GB2261681A

GB2261681A - Electric coil winding

Info

Publication number: GB2261681A
Application number: GB9124520A
Authority: GB
Inventors: Rudi Renner; Stefan Nowak
Original assignee: Siemens Matsushita Components GmbH and Co KG
Current assignee: TDK Electronics AG
Priority date: 1990-05-21
Filing date: 1991-11-19
Publication date: 1993-05-26
Also published as: EP0457933B1; DE59009023D1; JPH04229608A; GB9124520D0; EP0457933A1

Abstract

To wind a coil, wire feed nozzle 14 is rotated to wind wire about connector pin 16. Former 15 is then rotated, via gear 23, to wind the coil body, and nozzle 14 is again rotated first to wind wire about pin 17, and then about pin 18. Wire between such adjacent pins may be cut as winding proceeds, or after winding. The wound pins may be pressed into former 15 to minimise their length (Fig. 9). The wound former may be bonded to core 22. The pins may extend axially of the former (Fig. 11). Winding may use several wire feeds simultaneously. The wire turns may be soldered to the pins. An adaptor may be connected to the non-wound pin ends (Figs. 15, 16). <IMAGE>

Description

improvements in or relating to Coils This invention relates to coils and

is concerned with coils including an open, divided or closed coil former to be wound with wire. The winding may be completely automatic and result in the formation of gemometrically differently open or closed core systems.

Core formers conventionally comprise a core body around which wire is wound and at least two connector pins electrically connected to the wire. It is known from the prior art that the process of attaching the wire to the connector pins and the winding of the wire about the core body in geometrically differently closed core systems are operations which are carried out separately from each other. When winding the core former therefore, the beginning and the end of the wire are in the form of floppy free ends which have to be picked up again in a separate operation and wound onto the connector pins for example an adaptor. 20 It is an object of the present invention to provide a coil former which enables the attachment of the wire to the pins and the winding of the wire about the core body to be carried out in an economical and expedient manner. 25 This object is achieved by attaching the wire to the connector pins and rotating the pins with respect to the wire. According to the present invention, there is provided a process for producing a coil which comprises:

(i) providing a coil former comprising a core body and first and second connector pins, (ii) feeding wire from a source to the first 35 connector pin and winding the wire around the first connector pin by subjecting the source and the first connector pin to relative rotation about one another, rotating the core body with respect to the source to wind the wire around the core body, and winding the wire around the second connector pin by subjecting the source and the second connector pin to relative rotation about one another.

The invention is particularly suitable for the production of coils for chokes, transformers or the like.

- It is particularly advantageous if the connector pins are movably mounted on the core body. In this case the connector pins may be mounted on the core body so as to be movable in the direction of their longitudinal axes.

In an embodiment the core body includes a plurality of axially spaced zones, and connector pins are provided for each zone. In this case the wire is directly connected to the connector pin of the next zone after each individual zone has been wound when winding several zones in succession. The wire between the individual zones is then severed after completion of the winding operations. A plurality of zones may be wound simultaneously using a corresponding number of wire feeds.

For a better understanding of the. invention and to show how the same may be carried into effect, reference will now be made by way of example only, to the following drawings, in which: Figure 1 shows a side view of one embodiment of a coil former, 35 Figure 2 shows a side view of the coil former of Figure 1 illustrating the winding of wire onto a first (iii) (iv) connector pin prior to winding the wire onto the core body, Figure 3 shows an end view of the coil former of Figure 2, 5 Figure 4 shows a side view of the coil former of Figure 3 in which the winding of a first zone of the core body is taking place, Figure 5 shows an end view of the coil former of Figure 4 at the next stage and where the wire is being wound onto the second connector pin, Figure 6 shows a side view of the coil former of Figure 5 completely wound, Figure 7 shows a side view of another embodiment of acoil former, partially wound, Figure 8 shows a cross-sectional view of the coil former of Figure 7 along the line VIII to VIII in Figure 7, Figure 9 shows a side view of the coil former of Figure 7 where several individually fed zones of the core body are being wound simultaneously, Figure 10 shows an end view of the wound coil former of Figures 7 to 9, Figure 11 shows a side view of a third embodiment of a coil former, Figure 12 shows an end view of the coil former of Figure 11, Figure 13 shows a side view of the coil former of Figure 11 after winding, Figure 14 shows a side view of another embodiment of a coil former, fully wound, Figure 15 shows an end view of the coil former of Figure 14 connected to an adaptor, and Figure 16 shows a side view of the coil former of Figure 15.

Referring now to Fig. 1 there is shown a coil former 1 which is rotatably mounted on a closed core 2.

The coil former 1 includes a coil body having axially spaced regions 9, 10 and 11 constituting separate winding chambers. The coil former includes a plurality of connector pins 3 to 8, a pair of connector pins being associated with each chamber. Each connector pin extends beyond the core body in a radial plane passing through the core former. The coil former includes a gear wheel 12 which is used to rotate the coil former 1.

Fig. 2 shows a nozzle 14 constituting a source of wire 13 to feed to the coil former. The wire 13 is first of all wound about the first connector pin 3 by rotating the nozzle 14 about the connector pin 3. Then the nozzle 14 is moved to the first winding chamber 9.

Figs. 3 and 4 show that the coil former 1 is set into rotation in the direction of arrow 15a so that the wire 13 is pulled out of the nozzle 14 and an appropriate number of turns is applied to the first winding chamber 9.

Fig. 5 shows that when the winding operation in chamber 9 is over, the wire 13 is then wound on the second connector pin 5 by rotating the nozzle 14 about the pin 5. Thus the winding of winding chamber 9 is completed. The foregoing procedure is then repeated, in respect of the next chamber 10 by winding the wire about first connector pin 4, the chamber 10, and the second connector pin 7. Similarly, the chamber 11 is wound by winding the wire about first connector pin 6, the chamber 11, and the second connector pin 8.

Fig. 6 shows the resultant fully wound coil former 1. In this exemplary embodiment the wire 13 is cut off after being wound about each of the second connector pins 5 and 7 before being wound around the connector pins 4 and 6 of the next chambers.

However, it is also possible to guide the wire 13 directly from each first connector pin to the next second connector pin and to continue the winding. Then when the winding has been completed, the connecting wires between the individual winding chambers of the coil formers are severed. In a similar way, adjacent coil formers can be wound using a continuous wire followed by severing of the wire between adjacent coil formers.

Furthermore the winding of the wire onto the connector pins and the winding of the wire on to the core body may be carried out using several wire feeds simultaneously.

The final completion of the coil in one operation allows the subsequent joining of the wires and connector pins, e.g. by dip soldering, as well as electrical testing, to take place immediately.

Referring now to Figures 7 to 10, there is shown a schematic representation of the winding of the wire onto the pins and the winding of the wire onto the core body in the case where coil former 15 has movable connector pins 16 to 21. The coil former 15 is rotatably arranged on a closed core 22 and can be rotated with the aid of gear wheel 23. As can be seen from Fig. 8, the connector pins 16 to 21 are arranged in the coil former 15 in such a way that they project on both sides to the same degree. Thus the intermediate space 24 between coil former 15 and core 22 can be further reduced with respect to the exemplary embodiments shown in Figs. 1 to 6. 30 It can be seen from Fig. 9 that following the winding of the wire onto the connector pins 16 to 21, the pins are pressed downwards along their longitudinal axes in the direction of the arrows 25. In this way, on the one hand the winding on the pins is protected and on the other hand the desirable free minimum length of the connector pins 16 to 21 is achieved.

Fig. 10 shows that after the winding has been completed the coil former 15 is fixed in the correct position with respect to the core 22, e.g. by an adhesive 26, so that it is no longer rotatable about 5 the core.

Figs. 11 to 13 show an exemplary embodiment in which a coil former 27 is rotatably arranged on a core 28. In this case, the coil former 27 has axial connector pins 29 to 34.

After the wire 13 has been attached to first connector pin 29 by the nozzle 14, the coil former 27 is set into rotation with the aid of gear wheel 43 in order to produce the appropriate number of turns of wire.about the core body of the core former 27.

After completion of the coil, the coil former 27 is slid along the core 28 and is fixed in its correct position by a means 35 (e.g. adhesive) to prevent rotation of the core former 27 about core 28.

It will be appreciated that, instead of using gear wheels 12,23 and 43, the core former can be rotated by some other means, for example, a friction drive.

The exemplary embodiments shown in Figs. 1 to 13 require no connecting adaptor since the connector pins themselves can be used as connector elements.

However, it is also possible, as shown in Figs. 14 to 16, to connect a coil former 36 by means of an adaptor 38. When the winding has been completed, the coil former 36 is placed onto the adaptor 38 which is used as a connection for the coil and also prevents the coil former rotating with respect to the core 37. The non-wound ends of the connector pins 39 to 42 are connected to the adaptor.

Apart from the closed core systems described in the exemplary embodiments, it is also possible to utilise the coil former in open core systems. Apart from the closed coil formers shown, divisible or open -7 coil formers can also be used. Also one or several coil formers can be arranged on a core, and can be processed either at the same time or one after the other.

As a further exemplary embodiment it is possible for the attachment of the wire to the connector pins and the winding of the wire on the core body to be carried out by rotation of the core and the wire source in the case of a fixed coil former.

The invention ensures that the attachment of the wire to the connector pins and the winding of the wire on the core body can be carried out economically and expediently.

Claims

1.

(i) (ii) (iii) (iv) Process for producing a coil which comprises: providing a coil former comprising a core body and first and second connector pins, feeding wire from a source to the first connector pin and winding the wire around the first connector pin by subjecting the source and the first connector pin to relative rotation about one another, rotating the core body with respect to the source to wind the wire around the core body, and winding the wire around the second connector pin by subjecting the source and the second connector pin to relative rotation about one another.

2. Processing according to claim 1 wherein the core body includes a plurality of axially arranged regions and a pair of first and second connector pins is provided for each region, in which process each region of the core body is wound sequentially with the wire being fed from the second connector pin of one region to the first connector pin of the next succeeding region.

3. Process according to claim 2 wherein the wire extending between the second connector pin of said one region and the first connector pin of said next succeeding region is severed.

4. Process according to claim 1 wherein the core body includes a plurality of axially arranged regions and a pair of first and second connector pins is provided for each region, in which process each region is fed with wire from a different source.

5. Process according to claim 1 wherein a -g- plurality of said core formers is provided, in which process the core body of each core former is wound sequentially with the wire being fed from the second connector pin of one of the core formers to the first 5 connector pin of the next succeeding core former.

6. Process according to claim 5 wherein the wire extending between the second connector pin of said one of the core formers and the first connector pin of said next succeeding core former is severed.

7. Process according to claim 1 wherein a plurality of said core formers is provided in which process each core former is fed with wire from a different source.

8. Process according to any preceding claim wherein the coil former is rotated with respect to the source by means of a gear or friction drive.

9. Process according to any preceding claim wherein the core former is mounted for rotation about a core, which process comprises the additional step of fixing the core former with respect to the core, after the wire has been wound around the core body.

10. Process according to claim 9 wherein the core former is fixed by means of an adhesive.

11. Process according to any preceding claim wherein the connector pins extend axially with respect to the core body.

12. Process according to any one of claims 1 to 10 wherein each connector pin protrudes from the core body in a radial plane passing through the core former. 30

13. Process according to any preceding claim wherein the connector pins are movable with respect to the core body.

14. Process according to claim 13 wherein the connector pins are displaceable along their longitudinal axes.

15. Process according to claim 1 substantially as hereinbefore described with reference to and as illustrated in Figures 1 to 6, Figures 7 to 10, Figures 11 to 13, or Figures 14 to 16 of the accompanying drawings. 5

16. A coil whenever produced by the process claimed in any preceding claim.

17. A coil as claimed in claim 16 and including an adaptor connected to the connector pins.

18. A coil former comprising a core body and first and second connector pins being movable with respect to the core body.