • the winding of the wire is designed to be compressed.
  • adjacent turns are tight against one another.
  • the winding is designed without gaps or almost without gaps, so that adjacent turns are in direct contact with one another.
  • the pitch of the helical winding is in the range of the wire thickness. In this way, a particularly high degree of filling of the winding can be achieved.
  • the inductive component can have a core, in particular a ferrite core.
  • the wire can be wrapped directly around the core.
  • the wire is not wound around a bobbin made of plastic.
  • the core has a closed shape.
  • the inductive component can also be designed as an air-core coil.
  • the wire can be designed as a rectangular or flat wire, for example. Alternatively, it can also be a round wire.
  • the core has, in cross section, an outer circumference that is not circular.
  • the core can have edges.
  • the core has corners in cross section.
  • the core can have an outer circumferential line in the form of a polygon.
  • Figure 1 shows an embodiment of a device 1 for winding a wire 2, which by means of the device 1 can be wound helically as an air coil or around a leg of a closed frame core 3 of an inductive component 4, for example a transformer.
  • an inductive component 4 for example a transformer.
  • two parallel wires 2 can be wound around two legs of a closed frame core 3 at the same time.
  • the device 1 comprises a feed device 10 for moving the wire in a guide device 50 for guiding the wire 2.
  • the feed device 10 has a carriage 11 which is movably arranged on a rail 100.
  • the device 1 comprises two carriages 11 which are arranged on the rail 100 so as to be displaceable in the horizontal direction.
  • a plate 12 of the feed device is located above the carriage 11 and has at least one guide 13 on its upper side for guiding at least one wire 2.
  • the guide 13 can be designed as a recess in the plate 12.
  • two wires 2 shown can, as in the case of the in Figure 1 embodiment shown of the device 1 for winding the wire, two guides 13 can be arranged in parallel in the plate 12.
  • a cover plate 15 can be arranged at least partially on the plate 12.
  • the cover plate 15 can be pressed onto the plate 12 by means of a press 14, so that the open side of the guide 13 is covered by the cover plate 15 and the wire 2 is clamped in the guide 13.
  • a punch 16 is provided above the press 14, which presses the cover plate 15 onto the plate 12 with the guide 13.
  • the plate 12, the cover plate 15 and the punch 17 can be moved back and forth with the movement of the carriages 11 in the horizontal displacement direction of the wire shown by the arrows on the plate 12.
  • a drive unit 110 is provided for moving the feed device 10. During the forward movement of the wire 2 in the direction of the frame core 3, the wire 2 is pressed firmly in the guide 13 by means of the cover plate 15 and is thus displaced along the guide device 50. The press then lifts the cover plate 15 so that the wire is no longer clamped in the guide 13 of the plate 12. The carriage 11 then moves the plate 12 back into the starting position. The wire feed process is then repeated.
  • the Figures 2 and 3 show a front area of the device 1 with a guide device 50 for guiding the wires 2 in an enlarged view.
  • the guide device 50 is arranged as a recess in a plate 80.
  • the guide device 50 has a straight course in a plane E of the plate 80.
  • the device 1 has, in addition to the feed device 10 and the guide device 50, a shaping device 20 for bending the wire 2 in the plane E and a pitch transmitter device 30 for bending the wire 2 with a pitch out of the plane E.
  • the shaping device 20 and the pitch transmitter device 30 are designed in such a way that when the wire 2 is moved by the feed device 10, it is first displaced in the guide device 50 in the longitudinal direction and then introduced into the shaping device 20 and the pitch transmitter device 30.
  • the shaping device 20 and the pitch transmitter device 30 are designed in such a way that the wire 2 is bent helically when it is moved in the shaping device 20 and the pitch transmitter device 30.
  • the shaping device 20 and the guide device 50 can be designed as part of the plate 80 common to them.
  • the shaping device 20 can have a depression 23 in the plate 80, the depression having a curved course in the plane E of the plate.
  • the recess can be curved, for example, in the shape of a segment of a circle, in particular in a semicircle.
  • the shaping device 20 can have a bottom surface 21 for supporting the wire 2 and at least one side wall 22.
  • the at least one side wall 22 has the curved course.
  • the conversion device 20 is thus designed in such a way that the wire 2 is bent circularly along the side wall 22 when it is moved in the shaping device 20.
  • the guide device 50 can have a recess 53 in the plate 80, which has a straight course in the plane E of the plate and opens into the recess 23 of the shaping device 20.
  • the guide device 50 has a bottom surface 51 and a side wall 52, which are arranged at right angles to one another and thus form the recess 53 within the plate 80.
  • the shaping device 20 and the guide device 50 are designed in particular to guide a rectangular or flat wire.
  • a rectangular or flat wire is to be understood as a wire with a rectangular cross section, which has a larger and a smaller side surface, the side surfaces being arranged at right angles to one another.
  • the wire 2 is designed as a flat or rectangular wire with a larger side surface S2a and a smaller side surface S2b.
  • the flat or rectangular wire 2 with the larger side surface S2a rests on the bottom surface 51 of the guide device 50.
  • the smaller side surface S2b of the flat or rectangular wire 2 rests on the side wall 52 of the guide device 50.
  • the shaping device 20 following the guide device 50 in the exemplary embodiment shown is designed in such a way that the flat or rectangular wire 2 with the larger one when guiding and bending in the shaping device 20 Side surface S2a rests on the bottom surface 21 of the deformation device and the smaller side surface S2b rests on the side wall 22 of the deformation device.
  • the outer area of the wire which rests closer than an inner area of the wire to the side wall 22 of the shaping device 20, is stretched, while the inner area of the wire is compressed when it is bent.
  • the shaping device 20 is open on the side opposite the bottom surface 21.
  • the device 1 can comprise a displaceable cover device 40.
  • the cover device 40 can be arranged displaceably on the plate 80.
  • the cover device 40 can be displaced on the plate 80 in such a way that the guide device 50 is completely covered and the shaping device 20 is at least partially covered by the cover device 40.
  • only one cover device 40 is shown, which completely covers the depressions of the rear guide device 50 and of the rear deformation device 20 partially.
  • the cover device 40 can be designed in the form of a plate which is arranged displaceably on the plate 80.
  • the cover device 40 can be displaced along the two recesses 41 transversely to the longitudinal direction of the wire 2 and thus transversely to the longitudinal direction of the guide device 50 on the plate 80.
  • the displaceable cover device 40 is displaced in such a way that the guide device 50 is completely covered and the shaping device 20 is partially covered by the cover device 40.
  • the front area AB of the shaping device 20 delimited by a dashed line in FIG. 3, with the portion of the wire lying therein is covered by the covering device.
  • the plate of the covering device 40 has a semicircular recess 42 above the area AB of the shaping device 20.
  • the cover device has a thin plate 43 made of a hardened material. This plate 43 can be only a few tenths of a millimeter thick, for example.
  • the thin plate 43 arranged at the lower end of the recess 42 covers the wire 2 guided in the recess of the shaping device.
  • the thin plate 43 prevents the wire from jumping out or tipping over in the forming device 20 located in the shaping device 20, are arranged.
  • the upper layer of the wire lies over the plate 43, while the lower layer of the wire is guided under the plate 43 in the forming device.
  • the lower layer and the upper layer of the wire winding arranged above it are separated from one another by the thin plate 43 during the winding process.
  • the illustrated embodiment of the device 1 for bending the wire is the guide device 50 and thus also the plate 80 are arranged behind the feed device 10 in the feed direction of the wire 2.
  • the shaping device 20 is arranged behind the guide device 50 in the feed direction of the wire, so that the wire 2 is pushed into the shaping device 20 when it is displaced out of the guide device 50.
  • the pitch transmitter device 30 can be arranged behind the shaping device 20, so that the wire 2 is guided to the pitch transmitter device 30 when it is moved after the shaping in the shaping device 20.
  • the pitch transmitter device 30 can also be integrated into the shaping device.
  • the bottom surface 21 of the shaping device rises in the horizontal direction, so that the wire also experiences an incline when it is bent circularly in the shaping device.
  • the slope transmitter device 30 is arranged behind the shaping device 20.
  • the pitch transmitter device 30 can, for example, have an inclined plate for generating the pitch of the wire.
  • the slope of the plate can be adjustable depending on the pitch of the wire.
  • Figure 4 shows the wire 2 guided in the guide device 50 and the shaping device 20, which is wound around the leg 3, shown in abbreviated form, of the inductive component 4 and the inclination sensor 30.
  • the pitch sensor 30 is designed as a ball pin.
  • the pitch sensor has, for example, a cylindrical body with a spherical bulge 31 at its upper end.
  • the incline sensor is arranged on the plate 80 or can be sunk into the plate 80.
  • the incline sensor can be lifted out of the plane E of the plate 80.
  • the wire runs onto the spherical arch 31 and, due to its spherical shape, has a pitch that is necessary to produce the actual helical winding of the wire and thus more than one turn of the wire.
  • the incline sensor can be raised, for example, according to the desired incline, as soon as the wire has slid onto the spherical arch.
  • the wire After the wire has been pushed over the inclined plate or the spherical curvature 31 of the inclination device, the wire is bent out of plane E and can be placed over the section of the wire underneath, which is simultaneously introduced into the forming device. This creates the helical winding of the wire.
  • the device 1 In order to wind the wire around a leg of the closed frame core 3, the device 1 has a receiving device 60 for positioning the core 3 of the inductive component 4.
  • the forming device 20 and the pitch transmitter device 30 are arranged around the receiving device 60 in such a way that the wire 2 is wound helically around the leg of the core 3 of the inductive component when the core 3 is positioned in the receiving device 60 and the wire 2 through the forming device 20 and the incline sensor device 30 is guided.
  • the bending or winding of the wire 2 by means of the device 1 is explained in more detail below.
  • the method for winding a wire is described for only one wire 2.
  • the device can also use two wires at the same time be wrapped around two different legs of a closed frame core.
  • the cover plate 15 is first lifted from the plate 12 so that the wire 2 can be inserted into the guide 13 and pushed through the guide device 50 to the start of the shaping device 20.
  • the cover plate 15 is then pressed onto the plate 12 by means of the press 14 and the punch 16, so that the wire 2 is clamped within the guide 13.
  • the carriages 11 and thus the plate 12 are displaced in the direction of the arrow, so that the front end of the wire is pushed into the shaping device 20 by the guide device 50.
  • the front section of the wire which is guided through the shaping device 20, is bent in a semicircle in the plane E of the plate 80.
  • the cover plate 15 is raised by the punch 16 and the press 14 and the carriages 11 with the plate 12 fastened thereon are raised against the position shown in FIG Figure 1 direction shown by the arrow. Due to the bending of the front end of the wire, the wire is fixed and is not pushed back with the movement of the plate 12 and the carriage 11. To advance the wire further, the cover plate 15 is pressed again onto the plate 12 so that the wire is clamped in the guide 13 again. The plate 12 is then moved forward again through the carriage 11, as a result of which the wire 2 is pushed further into the shaping device 20 and is bent into a semicircle there.
  • the front end of the The wire now reaches the pitch transmitter device 30 and is bent out of the plane E of the plate 80 as it continues through the pitch transmitter device 30.
  • the wire can ultimately be helical by means of the device, as in FIG Figures 1 to 3 shown to be bent.
  • the method described for bending the wire by means of the device 1 can be carried out, for example, for bending a wire with a width of 5 mm and a thickness of 1.5 mm to 1.7 mm.
  • the front end section A of the wire 2 can be pre-bent before being pushed into the guide device 50 or the shaping device 20.
  • the device 1 has the Figures 1 , 2 , 5 , 6th and 7th Pre-bending device 70 shown for bending the end section A of the wire 2.
  • the pre-bending device 70 can be part of a plate 90 which is arranged on a holder 120 of the device 1 so as to be movable in the vertical direction.
  • FIG. 13 shows a top side of the pre-bending device 70, while the bottom side of the pre-bending device 70 in FIG Figures 6 and 7th is shown.
  • the pre-bending device 70 has a bending mandrel 71 around which the end section A of the wire 2 can be bent.
  • the bending mandrel 71 can be designed as a cylindrical pin which protrudes from the underside of the plate 90.
  • the pre-bending device 70 has a bending element 72 which is attached to a lever 73 as a pin or a cylindrical roller can be.
  • the lever 73 can be rotatably mounted on a joint 76.
  • the pre-bending device 70 furthermore has a recess 74 in the plate 90, in which the bending element 72 is movably arranged at a distance around the bending mandrel 71.
  • the bending element 72 can be moved by means of the lever 73 along the path of a segment of a circle within the recess 74.
  • the recess 74 is also arranged in the form of a segment of a circle in the plate 90.
  • the material recess 74 in the plate 90 has two circular segment-shaped partial recesses that merge into one another.
  • the Figures 5 , 6th and 7th The embodiments of the pre-bending device 70 shown here only show a wire 2 with an end section A which is bent by means of the pre-bending device 70.
  • the wire is first clamped in the feed device 10 such that the front end section A of the wire protrudes from the feed device on the side of the feed device on which the guide device 50 is arranged.
  • the plate 80 with the guide device 50, the shaping device 20 and the pitch transmitter device 30 fixed on the plate is arranged displaceably on the holder 120.
  • the plate 80 is displaced along the holder 120 to a position P3.
  • the pre-bending device 70 is connected to the plate 80 via a coupling element 130.
  • the coupling element 130 is arranged on the holder 120 such that it can be displaced in the vertical direction.
  • the pre-bending device 70 When the plate 80 is displaced to the position P3, the pre-bending device 70 is accordingly displaced downward to a position P2, at the height of which the wire 2 protrudes from the feed device 1. To accommodate the wire 2, the pre-bending device 70 has the guide 75. After the plate 90 has been moved with the pre-bending device 70 from a position P1 above the position P2 to the position P2, the section A 'of the wire 2 located behind the end section A lies in the guide 75 of the pre-bending device, while the front section A of the initially still unbent wire 2 protrudes from the guide 75, as shown in FIG Figure 6 is shown.
  • FIG. 11 shows the pre-bent end portion A of the wire 2 bent into a curved portion of the guide 75.
  • a cover 78 is provided over the curved portion of the guide 75.
  • the cover 78 is arranged on the underside of the plate 80 and can have a cross-section in the shape of a segment of a circle. For the sake of clarity, in Figure 7 only one cover 78 is shown.
  • a further second wire which is guided parallel to the first wire in the device 1, can be bent by means of the pre-bending device 70.
  • the pre-bending device a further lever 73 which moves a further bending element in a further recess 74.
  • the plate 90 is moved with the pre-bending device 70 from the position P2 back to the position P1.
  • the plate 80 is moved from position P3, which is below position P2, back to position P2, as a result of which the front end section A of the now pre-bent wire 2 is inserted into the guide device 50 or the shaping device 20.
  • the further bending or winding of the wire around the leg of the closed frame core 3 can now take place in a further automated manner by means of the device 1 as described above.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Wire Processing (AREA)
  • Coil Winding Methods And Apparatuses (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Description

Die Erfindung betrifft eine Vorrichtung zum Wickeln eines Drahtes, der beispielsweise als Luftspule oder als Teil eines induktiven Bauelements, insbesondere als Wicklung eines Transformators, verwendbar ist.The invention relates to a device for winding a wire which can be used, for example, as an air-core coil or as part of an inductive component, in particular as the winding of a transformer.

Zur Herstellung von induktiven Bauteilen, beispielsweise einer Luftspule oder eines Transformators, ist es erforderlich, einen Draht entsprechend zu verformen. Zur Herstellung einer Luftspule muss der Draht beispielsweise schraubenförmig gewickelt werden. Zur Herstellung eines Transformators ist es erforderlich, den Draht um einen Schenkel des Transformators zu wickeln. Wenn der Transformator einen geschlossenen Kern aufweist, stellt ein automatisiertes, direktes Bewickeln des geschlossenen Kerns eine besondere Herausforderung dar.To manufacture inductive components, for example an air-core coil or a transformer, it is necessary to deform a wire accordingly. For example, to produce an air core coil, the wire must be wound in a helical shape. To manufacture a transformer, it is necessary to wrap the wire around one leg of the transformer. If the transformer has a closed core, an automated, direct winding of the closed core is a particular challenge.

Bis zu einem gewissen Verhältnis von Drahtquerschnitt, Wickelspiralendurchmesser, Windungszahl und Kernquerschnitt ist es bedingt möglich, vorgeformte Luftspulen auf einen geschlossenen Kern eines Transformators zu "drehen". Die schraubenförmige Luftspule, die einer Zugfeder ähnelt, muss hierfür soweit aufgespreizt werden, dass der Kernquerschnitt überwunden werden kann. Während dieses im Allgemeinen sehr aufwendigen und zeitraubenden Verfahrens wirken jedoch hohe mechanische Kräfte auf den zu bewickelnden Kern. Durch die Spreizung der "Zugfeder" zur "Druckfeder" ist der mögliche Füllgrad eines geschlossenen Kerns zwangsweise beschränkt beziehungsweise die "Zugfeder" erzeugt dauerhaft mechanische Spannungen. Die im Allgemeinen für einen Transformator verwendeten Ferritkern-Materialien sind in Bezug auf das Einwirken von mechanischen Spannungen jedoch sehr empfindlich.Up to a certain ratio of wire cross-section, spiral winding diameter, number of turns and core cross-section, it is possible to a certain extent to "turn" preformed air coils onto a closed core of a transformer. The helical air core coil, which resembles a tension spring, has to be spread apart so that the core cross-section can be overcome. During this generally very complex and time-consuming process, however, high mechanical forces act on the core to be wound. By spreading the "tension spring" to the "compression spring", the possible degree of filling of a closed core is inevitably limited or the "tension spring" creates permanent mechanical stresses. The ones commonly used for a transformer Ferrite core materials are, however, very sensitive to the effects of mechanical stresses.

Besonders schwierig gestaltet sich die Herstellung von Transformatoren, die einen geschlossenen Kern aufweisen und bei denen anstelle von Runddrähten Flachdrähte mit rechteckigem Querschnitt (Rechteckdrähte) für die Wicklung verwendet werden. Diese Art von Transformatoren ermöglicht das Führen von Strömen mit hoher Stromstärke bei hoher Induktivität des Bauteils bedingt durch die hohe erzielbare Windungszahl. Das Aufbringen eines Rechteck- beziehungsweise Flachdrahts auf einen geschlossenen Kern kann üblicherweise nicht mehr automatisiert erfolgen und ist somit im Allgemeinen sehr zeitaufwendig.It is particularly difficult to manufacture transformers that have a closed core and in which flat wires with a rectangular cross-section (rectangular wires) are used for the winding instead of round wires. This type of transformer enables currents with high amperage to be carried with high inductance of the component due to the high number of turns that can be achieved. The application of a rectangular or flat wire to a closed core can usually no longer be carried out in an automated manner and is therefore generally very time-consuming.

Die Druckschriften US 2009/065623 A1 , JP 2004-327461 A , US 5,331,729 A und JP 2004-158653 A beschreiben Vorrichtungen und Verfahren zum Wickeln einer Spule um einen Magnetkern.The pamphlets US 2009/065623 A1 , JP 2004-327461 A , U.S. 5,331,729 A and JP 2004-158653 A describe devices and methods for winding a coil around a magnetic core.

Es ist wünschenswert eine Vorrichtung zum Wickeln eines Drahtes anzugeben, mit der es ermöglicht wird, einen Draht, insbesondere einen Rechteck- oder Flachdraht, automatisiert als Luftspule zu wickeln oder um einen geschlossenen Kern eines Transformators zu wickeln. Des Weiteren soll ein Verfahren zum Wickeln eines Drahtes angegeben werden, mit dem es ermöglicht wird, einen Draht, insbesondere einen Rechteck- oder Flachdraht, automatisiert als Luftspule zu wickeln oder um einen geschlossenen Kern eines Transformators zu wickeln. Die Vorrichtung und das Verfahren können auch zum Wickeln eines Runddrahtes eingesetzt werden.It is desirable to specify a device for winding a wire with which it is possible to automatically wind a wire, in particular a rectangular or flat wire, as an air-core coil or to wind it around a closed core of a transformer. Furthermore, a method for winding a wire is to be specified with which it is possible to automatically wind a wire, in particular a rectangular or flat wire, as an air-core coil or to wind it around a closed core of a transformer. The device and the method can also be used to wind a round wire.

Im Patentanspruch 1 ist eine derartige Vorrichtung zum Wickeln eines Drahtes angegeben. Die Vorrichtung umfasst eine Vorschubeinrichtung zum Verschieben des Drahtes, eine Umformungseinrichtung und eine Steigungsgebereinrichtung zum Biegen des Drahtes. Insbesondere dienen die Umformungseinrichtung zum Biegen des Drahtes in einer Ebene und die Steigungsgebereinrichtung zum Biegen des Drahtes mit einer Steigung aus der Ebene. Beispielsweise ist die Steigungsgebereinrichtung hinter der Umformungseinrichtung angeordnet. Die Steigungsgebeeinrichtung kann auch in die Umformungseinrichtung integriert sein, so dass der Draht beim kreisförmigen Biegen in der Umformungseinrichtung gleichzeitig auch eine Steigung erfährt. Die Umformungseinrichtung und die Steigungsgebereinrichtung sind derart angeordnet, dass der Draht bei dem Verschieben durch die Vorschubeinrichtung in die Umformungseinrichtung und die Steigungsgebereinrichtung eingeführt wird. Die Umformungseinrichtung und die Steigungsgebereinrichtung sind derart ausgebildet, dass der Draht bei dem Verschieben in der Umformungseinrichtung und der Steigungsgebereinrichtung schraubenförmig gebogen wird.In claim 1 such a device is for Winding a wire indicated. The device comprises a feed device for displacing the wire, a shaping device and a pitch transmitter device for bending the wire. In particular, the shaping device is used to bend the wire in one plane and the pitch transmitter device for bending the wire with a slope out of the plane. For example, the pitch transmitter device is arranged behind the shaping device. The pitch generating device can also be integrated into the shaping device, so that the wire also experiences a pitch during circular bending in the shaping device. The shaping device and the pitch transmitter device are arranged in such a way that the wire is introduced into the shaping device and the pitch transmitter device when it is displaced by the feed device. The shaping device and the pitch transmitter device are designed in such a way that the wire is bent helically during displacement in the shaping device and the pitch transmitter device.

Im Patentanspruch 9 ist ein Verfahren zum Wickeln eines Drahtes angegeben. Das Verfahren sieht das Bereitstellen einer Vorrichtung, insbesondere der oben angegebenen Vorrichtung, zum Bewickeln des Drahtes vor. Der Draht wird in der Vorrichtung derart verschoben, dass der Draht einer Umformungseinrichtung und einer Steigungsgebereinrichtung zugeführt wird. Beim Durchführen des Drahtes durch die Umformungseinrichtung und die Steigungsgebereinrichtung wird der Draht schraubenförmig gebogen. Beispielsweise wird der Draht beim Durchführen durch die Umformungseinrichtung in der Ebene gebogen und beim Durchführen durch die Steigungsgebereinrichtung mit einer Steigung aus der Ebene herausgebogen.
Mittels der angegebenen Vorrichtung beziehungsweise durch das angegebene Verfahren können nahezu beliebige Querschnitte, vorzugsweise dicke und dadurch sehr steife Querschnitte, eines Drahtes, insbesondere eines Rechteck- beziehungsweise Flachdrahtes sehr schnell und direkt auf geschlossene Kernquerschnitte automatisiert aufgewickelt werden. Die komprimierte "Druckfeder" der Wicklung bleibt erhalten. Der Kern kann nahezu vollständig bewickelt werden, ohne dass mechanische Spannungen in Wickelrichtung erzeugt werden und somit nahezu ohne mechanische Kräfte auf den Kern wirken zu lassen.
In claim 9 a method for winding a wire is specified. The method provides for the provision of a device, in particular the device specified above, for winding the wire. The wire is displaced in the device in such a way that the wire is fed to a shaping device and a pitch transmitter device. When the wire is passed through the shaping device and the pitch transmitter device, the wire is bent in a helical shape. For example, the wire is bent in the plane when it is passed through the shaping device and bent out of the plane with an incline when it is passed through the incline transmitter device.
By means of the specified device or the specified method, almost any cross-sections, preferably thick and therefore very stiff cross-sections, of a wire, in particular a rectangular or flat wire, can be applied very quickly and directly to closed core cross-sections be wound up automatically. The compressed "compression spring" of the winding is retained. The core can be wound almost completely without mechanical stresses being generated in the winding direction and thus with almost no mechanical forces acting on the core.

Gemäß einer möglichen Ausführungsform kann die Vorrichtung zum Wickeln des Drahtes eine Führungseinrichtung zum Führen des Drahtes in der Ebene enthalten, wobei die Führungseinrichtung in der Ebene einen geraden Verlauf aufweist. Der Draht wird in die Führungseinrichtung eingelegt und mittels der Vorschubeinrichtung in die Umformungseinrichtung, die in Vorschubrichtung des Drahtes hinter der Führungseinrichtung angeordnet ist, eingeschoben. Die Vorschubeinrichtung kann beispielsweise als eine Exzenter-Hub-Presse ausgebildet sein. Mittels der Vorrichtung wird somit eine Art "Schubdrahttechnik" bereitgestellt, mit der sehr hohe Schubkräfte auf den in der Führungseinrichtung und der Umformungseinrichtung geführten Draht eingeleitet werden können.According to a possible embodiment, the device for winding the wire can contain a guide device for guiding the wire in the plane, the guide device having a straight course in the plane. The wire is placed in the guide device and, by means of the feed device, is pushed into the shaping device which is arranged behind the guide device in the feed direction of the wire. The feed device can be designed, for example, as an eccentric lifting press. The device thus provides a type of “push wire technique” with which very high push forces can be introduced onto the wire guided in the guide device and the shaping device.

Die Umformungseinrichtung kann als eine Vertiefung in einer Platte ausgebildet sein. Der Draht kann dann durch die Umformungseinrichtung in der Ebene der Platte verbogen werden. Die Umformungseinrichtung weist eine Bodenfläche zur Auflage des Drahtes sowie eine gebogene Seitenwand auf. Beim Verschieben des Drahtes von der Führungseinrichtung in die Umformungseinrichtung wird der Draht auf der Bodenfläche aufliegend entlang der gebogenen Seitenwand geführt. Die Seitenwand kann halbkreisförmig gebogen sein, so dass der Draht kreisförmig gebogen wird. Durch die Steigungsgebereinrichtung wird der Draht aus der Ebene der Platte herausgebogen, so dass aus der kreisförmigen Biegung eine schraubenförmige Windung des Drahtes entsteht. Die Form des Drahtes kann auch als "helikal" oder "spiralförmig" im Sinne einer zylindrischen Spirale beschreiben werden.The shaping device can be designed as a recess in a plate. The wire can then be bent in the plane of the plate by the deformation device. The shaping device has a bottom surface for supporting the wire and a curved side wall. When the wire is moved from the guide device into the shaping device, the wire is guided along the curved side wall, resting on the bottom surface. The side wall can be bent in a semicircle so that the wire is bent in a circle. The wire is bent out of the plane of the plate by the pitch transmitter device, so that a helical turn of the wire is created from the circular bend. The shape of the wire can also be called "helical" or "spiral" in the sense of a cylindrical spiral.

Die Vorrichtung eignet sich insbesondere zum Biegen eines Flachdrahtes, wobei der Flachdraht mit seiner größeren Seitenfläche auf der Bodenfläche der Umformungseinrichtung aufliegt und mit seiner kleineren Seitenfläche an der Seitenwand der Umformungseinrichtung anliegt. Um ein Umkippen des Drahtes in der Umformungseinrichtung zu verhindern, kann die der Bodenfläche gegenüberliegende Seite der Vertiefung, die offen ist, durch eine verschiebbare Abdeckeinrichtung abgedeckt werden. Diese spezielle Formkulisse verhindert somit das natürliche Bestreben des Drahtes beim Biegen umzukippen. Durch die Steigungsgebereinrichtung erfährt der Draht eine Steigung, so dass er nach einer Windung seine eigene Höhe übersteigt und über einen darunter liegenden Abschnitt des Drahtes gebogen wird.The device is particularly suitable for bending a flat wire, the flat wire resting with its larger side surface on the bottom surface of the forming device and with its smaller side surface resting on the side wall of the forming device. In order to prevent the wire from tipping over in the shaping device, the side of the recess which is opposite the bottom surface and which is open can be covered by a sliding cover device. This special shape prevents the wire from tipping over when it is bent. The incline sensor device causes the wire to incline, so that after one turn it exceeds its own height and is bent over a section of the wire lying underneath.

Die Vorrichtung kann eine Aufnahmeeinrichtung zum Positionieren eines Kerns, insbesondere eines geschlossenen Kern, eines induktiven Bauelements, beispielsweise eines Transformators, aufweisen. Die Umformungseinrichtung und die Steigungsgebereinrichtung sind um die Aufnahmeeinrichtung derart angeordnet, dass der Draht beim Verschieben durch die Umformungseinrichtung und die Steigungsgebereinrichtung schraubenförmig um einen Schenkel des geschlossenen Kerns gewickelt werden kann, ohne den empfindlichen Lack des Drahtes, beispielsweise eines Kupferlackdrahtes, oder die Isolationsbeschichtung des Kerns zu beschädigen. Ein sonst üblicher Wickeldorn ist nicht erforderlich. Mittels der Vorrichtung lassen sich Flach- beziehungsweise Rechteckdrähte mit einer Breite von beispielsweise 5 mm und einer Dicke von 1 mm bis 2 mm als Luftspule schraubenförmig biegen beziehungsweise schraubenförmig um einen Schenkel eines geschlossenen Rahmenkerns eines Transformators biegen.The device can have a receiving device for positioning a core, in particular a closed core, of an inductive component, for example a transformer. The shaping device and the pitch transmitter device are arranged around the receiving device in such a way that the wire can be wound helically around a leg of the closed core when it is moved by the shaping device and the pitch transmitter device, without the sensitive lacquer of the wire, for example an enamelled copper wire, or the insulation coating of the core to damage. An otherwise customary winding mandrel is not required. By means of the device, flat or rectangular wires with a width of, for example, 5 mm and a thickness of 1 mm to 2 mm can be bent helically as an air-core coil or helically around one Bend the legs of a closed frame core of a transformer.

Beim Biegen von Flach- beziehungsweise Rechteckdrähten mit einer Dicke des Drahtes von mehr als 1,8 mm kann ein Endabschnitt des Drahtes durch eine Vorbiegeeinrichtung der Vorrichtung vorgebogen werden. Dazu wird der Draht in die Vorschubeinrichtung derart eingespannt, dass der vorzubiegende Endabschnitt des Drahtes aus der Vorrichtung an der Seite, an der die Führungseinrichtung beziehungsweise die Umformungseinrichtung angeordnet ist, herausragt. Mittels der Vorbiegeeinrichtung wird der Endabschnitt des Drahtes derart gebogen, dass der Draht anschließend in die nach oben offene Vertiefung der Umformungseinrichtung eingelegt werden kann. Das weitere Biegen des Drahtes erfolgt, wie oben beschrieben, automatisiert durch Verschieben des Drahtes durch die Umformungseinrichtung und die Steigungsgebereinrichtung.When bending flat or rectangular wires with a wire thickness of more than 1.8 mm, an end section of the wire can be pre-bent by a pre-bending device of the device. For this purpose, the wire is clamped in the feed device in such a way that the end section of the wire to be bent protrudes from the device on the side on which the guide device or the shaping device is arranged. By means of the pre-bending device, the end section of the wire is bent in such a way that the wire can then be inserted into the upwardly open depression of the forming device. The further bending of the wire takes place, as described above, in an automated manner by moving the wire through the shaping device and the pitch transmitter device.

Gemäß einem illustrativen Beispiel wird ein induktives Bauelement angegeben. Das Bauelement ist vorzugsweise durch das vorgehend beschriebene Verfahren hergestellt. Der Draht ist insbesondere kreisförmig mit einer Steigung, d.h., schraubenförmig, gewickelt.According to an illustrative example, an inductive component is specified. The component is preferably produced by the method described above. In particular, the wire is wound circularly with a pitch, i.e., helically.

In einem illustrativen Beispiel ist die Wicklung des Drahtes komprimiert ausgebildet. Bei einer komprimierten Wicklung liegen benachbarte Windungen eng aneinander an. Insbesondere ist die Wicklung spaltfrei oder nahezu spaltfrei ausgebildet, so dass benachbarte Windungen direkt aneinander anliegen. Beispielsweise liegt die Ganghöhe der schraubenförmigen Wicklung im Bereich der Drahtdicke. Auf diese Weise kann ein besonders hoher Füllgrad der Wicklung erreicht werden.In an illustrative example, the winding of the wire is designed to be compressed. In the case of a compressed winding, adjacent turns are tight against one another. In particular, the winding is designed without gaps or almost without gaps, so that adjacent turns are in direct contact with one another. For example, the pitch of the helical winding is in the range of the wire thickness. In this way, a particularly high degree of filling of the winding can be achieved.

Das induktive Bauelement kann einen Kern, insbesondere einen Ferritkern, aufweisen. Der Draht kann direkt um den Kern gewickelt sein. Insbesondere ist der Draht in diesem Fall dabei nicht um einen Spulenkörper aus Plastik gewickelt. In einer Ausführungsform weist der Kern eine geschlossene Form auf. Das induktive Bauelement kann auch als Luftspule ausgebildet sein.The inductive component can have a core, in particular a ferrite core. The wire can be wrapped directly around the core. In particular, in this case the wire is not wound around a bobbin made of plastic. In one embodiment, the core has a closed shape. The inductive component can also be designed as an air-core coil.

Der Draht kann beispielsweise als Rechteck- bzw. als Flachdraht ausgebildet sein. Alternativ kann es sich auch um einen Runddraht handeln.The wire can be designed as a rectangular or flat wire, for example. Alternatively, it can also be a round wire.

In einem illustrativen Beispiel weist der Kern im Querschnitt eine äußere Umfangslinie auf, die nicht kreisförmig ausgebildet ist. Insbesondere kann der Kern Kanten aufweisen. Beispielsweise weist der Kern im Querschnitt Ecken auf. Insbesondere kann der Kern eine äußere Umfangslinie in Form eines Vielecks aufweisen.In an illustrative example, the core has, in cross section, an outer circumference that is not circular. In particular, the core can have edges. For example, the core has corners in cross section. In particular, the core can have an outer circumferential line in the form of a polygon.

Die Erfindung wird im Folgenden anhand von Figuren, die Ausführungsformen der vorliegenden Erfindung zeigen, näher erläutert.The invention is explained in more detail below with reference to figures which show embodiments of the present invention.

Es zeigen:

Figur 1
eine Ausführungsform einer Vorrichtung zum Wickeln eines Drahtes,
Figur 2
einen Ausschnitt der Vorrichtung zum Wickeln eines Drahtes,
Figur 3
einen weiteren Ausschnitt der Vorrichtung zum Wickeln eines Drahtes,
Figur 4
eine Ausführungsform einer Steigungsgebereinrichtung,
Figur 5
eine Draufsicht auf eine erste Seite einer Ausführungsform einer Vorbiegeeinrichtung zum Biegen eines Endabschnitts eines Drahtes,
Figur 6
eine Draufsicht auf eine zweite Seite einer Ausführungsform einer Vorbiegeeinrichtung zum Biegen eines Endabschnitts eines Drahtes,
Figur 7
eine Draufsicht auf eine zweite Seite einer Ausführungsform einer Vorbiegeeinrichtung zum Biegen eines Endabschnitts eines Drahtes.
Show it:
Figure 1
an embodiment of a device for winding a wire,
Figure 2
a section of the device for winding a wire,
Figure 3
another section of the device for winding a wire,
Figure 4
an embodiment of a slope transmitter device,
Figure 5
a plan view of a first side of an embodiment of a pre-bending device for bending an end portion of a wire,
Figure 6
a plan view of a second side of an embodiment of a pre-bending device for bending an end portion of a wire,
Figure 7
a plan view of a second side of an embodiment of a prebending device for bending an end portion of a wire.

Figur 1 zeigt eine Ausführungsform einer Vorrichtung 1 zum Wickeln eines Drahtes 2, der mittels der Vorrichtung 1 schraubenförmig als Luftspule oder um einen Schenkel eines geschlossenen Rahmenkerns 3 eines induktiven Bauelements 4, beispielsweise eines Transformators, gewickelt werden kann. Mittels der Vorrichtung 1 können insbesondere zwei parallel geführte Drähte 2 um zwei Schenkel eines geschlossenen Rahmenkerns 3 gleichzeitig gewickelt werden. Figure 1 shows an embodiment of a device 1 for winding a wire 2, which by means of the device 1 can be wound helically as an air coil or around a leg of a closed frame core 3 of an inductive component 4, for example a transformer. By means of the device 1, in particular two parallel wires 2 can be wound around two legs of a closed frame core 3 at the same time.

Die Vorrichtung 1 umfasst eine Vorschubeinrichtung 10 zum Verschieben des Drahtes in einer Führungseinrichtung 50 zum Führen des Drahtes 2. Die Vorschubeinrichtung 10 weist einen Schlitten 11 auf, der auf einer Schiene 100 beweglich angeordnet ist. Im Ausführungsbeispiel der Figur 1 umfasst die Vorrichtung 1 zwei Schlitten 11, die auf der Schiene 100 in horizontaler Richtung verschieblich angeordnet sind. Über den Schlitten 11 befindet sich eine Platte 12 der Vorschubeinrichtung, die auf ihrer Oberseite mindestens eine Führung 13 zum Führen von mindestens einem Draht 2 aufweist. Die Führung 13 kann als eine Vertiefung in der Platte 12 ausgebildet sein. Zur parallelen Führung der in Figur 1 gezeigten beiden Drähte 2 können, wie bei der in Figur 1 gezeigten Ausführungsform der Vorrichtung 1 zum Wickeln des Drahtes, zwei Führungen 13 parallel in der Platte 12 angeordnet sein.The device 1 comprises a feed device 10 for moving the wire in a guide device 50 for guiding the wire 2. The feed device 10 has a carriage 11 which is movably arranged on a rail 100. In the embodiment of Figure 1 the device 1 comprises two carriages 11 which are arranged on the rail 100 so as to be displaceable in the horizontal direction. A plate 12 of the feed device is located above the carriage 11 and has at least one guide 13 on its upper side for guiding at least one wire 2. The guide 13 can be designed as a recess in the plate 12. For parallel guidance of the in Figure 1 two wires 2 shown can, as in the case of the in Figure 1 embodiment shown of the device 1 for winding the wire, two guides 13 can be arranged in parallel in the plate 12.

Zur Abdeckung der nach oben offenen Führung 13 in der Platte 12 kann eine Abdeckplatte 15 zumindest teilweise auf der Platte 12 angeordnet werden. Die Abdeckplatte 15 kann mittels einer Presse 14 auf die Platte 12 gepresst werden, so dass die offene Seite der Führung 13 durch die Abdeckplatte 15 bedeckt ist und der Draht 2 in der Führung 13 geklemmt ist. Zum Aufdrücken der Abdeckplatte 15 auf die Führung 13 ist über der Presse 14 ein Stempel 16 vorgesehen, der die Abdeckplatte 15 auf die Platte 12 mit der Führung 13 aufpresst. Die Platte 12, die Abdeckplatte 15 und der Stempel 17 lassen sich mit der Bewegung der Schlitten 11 in der durch die Pfeile an der Platte 12 gezeigte horizontalen Verschieberichtung des Drahtes vor und zurück bewegen.To cover the upwardly open guide 13 in the plate 12, a cover plate 15 can be arranged at least partially on the plate 12. The cover plate 15 can be pressed onto the plate 12 by means of a press 14, so that the open side of the guide 13 is covered by the cover plate 15 and the wire 2 is clamped in the guide 13. To press the cover plate 15 onto the guide 13, a punch 16 is provided above the press 14, which presses the cover plate 15 onto the plate 12 with the guide 13. The plate 12, the cover plate 15 and the punch 17 can be moved back and forth with the movement of the carriages 11 in the horizontal displacement direction of the wire shown by the arrows on the plate 12.

Zur Bewegung der Vorschubeinrichtung 10 ist eine Antriebseinheit 110 vorgesehen. Bei der Vorwärtsbewegung des Drahtes 2 in Richtung auf den Rahmenkern 3 wird der Draht 2 in der Führung 13 mittels der Abdeckplatte 15 festgepresst und somit entlang der Führungseinrichtung 50 verschoben. Nachfolgend hebt die Presse die Abdeckplatte 15 an, so dass der Draht nicht mehr in der Führung 13 der Platte 12 geklemmt wird. Der Schlitten 11 fährt dann die Platte 12 wieder in die Ausgangsposition zurück. Anschließend wird der Vorschubvorgang des Drahtes wiederholt.A drive unit 110 is provided for moving the feed device 10. During the forward movement of the wire 2 in the direction of the frame core 3, the wire 2 is pressed firmly in the guide 13 by means of the cover plate 15 and is thus displaced along the guide device 50. The press then lifts the cover plate 15 so that the wire is no longer clamped in the guide 13 of the plate 12. The carriage 11 then moves the plate 12 back into the starting position. The wire feed process is then repeated.

Die Figuren 2 und 3 zeigen einen vorderen Bereich der Vorrichtung 1 mit einer Führungseinrichtung 50 zur Führung der Drähte 2 in einer vergrößerten Darstellung. Die Führungseinrichtung 50 ist als eine Vertiefung in einer Platte 80 angeordnet. Die Führungseinrichtung 50 weist in einer Ebene E der Platte 80 einen geraden Verlauf auf. Wie anhand der Figuren 1, 2 und 3 deutlich wird, weist die Vorrichtung 1 neben der Vorschubeinrichtung 10 und der Führungseinrichtung 50 eine Umformungseinrichtung 20 zum Biegen des Drahtes 2 in der Ebene E sowie eine Steigungsgebereinrichtung 30 zum Biegen des Drahtes 2 mit einer Steigung aus der Ebene E heraus auf.The Figures 2 and 3 show a front area of the device 1 with a guide device 50 for guiding the wires 2 in an enlarged view. The guide device 50 is arranged as a recess in a plate 80. The guide device 50 has a straight course in a plane E of the plate 80. How with the Figures 1 , 2 and 3 As becomes clear, the device 1 has, in addition to the feed device 10 and the guide device 50, a shaping device 20 for bending the wire 2 in the plane E and a pitch transmitter device 30 for bending the wire 2 with a pitch out of the plane E.

Die Umformungseinrichtung 20 und die Steigungsgebereinrichtung 30 sind derart ausgebildet, dass der Draht 2 bei einem Verschieben durch die Vorschubeinrichtung 10 zunächst in der Führungseinrichtung 50 in Längsrichtung verschoben wird und anschließend in die Umformungseinrichtung 20 und die Steigungsgebereinrichtung 30 eingeführt wird. Die Umformungseinrichtung 20 und die Steigungsgebereinrichtung 30 sind derart ausgebildet, dass der Draht 2 bei dem Verschieben in der Umformungseinrichtung 20 und der Steigungsgebereinrichtung 30 schraubenförmig gebogen wird.The shaping device 20 and the pitch transmitter device 30 are designed in such a way that when the wire 2 is moved by the feed device 10, it is first displaced in the guide device 50 in the longitudinal direction and then introduced into the shaping device 20 and the pitch transmitter device 30. The shaping device 20 and the pitch transmitter device 30 are designed in such a way that the wire 2 is bent helically when it is moved in the shaping device 20 and the pitch transmitter device 30.

Die Umformungseinrichtung 20 und die Führungseinrichtung 50 können als Teil der ihnen gemeinsamen Platte 80 ausgebildet sein. Die Umformungseinrichtung 20 kann eine Vertiefung 23 in der Platte 80 aufweisen, wobei die Vertiefung in der Ebene E der Platte einen gebogenen Verlauf aufweist. Die Vertiefung kann beispielsweise kreissegmentförmig, insbesondere halbkreisförmig, gebogen sein. Die Umformungseinrichtung 20 kann eine Bodenfläche 21 zur Auflage des Drahtes 2 und mindestens eine Seitenwand 22 aufweisen. Die mindestens eine Seitenwand 22 weist den gebogenen Verlauf auf. Die Umformungseinrichtung 20 ist somit derart ausgebildet, dass der Draht 2 bei dem Verschieben in der Umformungseinrichtung 20 entlang der Seitenwand 22 kreisförmig gebogen wird.The shaping device 20 and the guide device 50 can be designed as part of the plate 80 common to them. The shaping device 20 can have a depression 23 in the plate 80, the depression having a curved course in the plane E of the plate. The recess can be curved, for example, in the shape of a segment of a circle, in particular in a semicircle. The shaping device 20 can have a bottom surface 21 for supporting the wire 2 and at least one side wall 22. The at least one side wall 22 has the curved course. The conversion device 20 is thus designed in such a way that the wire 2 is bent circularly along the side wall 22 when it is moved in the shaping device 20.

Die Führungseinrichtung 50 kann in der Platte 80 eine Vertiefung 53 aufweisen, die in der Ebene E der Platte einen geraden Verlauf hat und in die Vertiefung 23 der Umformungseinrichtung 20 einmündet. Die Führungseinrichtung 50 weist eine Bodenfläche 51 und eine Seitenwand 52 auf, die rechtwinklig zueinander angeordnet sind und somit die Vertiefung 53 innerhalb der Platte 80 bilden.The guide device 50 can have a recess 53 in the plate 80, which has a straight course in the plane E of the plate and opens into the recess 23 of the shaping device 20. The guide device 50 has a bottom surface 51 and a side wall 52, which are arranged at right angles to one another and thus form the recess 53 within the plate 80.

Die Umformungseinrichtung 20 und die Führungseinrichtung 50 sind insbesondere zum Führen eines Rechteck- beziehungsweise Flachdrahtes ausgebildet. Unter einem Rechteck- beziehungsweise Flachdraht ist dabei ein Draht mit einem rechteckigen Querschnitt zu verstehen, der eine größere und eine kleinere Seitenfläche aufweist, wobei die Seitenflächen rechtwinklig zueinander angeordnet sind. In den Figuren 1 bis 3 ist der Draht 2 jeweils als Flach- beziehungsweise Rechteckdraht mit einer größeren Seitenfläche S2a und einer kleineren Seitenfläche S2b ausgebildet.The shaping device 20 and the guide device 50 are designed in particular to guide a rectangular or flat wire. A rectangular or flat wire is to be understood as a wire with a rectangular cross section, which has a larger and a smaller side surface, the side surfaces being arranged at right angles to one another. In the Figures 1 to 3 the wire 2 is designed as a flat or rectangular wire with a larger side surface S2a and a smaller side surface S2b.

Beim Verschieben des Drahtes in der Führungseinrichtung 50 liegt der Flach- beziehungsweise Rechteckdraht 2 mit der größeren Seitenfläche S2a auf der Bodenfläche 51 der Führungseinrichtung 50 auf. Die kleinere Seitenfläche S2b des Flachbeziehungsweise Rechteckdrahtes 2 liegt an der Seitenwand 52 der Führungseinrichtung 50 an. Die sich bei dem gezeigten Ausführungsbeispiel an die Führungseinrichtung 50 anschließende Umformungseinrichtung 20 ist derart ausgebildet, dass der Flach- beziehungsweise Rechteckdraht 2 beim Führen und Verbiegen in der Umformungseinrichtung 20 mit der größeren Seitenfläche S2a auf der Bodenfläche 21 der Umformungseinrichtung aufliegt und mit der kleineren Seitenfläche S2b an der Seitenwand 22 der Umformungseinrichtung anliegt.When the wire is displaced in the guide device 50, the flat or rectangular wire 2 with the larger side surface S2a rests on the bottom surface 51 of the guide device 50. The smaller side surface S2b of the flat or rectangular wire 2 rests on the side wall 52 of the guide device 50. The shaping device 20 following the guide device 50 in the exemplary embodiment shown is designed in such a way that the flat or rectangular wire 2 with the larger one when guiding and bending in the shaping device 20 Side surface S2a rests on the bottom surface 21 of the deformation device and the smaller side surface S2b rests on the side wall 22 of the deformation device.

Beim Verbiegen des Drahtes 2 in der Umformungseinrichtung 20 wird der äußere Bereich des Drahtes, der näher als ein innerer Bereich des Drahtes an der Seitenwand 22 der Umformungseinrichtung 20 anliegt gedehnt, während der innere Bereich des Drahtes beim Verbiegen gestaucht wird. Die Umformungseinrichtung 20 ist an der der Bodenfläche 21 gegenüberliegenden Seite offen. Um ein Umkippen des Flach- beziehungsweise Rechteckdrahtes in der Umformungseinrichtung 20 aufgrund der beim Biegen auftretenden Spannungen im Material des Drahtes 2 zu verhindern, kann die Vorrichtung 1 eine verschiebbare Abdeckeinrichtung 40 umfassen.When the wire 2 is bent in the shaping device 20, the outer area of the wire, which rests closer than an inner area of the wire to the side wall 22 of the shaping device 20, is stretched, while the inner area of the wire is compressed when it is bent. The shaping device 20 is open on the side opposite the bottom surface 21. In order to prevent the flat or rectangular wire from tipping over in the shaping device 20 due to the stresses occurring in the material of the wire 2 during bending, the device 1 can comprise a displaceable cover device 40.

Die Abdeckeinrichtung 40 kann verschiebbar auf der Platte 80 angeordnet sein. Die Abdeckeinrichtung 40 kann auf der Platte 80 derart verschoben werden, dass die Führungseinrichtung 50 vollständig und die Umformungseinrichtung 20 zumindest teilweise von der Abdeckeinrichtung 40 abgedeckt ist. Im Ausführungsbeispiel der Figuren 2 und 3 ist aus Gründen der besseren Darstellung nur eine Abdeckeinrichtung 40 dargestellt, die die Vertiefungen der hinteren Führungseinrichtung 50 vollständig und der hinteren Umformungseinrichtung 20 teilweise abdeckt.The cover device 40 can be arranged displaceably on the plate 80. The cover device 40 can be displaced on the plate 80 in such a way that the guide device 50 is completely covered and the shaping device 20 is at least partially covered by the cover device 40. In the embodiment of Figures 2 and 3 For the sake of better illustration, only one cover device 40 is shown, which completely covers the depressions of the rear guide device 50 and of the rear deformation device 20 partially.

Die Abdeckeinrichtung 40 kann in Form einer auf der Platte 80 verschiebbar angeordneten Platte ausgebildet sein. Die Abdeckeinrichtung 40 ist dazu entlang der beiden Aussparungen 41 quer zur Längsrichtung des Drahtes 2 und somit quer zur Längsrichtung der Führungseinrichtung 50 auf der Platte 80 verschiebbar. Bevor der Draht mittels der Vorschubeinrichtung 10 von der Führungseinrichtung 50 in die Umformungseinrichtung 20 eingeführt wird, wird die verschiebbare Abdeckeinrichtung 40 derart verschoben, dass die Führungseinrichtung 50 komplett und die Umformungseinrichtung 20 teilweise von der Abdeckeinrichtung 40 bedeckt wird. Dadurch ist der in Figur 3 durch eine Strichlierung abgegrenzte vordere Bereich AB der Umformungseinrichtung 20 mit dem darin liegenden Abschnitt des Drahtes von der Abdeckeinrichtung bedeckt.The cover device 40 can be designed in the form of a plate which is arranged displaceably on the plate 80. For this purpose, the cover device 40 can be displaced along the two recesses 41 transversely to the longitudinal direction of the wire 2 and thus transversely to the longitudinal direction of the guide device 50 on the plate 80. Before the wire by means of the feed device 10 is introduced into the shaping device 20 by the guide device 50, the displaceable cover device 40 is displaced in such a way that the guide device 50 is completely covered and the shaping device 20 is partially covered by the cover device 40. As a result, the front area AB of the shaping device 20, delimited by a dashed line in FIG. 3, with the portion of the wire lying therein is covered by the covering device.

Die Platte der Abdeckeinrichtung 40 weist über dem Bereich AB der Umformungseinrichtung 20 eine halbkreisförmige Aussparung 42 auf. Am unteren Ende der halbkreisförmigen Aussparung weist die Abdeckeinrichtung eine dünne Platte 43 aus einem gehärteten Material auf. Diese Platte 43 kann beispielsweise nur wenige Zehntel Millimeter dick sein. Beim Verschieben der Abdeckeinrichtung, deckt die am unteren Ende der Aussparung 42 angeordnete dünne Platte 43 den in der Vertiefung der Umformungseinrichtung geführten Draht 2 ab. Beim Einlaufen des Drahtes in die Umformungseinrichtung verhindert die dünne Platte 43 ein Herausspringen beziehungsweise Umkippen des Drahtes in der Umformungseinrichtung 20. Wenn der Draht schraubenförmig gewickelt wird, kann eine obere Lage des Drahtes nach Durchführen durch die Steigungsgebereinrichtung über einer unteren Lage des Drahtes, die sich in der Umformungseinrichtung 20 befindet, angeordnet werden. Die obere Lage des Drahtes legt sich über die Platte 43, während die untere Lage des Drahtes unter der Platte 43 in der Umformungseinrichtung geführt wird. Die untere Lage sowie die darüber angeordnete obere Lage der Drahtwicklung sind bei dem Wickelvorgang durch die dünne Platte 43 voneinander getrennt.The plate of the covering device 40 has a semicircular recess 42 above the area AB of the shaping device 20. At the lower end of the semicircular recess, the cover device has a thin plate 43 made of a hardened material. This plate 43 can be only a few tenths of a millimeter thick, for example. When the cover device is displaced, the thin plate 43 arranged at the lower end of the recess 42 covers the wire 2 guided in the recess of the shaping device. When the wire runs into the forming device, the thin plate 43 prevents the wire from jumping out or tipping over in the forming device 20 located in the shaping device 20, are arranged. The upper layer of the wire lies over the plate 43, while the lower layer of the wire is guided under the plate 43 in the forming device. The lower layer and the upper layer of the wire winding arranged above it are separated from one another by the thin plate 43 during the winding process.

Bei der in den Figuren 1 bis 3 gezeigten Ausführungsform der Vorrichtung 1 zum Biegen des Drahtes ist die Führungseinrichtung 50 und somit auch die Platte 80 in Vorschubrichtung des Drahtes 2 hinter der Vorschubeinrichtung 10 angeordnet. Die Umformungseinrichtung 20 ist in Vorschubrichtung des Drahtes hinter der Führungseinrichtung 50 angeordnet, so dass der Draht 2 bei einem Verschieben aus der Führungseinrichtung 50 in die Umformungseinrichtung 20 eingeschoben wird. Die Steigungsgebereinrichtung 30 kann hinter der Umformungseinrichtung 20 angeordnet sein, so dass der Draht 2 beim Verschieben nach der Umformung in der Umformungseinrichtung 20 zu der Steigungsgebereinrichtung 30 geführt wird. Die Steigungsgebereinrichtung 30 kann auch in die Umformungseinrichtung integriert sein. Bei dieser Ausführungsform steigt die Bodenfläche 21 der Umformungseinrichtung in horizontaler Richtung an, so dass der Draht beim kreisförmigen Biegen in der Umformungseinrichtung gleichzeitig auch eine Steigung erfährt.In the case of the Figures 1 to 3 The illustrated embodiment of the device 1 for bending the wire is the guide device 50 and thus also the plate 80 are arranged behind the feed device 10 in the feed direction of the wire 2. The shaping device 20 is arranged behind the guide device 50 in the feed direction of the wire, so that the wire 2 is pushed into the shaping device 20 when it is displaced out of the guide device 50. The pitch transmitter device 30 can be arranged behind the shaping device 20, so that the wire 2 is guided to the pitch transmitter device 30 when it is moved after the shaping in the shaping device 20. The pitch transmitter device 30 can also be integrated into the shaping device. In this embodiment, the bottom surface 21 of the shaping device rises in the horizontal direction, so that the wire also experiences an incline when it is bent circularly in the shaping device.

Bei der in den Figuren 1 bis 3 gezeigten Ausführungsform der Vorrichtung 1 ist die Steigungsgebereinrichtung 30 hinter der Umformungseinrichtung 20 angeordnet. Die Steigungsgebereinrichtung 30 kann zum Erzeugen der Steigung des Drahtes beispielsweise eine schräge Platte aufweisen. Die Schräge der Platte kann in Abhängigkeit von der Steigung des Drahtes einstellbar sein. Figur 4 zeigt den in der Führungseinrichtung 50 und der Umformungseinrichtung 20 geführten Draht 2, der um den verkürzt dargestellten Schenkel 3 des induktiven Bauelements 4 gewickelt wird und den Steigungsgeber 30. Bei der in Figur 4 dargestellten Ausführungsform ist der Steigungsgeber 30 als ein Kugelstift ausgebildet. Der Steigungsgeber weist beispielsweise einen zylindrischen Körper mit einer kugelförmigen Wölbung 31 an seinem oberen Ende auf. Der Steigungsgeber ist auf der Platte 80 angeordnet beziehungsweise kann in die Platte 80 versenkt werden.In the case of the Figures 1 to 3 The embodiment of the device 1 shown in the figure, the slope transmitter device 30 is arranged behind the shaping device 20. The pitch transmitter device 30 can, for example, have an inclined plate for generating the pitch of the wire. The slope of the plate can be adjustable depending on the pitch of the wire. Figure 4 shows the wire 2 guided in the guide device 50 and the shaping device 20, which is wound around the leg 3, shown in abbreviated form, of the inductive component 4 and the inclination sensor 30. In the case of the in FIG Figure 4 In the illustrated embodiment, the pitch sensor 30 is designed as a ball pin. The pitch sensor has, for example, a cylindrical body with a spherical bulge 31 at its upper end. The incline sensor is arranged on the plate 80 or can be sunk into the plate 80.

Je nach Steigung kann der Steigungsgeber aus der Ebene E der Platte 80 angehoben werden. Beim Wickeln des Drahtes 2 läuft der Draht auf die kugelförmige Wölbung 31 auf und erhält aufgrund der Kugelform eine Steigung, die notwendig ist, um die eigentliche schraubenförmige Wicklung des Drahtes und somit mehr als eine Windung des Drahtes zu erzeugen. Zur Biegung des Drahtes aus der Ebene E der Platte 80 heraus, kann der Steigungsgeber beispielsweise entsprechend der gewünschten Steigung angehoben werden, sobald der Draht auf die kugelförmige Wölbung aufgeglitten ist. Nach dem Schieben des Drahtes über die schräge Platte beziehungsweise die kugelförmige Wölbung 31 der Steigungsgebereinrichtung wird der Draht aus der Ebene E herausgebogen und kann über den darunterliegenden Abschnitt des Drahtes gelegt werden, der zeitgleich in die Umformungseinrichtung eingeführt wird. Dadurch entsteht die schraubenförmige Wicklung des Drahtes.Depending on the incline, the incline sensor can be lifted out of the plane E of the plate 80. When the wire 2 is wound, the wire runs onto the spherical arch 31 and, due to its spherical shape, has a pitch that is necessary to produce the actual helical winding of the wire and thus more than one turn of the wire. To bend the wire out of the plane E of the plate 80, the incline sensor can be raised, for example, according to the desired incline, as soon as the wire has slid onto the spherical arch. After the wire has been pushed over the inclined plate or the spherical curvature 31 of the inclination device, the wire is bent out of plane E and can be placed over the section of the wire underneath, which is simultaneously introduced into the forming device. This creates the helical winding of the wire.

Um den Draht um einen Schenkel des geschlossenen Rahmenkerns 3 zu wickeln, weist die Vorrichtung 1 eine Aufnahmeeinrichtung 60 zum Positionieren des Kerns 3 des induktiven Bauelements 4 auf. Die Umformungseinrichtung 20 und die Steigungsgebereinrichtung 30 sind derart um die Aufnahmeeinrichtung 60 angeordnet, dass der Draht 2 schraubenförmig um den Schenkel des Kerns 3 des induktiven Bauelements gewickelt wird, wenn der Kern 3 in der Aufnahmeeinrichtung 60 positioniert ist und der Draht 2 durch die Umformungseinrichtung 20 und die Steigungsgebereinrichtung 30 geführt wird.In order to wind the wire around a leg of the closed frame core 3, the device 1 has a receiving device 60 for positioning the core 3 of the inductive component 4. The forming device 20 and the pitch transmitter device 30 are arranged around the receiving device 60 in such a way that the wire 2 is wound helically around the leg of the core 3 of the inductive component when the core 3 is positioned in the receiving device 60 and the wire 2 through the forming device 20 and the incline sensor device 30 is guided.

Im Folgenden wird das Biegen beziehungsweise Wickeln des Drahtes 2 mittels der Vorrichtung 1 näher erläutert. Der Einfachheit halber wird das Verfahren zur Wicklung eines Drahtes nur für einen Draht 2 beschrieben. Es können mittels der Vorrichtung aber, wie oben erläutert, auch zwei Drähte gleichzeitig um zwei verschiedene Schenkel eines geschlossenen Rahmenkerns gewickelt werden.The bending or winding of the wire 2 by means of the device 1 is explained in more detail below. For the sake of simplicity, the method for winding a wire is described for only one wire 2. However, as explained above, the device can also use two wires at the same time be wrapped around two different legs of a closed frame core.

Zum Einlegen des Drahtes 2 in die Vorschubeinrichtung 10 wird die Abdeckplatte 15 zunächst von der Platte 12 angehoben, so dass der Draht 2 in die Führung 13 eingelegt und durch die Führungseinrichtung 50 bis zum Beginn der Umformungseinrichtung 20 geschoben werden kann. Anschließend wird die Abdeckplatte 15 mittels der Presse 14 und dem Stempel 16 auf die Platte 12 gepresst, so dass der Draht 2 innerhalb der Führung 13 geklemmt ist.To insert the wire 2 into the feed device 10, the cover plate 15 is first lifted from the plate 12 so that the wire 2 can be inserted into the guide 13 and pushed through the guide device 50 to the start of the shaping device 20. The cover plate 15 is then pressed onto the plate 12 by means of the press 14 and the punch 16, so that the wire 2 is clamped within the guide 13.

Mittels der Antriebseinheit 110 werden die Schlitten 11 und somit die Platte 12 in Pfeilrichtung verschoben, so dass das vordere Ende des Drahtes von der Führungseinrichtung 50 in die Umformungseinrichtung 20 eingeschoben wird. Beim Verschieben des Drahtes 2 wird der vordere Abschnitt des Drahtes, der durch die Umformungseinrichtung 20 geführt wird, halbkreisförmig in der Ebene E der Platte 80 gebogen.By means of the drive unit 110, the carriages 11 and thus the plate 12 are displaced in the direction of the arrow, so that the front end of the wire is pushed into the shaping device 20 by the guide device 50. When the wire 2 is displaced, the front section of the wire, which is guided through the shaping device 20, is bent in a semicircle in the plane E of the plate 80.

Zum weiteren Vorwärtsschieben des Drahtes wird die Abdeckplatte 15 von dem Stempel 16 und der Presse 14 angehoben und die Schlitten 11 werden mit der darauf befestigten Platte 12 entgegen der in Figur 1 gezeigten Pfeilrichtung zurückgeschoben. Aufgrund der Biegung des vorderen Endes des Drahtes ist der Draht fixiert und wird nicht mit der Bewegung der Platte 12 und der Schlitten 11 zurückgeschoben. Zum weiteren Vorschub des Drahtes wird die Abdeckplatte 15 erneut auf die Platte 12 gepresst, so dass der Draht wieder in der Führung 13 geklemmt wird. Anschließend erfolgt ein erneutes Vorwärtsbewegen der Platte 12 durch die Schlitten 11, wodurch der Draht 2 weiter in die Umformungseinrichtung 20 eingeschoben und dort halbkreisförmig gebogen wird. Das vordere Ende des Drahtes erreicht nun die Steigungsgebereinrichtung 30 und wird beim weiteren Durchführen durch die Steigungsgebereinrichtung 30 aus der Ebene E der Platte 80 herausgebogen. Durch ein weiteres Vorwärtsschieben des Drahtes kann der Draht mittels der Vorrichtung letztendlich schraubenförmig, wie in den Figuren 1 bis 3 gezeigt ist, gebogen werden.To push the wire further forwards, the cover plate 15 is raised by the punch 16 and the press 14 and the carriages 11 with the plate 12 fastened thereon are raised against the position shown in FIG Figure 1 direction shown by the arrow. Due to the bending of the front end of the wire, the wire is fixed and is not pushed back with the movement of the plate 12 and the carriage 11. To advance the wire further, the cover plate 15 is pressed again onto the plate 12 so that the wire is clamped in the guide 13 again. The plate 12 is then moved forward again through the carriage 11, as a result of which the wire 2 is pushed further into the shaping device 20 and is bent into a semicircle there. The front end of the The wire now reaches the pitch transmitter device 30 and is bent out of the plane E of the plate 80 as it continues through the pitch transmitter device 30. By pushing the wire further forward, the wire can ultimately be helical by means of the device, as in FIG Figures 1 to 3 shown to be bent.

Das beschriebene Verfahren zum Biegen des Drahtes mittels der Vorrichtung 1 lässt sich beispielsweise zum Verbiegen eines Drahtes mit einer Breite von 5 mm und einer Dicke von 1,5 mm bis 1,7 mm durchführen. Für dickere Drähte, beispielsweise Rechteck- beziehungsweise Flachdrähte mit einer Dicke von mehr als 1,8 mm, kann der vordere Endabschnitt A des Drahtes 2 vor dem Einschieben in die Führungseinrichtung 50 beziehungsweise die Umformungseinrichtung 20 vorgebogen werden. Die Vorrichtung 1 weist dazu die in den Figuren 1, 2, 5, 6 und 7 gezeigte Vorbiegeeinrichtung 70 zum Biegen des Endabschnitts A des Drahtes 2 auf.The method described for bending the wire by means of the device 1 can be carried out, for example, for bending a wire with a width of 5 mm and a thickness of 1.5 mm to 1.7 mm. For thicker wires, for example rectangular or flat wires with a thickness of more than 1.8 mm, the front end section A of the wire 2 can be pre-bent before being pushed into the guide device 50 or the shaping device 20. To this end, the device 1 has the Figures 1 , 2 , 5 , 6th and 7th Pre-bending device 70 shown for bending the end section A of the wire 2.

Die Vorbiegeeinrichtung 70 kann Teil einer Platte 90 sein, die an einer Halterung 120 der Vorrichtung 1 in vertikaler Richtung beweglich angeordnet ist. Figur 5 zeigt eine Oberseite der Vorbiegeeinrichtung 70, während die Unterseite der Vorbiegeeinrichtung 70 in den Figuren 6 und 7 dargestellt ist. Die Vorbiegeeinrichtung 70 weist einen Biegedorn 71, um den der Endabschnitt A des Drahtes 2 biegbar ist, auf. Der Biegedorn 71 kann als ein zylinderförmiger Zapfen ausgebildet sein, der aus der Unterseite der Platte 90 herausragt.The pre-bending device 70 can be part of a plate 90 which is arranged on a holder 120 of the device 1 so as to be movable in the vertical direction. Figure 5 FIG. 13 shows a top side of the pre-bending device 70, while the bottom side of the pre-bending device 70 in FIG Figures 6 and 7th is shown. The pre-bending device 70 has a bending mandrel 71 around which the end section A of the wire 2 can be bent. The bending mandrel 71 can be designed as a cylindrical pin which protrudes from the underside of the plate 90.

Zum eigentlichen Biegen des Endabschnitts A des Drahtes 2 um den Biegedorn 71 weist die Vorbiegeeinrichtung 70 ein Biegeelement 72 auf, das als ein mitführender Stift beziehungsweise eine zylinderförmige Walze an einem Hebel 73 befestigt sein kann. Der Hebel 73 kann an einem Gelenk 76 drehbar gelagert sein. Die Vorbiegeeinrichtung 70 weist des Weiteren in der Platte 90 eine Aussparung 74 auf, in der das Biegeelement 72 in einem Abstand um den Biegedorn 71 beweglich angeordnet ist. Das Biegeelement 72 ist mittels des Hebels 73 entlang der Bahn eines Kreissegmentes innerhalb der Aussparung 74 bewegbar. Die Aussparung 74 ist dazu ebenfalls in Form eines Kreissegmentes in der Platte 90 angeordnet. Bei den in den Figuren 1 bis 7 gezeigten Ausführungsformen der Vorrichtung zum Wickeln eines Drahtes, bei denen zwei Drähte gleichzeitig um verschiedene Schenkel des geschlossenen Rahmenkerns 3 gewickelt werden können, weist die Materialaussparung 74 in der Platte 90 zwei kreissegmentförmige Teilaussparungen auf, die ineinander übergehen. Zur besseren Darstellung ist bei den in den Figuren 5, 6 und 7 gezeigten Ausführungsformen der Vorbiegeeinrichtung 70 nur ein Draht 2 mit einem Endabschnitt A gezeigt, der mittels der Vorbiegeeinrichtung 70 gebogen wird.For the actual bending of the end section A of the wire 2 around the bending mandrel 71, the pre-bending device 70 has a bending element 72 which is attached to a lever 73 as a pin or a cylindrical roller can be. The lever 73 can be rotatably mounted on a joint 76. The pre-bending device 70 furthermore has a recess 74 in the plate 90, in which the bending element 72 is movably arranged at a distance around the bending mandrel 71. The bending element 72 can be moved by means of the lever 73 along the path of a segment of a circle within the recess 74. For this purpose, the recess 74 is also arranged in the form of a segment of a circle in the plate 90. In the Figures 1 to 7 The illustrated embodiments of the device for winding a wire, in which two wires can be wound around different legs of the closed frame core 3 at the same time, the material recess 74 in the plate 90 has two circular segment-shaped partial recesses that merge into one another. For the sake of clarity, the Figures 5 , 6th and 7th The embodiments of the pre-bending device 70 shown here only show a wire 2 with an end section A which is bent by means of the pre-bending device 70.

Zum Vorbiegen des Endabschnitts A des Drahtes 2 wird der Draht zunächst in der Vorschubeinrichtung 10 derart eingeklemmt, dass der vordere Endabschnitt A des Drahtes an der Seite der Vorschubeinrichtung, an der die Führungseinrichtung 50 angeordnet ist, aus der Vorschubeinrichtung herausragt. Die Platte 80 mit der Führungseinrichtung 50, der Umformungseinrichtung 20 und der auf der Platte fixierten Steigungsgebereinrichtung 30 ist verschiebbar an der Halterung 120 angeordnet. Zum Vorbiegen des Endabschnitts des Drahtes 2 wird die Platte 80 entlang der Halterung 120 auf eine Position P3 verschoben. Die Vorbiegeeinrichtung 70 ist über ein Kopplungselement 130 mit der Platte 80 verbunden. Das Kopplungselement 130 ist an der Halterung 120 in vertikaler Richtung verschiebbar angeordnet.To pre-bend the end section A of the wire 2, the wire is first clamped in the feed device 10 such that the front end section A of the wire protrudes from the feed device on the side of the feed device on which the guide device 50 is arranged. The plate 80 with the guide device 50, the shaping device 20 and the pitch transmitter device 30 fixed on the plate is arranged displaceably on the holder 120. In order to prebend the end section of the wire 2, the plate 80 is displaced along the holder 120 to a position P3. The pre-bending device 70 is connected to the plate 80 via a coupling element 130. The coupling element 130 is arranged on the holder 120 such that it can be displaced in the vertical direction.

Beim Verschieben der Platte 80 auf die Position P3 verschiebt sich die Vorbiegeeinrichtung 70 daher entsprechend nach unten auf eine Position P2, auf dessen Höhe der Draht 2 aus der Vorschubeinrichtung 1 herausragt. Zur Aufnahme des Drahtes 2 weist die Vorbiegeeinrichtung 70 die Führung 75 auf. Nach dem Verschieben der Platte 90 mit der Vorbiegeeinrichtung 70 von einer Position P1 oberhalb der Position P2 auf die Position P2 liegt der hinter dem Endabschnitt A angeordnete Abschnitt A' des Drahtes 2 in der Führung 75 der Vorbiegeeinrichtung, während der vordere Abschnitt A des zunächst noch ungebogenen Drahtes 2 aus der Führung 75 herausragt, wie dies in Figur 6 dargestellt ist.When the plate 80 is displaced to the position P3, the pre-bending device 70 is accordingly displaced downward to a position P2, at the height of which the wire 2 protrudes from the feed device 1. To accommodate the wire 2, the pre-bending device 70 has the guide 75. After the plate 90 has been moved with the pre-bending device 70 from a position P1 above the position P2 to the position P2, the section A 'of the wire 2 located behind the end section A lies in the guide 75 of the pre-bending device, while the front section A of the initially still unbent wire 2 protrudes from the guide 75, as shown in FIG Figure 6 is shown.

Durch Bewegen des Hebels 73 mit dem Biegeelement 72 in Pfeilrichtung um das Gelenk beziehungsweise einen Drehpunkt 76, an dem der Hebel 73 drehbar gelagert sein kann und der beispielsweise auf der Oberseite der Platte 90 auf dem Biegedorn 71 angeordnet ist, wird der Endabschnitt A des Drahtes um den Biegedorn 71 halbkreisförmig vorgebogen. Figur 7 zeigt den vorgebogenen Endabschnitt A des Drahtes 2, der in einen gekrümmten Abschnitt der Führung 75 gebogen ist. Um den Draht sicher in dem gekrümmten Abschnitt der Führung 75 entlang des Biegedorns zu halten, ist eine Abdeckung 78 über dem gekrümmten Abschnitt der Führung 75 vorgesehen. Die Abdeckung 78 ist an der Unterseite der Platte 80 angeordnet und kann einen kreissegmentförmigen Querschnitt aufweisen. Aus Gründen der besseren Übersicht ist in Figur 7 nur eine Abdeckung 78 dargestellt.By moving the lever 73 with the bending element 72 in the direction of the arrow around the joint or a pivot point 76 at which the lever 73 can be rotatably mounted and which is arranged, for example, on the upper side of the plate 90 on the bending mandrel 71, the end section A of the wire Pre-bent in a semicircular shape around the bending mandrel 71. Figure 7 FIG. 11 shows the pre-bent end portion A of the wire 2 bent into a curved portion of the guide 75. To hold the wire securely in the curved portion of the guide 75 along the bending mandrel, a cover 78 is provided over the curved portion of the guide 75. The cover 78 is arranged on the underside of the plate 80 and can have a cross-section in the shape of a segment of a circle. For the sake of clarity, in Figure 7 only one cover 78 is shown.

Neben dem in den Figuren 5, 6 und 7 gezeigten Draht kann ein weiterer zweiter Draht, der parallel zu dem ersten Draht in der Vorrichtung 1 geführt wird, mittels der Vorbiegeeinrichtung 70 verbogen werden. Dazu weist die Vorbiegeeinrichtung einen weiteren Hebel 73 auf, der ein weiteres Biegeelement in einer weiteren Aussparung 74 bewegt.In addition to the Figures 5 , 6th and 7th A further second wire, which is guided parallel to the first wire in the device 1, can be bent by means of the pre-bending device 70. The pre-bending device a further lever 73 which moves a further bending element in a further recess 74.

Zum weiteren Biegen beziehungsweise Wickeln des Drahtes 2 wird die Platte 90 mit der Vorbiegeeinrichtung 70 von der Position P2 wieder auf die Position P1 verfahren. Dabei wird die Platte 80 von der Position P3, die unterhalb der Position P2 liegt, wieder zurück auf die Position P2 verfahren, wodurch der vordere Endabschnitt A des nunmehr vorgebogenen Drahtes 2 in die Führungseinrichtung 50 beziehungsweise die Umformungseinrichtung 20 eingelegt wird. Das weitere Biegen beziehungsweise Wickeln des Drahtes um den Schenkel des geschlossenen Rahmenkerns 3 kann nun weiter automatisiert mittels der Vorrichtung 1 wie oben beschrieben erfolgen.For further bending or winding of the wire 2, the plate 90 is moved with the pre-bending device 70 from the position P2 back to the position P1. The plate 80 is moved from position P3, which is below position P2, back to position P2, as a result of which the front end section A of the now pre-bent wire 2 is inserted into the guide device 50 or the shaping device 20. The further bending or winding of the wire around the leg of the closed frame core 3 can now take place in a further automated manner by means of the device 1 as described above.

BezugszeichenlisteList of reference symbols

11
Vorrichtung zum Wickeln eines DrahtesDevice for winding a wire
22
Drahtwire
33
Kerncore
44th
induktives Bauelementinductive component
1010
VorschubeinrichtungFeed device
2020th
UmformungseinrichtungForming device
3030th
SteigungsgebereinrichtungIncline device
4040
AbdeckeinrichtungCovering device
5050
FührungseinrichtungGuide device
6060
AufnahmeeinrichtungReceiving facility
7070
VorbiegeeinrichtungPre-bending device
8080
Platteplate
9090
Platteplate
100100
Schienerail
110110
AntriebseinheitDrive unit
120120
Halterungbracket
130130
KopplungselementCoupling element

Claims (10)

  1. Device for winding a wire for an inductive component, comprising:
    - a advancing arrangement (10) for advancing the wire (2) ,
    - a shaping arrangement (20) and a pitch-producing arrangement (30) for bending the wire (2),
    - wherein the shaping arrangement (20) and the pitch-producing arrangement (30) are arranged in such a way that the wire (2), as it is advanced by the advancing arrangement (10), is introduced into the shaping arrangement (20) and the pitch-producing arrangement (30) ,
    - wherein the shaping arrangement (20) and the pitch-producing arrangement (30) are formed in such a way that the wire (2), as it is advanced, is bent in a coiled manner in the shaping arrangement (20) and the pitch-producing arrangement (30),
    - wherein the shaping arrangement (20) has a base face (21) for supporting the wire (2) and at least one side wall (22),
    - wherein the at least one side wall (22) has a curved course,
    - wherein the shaping arrangement (20) is formed in such a way that the wire (2) as it is advanced in the shaping arrangement (20) is bent along the side wall (22) and wherein the shaping arrangement (20) is open on the side opposite the base face (21).
  2. Device according to Claim 1,
    - wherein the shaping arrangement (20) is designed to guide a flat wire (2), which has a larger and a smaller side face (S2a, S2b),
    - wherein the shaping arrangement (20) is formed in such a way that the flat wire (2), as it is guided and bent in the shaping arrangement (20), rests via the larger side face (S2a) on the base face (21) of the shaping arrangement and bears via the smaller side face (S2b) on the side wall (22) of the shaping arrangement.
  3. Device according to either of Claims 1 or 2, comprising:
    - at least one displaceable cover arrangement (40),
    - wherein the cover arrangement (40) is designed to be displaceable into a position in which the cover arrangement (40) covers the shaping arrangement (20) on the side opposite the base face (21).
  4. Device according to any one of Claims 1 to 3, comprising:
    - a guide arrangement (50) for guiding the wire (2) in the plane (E), wherein the guide arrangement (50) has a straight course in the plane (E),
    - wherein the guide arrangement (50) and the shaping arrangement (20) are arranged in such a way that the wire (2), as it is advanced, is slid from the guide arrangement (50) into the shaping arrangement (20),
    - wherein the shaping arrangement (20) and the guide arrangement (50) are formed as part of a plate (80),
    - wherein the plate (80) is arranged after the advancing arrangement (10) in the advancing direction of the wire (2) ,
    - wherein the shaping arrangement (20) has a first indentation (23) in the plate (80) with a curved course in the plane (E) of the plate (80), and the guide arrangement (50) has a second indentation (53) in the plate (80) with a straight course in the plane of the plate (80), and
    - wherein the first indentation (23) within the plate (80) directly adjoins the second indentation (53).
  5. Device according to any one of Claims 1 to 4,
    wherein the pitch-producing arrangement (30) is arranged in such a way that the wire (2), as it is advanced in the shaping arrangement (20), is guided to the pitch-producing arrangement (30) following the bending in the shaping arrangement (20).
  6. Device according to any one of Claims 1 to 4, wherein the pitch-producing arrangement (30) is integrated in the shaping arrangement (20), such that the wire (2), as it is bent in the shaping arrangement (20), is also provided with a pitch at the same time.
  7. Device according to any one of Claims 1 to 6, comprising:
    - a receiving arrangement (60) for positioning a core (3), in particular a closed core, of an inductive component (4), in particular of a transformer, in the device,
    - wherein the shaping arrangement (20) and the pitch-producing arrangement (30) are arranged around the receiving arrangement (60) in such a way that the wire (2) is wound in a coiled manner around the core (3) of the inductive component when the core (3) of the inductive component is positioned in the receiving arrangement (60) and the wire (2) is guided through the shaping arrangement (20) and the pitch-producing arrangement (30).
  8. Device according to any one of Claims 1 to 7, comprising:
    - a pre-bending arrangement (70) for bending an end portion (A) of the wire (2),
    - wherein the wire (2) can be clamped in the advancing arrangement (10) in such a way that the end portion (A) of the wire protrudes from the advancing arrangement (1),
    - wherein the pre-bending arrangement (70) is formed in such a way that the end portion (A) of the wire (2) protruding from the advancing arrangement (10) can be laid in the shaping arrangement (20) following the bending by means of the pre-bending arrangement (70),
    - wherein the pre-bending arrangement (70) has a guide (75) for receiving the wire (2),
    - wherein the pre-bending arrangement (70) is formed in such a way that the pre-bending arrangement can be displaced from a first position (P1) at a distance from the end portion (A) of the wire (2) protruding from the advancing arrangement (10) into a second position (P2), in which the end portion (A) of the wire protruding from the advancing arrangement (10) lies in the guide (75) of the pre-bending arrangement (70).
  9. Method for winding a wire for an inductive component, comprising the following steps:
    - providing a device for winding a wire,
    - advancing the wire (2) in the device in such a way that the wire is fed to a shaping arrangement (20) and a pitch-producing arrangement (30),
    - bending the wire (2) as said wire is guided through the shaping arrangement (20) and the pitch-producing arrangement (30), in such a way that the wire (2) is bent in a coiled manner,
    - wherein the shaping arrangement (20) has a base face (21) for supporting the wire (2) and at least one side wall (22),
    - wherein the at least one side wall (22) has a curved course,
    - wherein the shaping arrangement (20) is formed in such a way that the wire (2) as it is advanced in the shaping arrangement (20) is bent along the side wall (22) and wherein the shaping arrangement (20) is open on the side opposite the base face (21).
  10. Method according to Claim 9, comprising:
    - arranging a closed core (3) of an inductive component (4) in the receiving arrangement (60) in order to position the core (3),
    - winding the wire (2) around a leg of the closed core (3) by advancing the wire (2) in the shaping arrangement (20) and the pitch-producing arrangement (30).
EP14805542.9A 2013-11-25 2014-11-25 Device, and method for winding a wire for an inductive component Active EP3074989B1 (en)

Applications Claiming Priority (2)

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DE102013113005 2013-11-25
PCT/EP2014/075531 WO2015075261A1 (en) 2013-11-25 2014-11-25 Inductive component, device, and method for winding a wire for an inductive component

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JP (2) JP6471310B2 (en)
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US20180358176A1 (en) 2018-12-13
JP6471310B2 (en) 2019-02-20
US10079093B2 (en) 2018-09-18
US20160268043A1 (en) 2016-09-15
DE112014005353A5 (en) 2016-08-04
WO2015075261A1 (en) 2015-05-28
JP2019071443A (en) 2019-05-09
EP3074989A1 (en) 2016-10-05
JP2017500737A (en) 2017-01-05

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