JP2000021669A - Method and device for manufacturing electromagnetic coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a method and device for manufacturing an electromagnetic oil which is small-sized and superior in strength. SOLUTION: A sheet conductor 3A from a coil 5 wound around a roller 6 has both its end surfaces made semicircular through an end surface machining part 7. Then a foreign matter removal part 8 removes foreign matters on the outer periphery, and the sheet conductor is wound around a spool 14 via a resin bath 11 for epoxy resin. The spool 14 is wound with an insulating tape 15 in advance to form an insulating cylinder 1A. After the conductor is wound, an outer periphery insulating layer is formed of the insulating tape 15 and is made to cure being irradiated with a light from a heating device 16.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electromagnetic coil such as a transformer or a reactor used for power transmission and reception and distribution, and more particularly to a method and an apparatus for manufacturing an electromagnetic coil having a conductor formed of a strip and a sheet.

[0002]

2. Description of the Related Art Transformers and reactors used for electric power and industrial use use conductors having a larger cross-sectional area as the capacity increases, and these conductors include various types such as round wires, flat wires, strips, sheets, and the like. Is adopted according to the specifications of the transformer.

[0003] Of these, strip and sheet conductors are employed in various transformers because of their simple winding configuration and easy winding operation. In particular, since there is no complicated winding work in which winding is performed using multiple flat wires and transposition occurs in the middle of the winding to reduce eddy current loss, it is widely used for oil-immersed transformers and molded transformer coils. Have been.

An example of a conventional electromagnetic coil using a strip and a sheet-like conductor will be described below with reference to FIG. FIG. 7 is a partial sectional view of a general molded transformer using a strip and a sheet-like conductor. A secondary coil 41 and a primary coil 42 are arranged concentrically around an iron core 40.

[0005] Of these, the secondary coil 41 is a sheet-like conductor made of an aluminum material with respect to the outer periphery of an insulating cylinder 1B made of reinforced plastics (FRP) made of epoxy resin glass fiber also serving as a winding frame. 3B and an insulating sheet 45 such as PET film or aramid paper wound a predetermined number of times.

With respect to the outer periphery of the insulating sheet 45,
An outer peripheral insulating layer 4B is formed by winding an epoxy glass prepreg tape or the like. The upper end 47 of this secondary coil 41
The lower end 48 is filled with an epoxy resin or the like to form an integral secondary coil 41.

In the method of manufacturing the secondary coil 41, first, the insulating cylinder 1B having mechanical and electrical strength is attached to the winding core of the winding machine. One end of the sheet-like conductor 44 to which the winding start terminal is connected is fixed thereon, and the sheet-like conductor 44 and the insulating sheet 45 are wound a predetermined number of times while applying tension.

Then, after connecting and fixing the winding end terminals, the outer peripheral insulating layer 4B is formed with an epoxy prepreg tape or the like, removed from the winding machine, and the outer peripheral insulating layer 46 is heated and hardened. Next, epoxy resin is poured into the end portions 47 and 48 to be cured, thereby obtaining the secondary coil 41 whose outer periphery is covered with the insulating layer.

A primary coil 42 inserted at a predetermined gap outside the secondary coil 41 is a block coil 51 made of an aluminum strip conductor 49 and an insulator 50 such as a PET film.
Are stacked in the axial direction by spacers (not shown) and connected in series, and then integrally molded with an epoxy resin 52 mixed with a filler.

In manufacturing the primary coil 42, first, a winding start end of an aluminum strip conductor 49 having a predetermined width is fixed on a winding frame (not shown), and is wound a predetermined number of times while applying tension together with the insulator 50. Thereafter, the block coil 51 is manufactured by fixing with a glass tape or the like.

[0011] Six block coils 51 are stacked and stacked in a mold (not shown) via a spacer, and after connecting each block coil 51, an outer mold is assembled, preheated and heated, and then filled in a vacuum tank. The epoxy resin 52 mixed with the material is injected and cured by heating.

Among these, the secondary coil 41 generates an electromagnetic force in a direction in which the diameter on the inner peripheral side becomes smaller due to the current at the time of short circuit. With respect to this electromagnetic force, the thickness of the insulating tube 1B is increased to increase the strength or the FRP is provided between the iron core 40 and the insulating tube 1B so that the thin sheet-shaped conductor 3B cannot withstand and buckle. Equal spacing pieces are inserted to increase the strength against electromagnetic force when the secondary coil 41 is short-circuited.

Further, an insulating sheet such as PET film or aramid paper having a thickness of 0.05 to 0.25 mm is processed into a prepreg sheet or an insulating sheet coated with an adhesive and wound, and the space between the sheet-like conductors 44 is heated or the like. In some cases, the rigidity is increased by bonding. The potential between the layers between the conductors 44 and 49 of the coils 41 and 42 varies depending on the capacitance, but is at most several tens of volts in use.

[0014]

Therefore, although a very thin insulating layer should be able to endure, when the insulating sheet 45 and the insulating material 50 are wound together with the strip conductor 49 and the sheet conductor 3B, meandering or wrinkling occurs. Since tension is applied in order to prevent such a problem, there is a possibility that the film will be cut if it is too thin. Therefore, a material thicker than necessary for insulation is used.

For this reason, not only the thermal conductivity is deteriorated, but also an obstacle to miniaturization. Furthermore, the sheet-like conductors 3B,
When simultaneously winding different materials of the insulator 49, the insulator sheet 45, and the insulator 50, meandering or swelling is apt to occur due to tolerance of these materials and a change in thickness due to moisture absorption, and it takes time to adjust them.

In particular, the block coil 51 of the strip conductor 49 having a small current carrying capacity, such as the primary coil 42, generally has a small thickness of the insulator 50 because the thickness of the strip conductor 49 itself is small. Then, damage to the insulator such as sharing occurs at the end face portion of the strip conductor 49, so that careful control of the tension and the like is required.

In addition, in order to reduce the width of the transformer to reduce the size and weight, the use of a rectangular tube-shaped coil has been increasing. Since it is wound in a rectangular cylindrical shape with a stretchable material, it is easier to swell in the straight part between the corners than in the cylindrical shape, the thermal conductivity is worse than the interstage insulator, and the current carrying capacity, that is, the rated current Is an obstacle to increase.

Further, the mechanical force at the time of short-circuiting of the rectangular tube-shaped coil is not uniformly distributed in the circumferential direction as in the case of the cylindrical coil, but there is a portion where a concentrated load is generated. Therefore, it is necessary to reinforce or increase the rigidity. Accordingly, it is an object of the present invention to provide a method and apparatus for manufacturing a compact electromagnetic coil having excellent strength.

[0019]

According to a first aspect of the present invention, there is provided a method of manufacturing an electromagnetic coil, comprising the steps of: forming an end surface of a continuously supplied conductor into a curved surface; It is characterized by comprising an attaching step of attaching the resin, a molding step of winding the conductor around the bobbin while heating the resin on the surface of the conductor, and a curing step of heating and curing the resin of the molded conductor.

According to a second aspect of the present invention, there is provided an apparatus for manufacturing an electromagnetic coil, comprising: a resin tank in which a conductor continuously drawn out from a wound and rotated coil is immersed and a thermosetting resin is stored; And a heater for winding the conductor to which the thermosetting resin has adhered, and a heater for heating the adhered thermosetting resin adjacent to the winding frame.

According to a third aspect of the present invention, there is provided an apparatus for manufacturing an electromagnetic coil, comprising: a powder tank in which a conductor continuously fed from a wound and rotated coil passes; It is characterized by comprising a winding frame for winding the conductor to which the powder resin has adhered through the tank, and a heater adjacent to the winding frame for heating the adhered powder resin.

According to a fourth aspect of the present invention, there is provided an apparatus for manufacturing an electromagnetic coil, in which a conductor continuously fed from a wound and rotated coil is immersed, a solution in which resin fine particles are dispersed and suspended is stored, and the fine particles are charged. It is provided with an adhesion tank to which a voltage is applied between the conductor, a bobbin for winding the conductor to which the fine particles adhere through the adhesion tank, and a heater disposed adjacent to the bobbin and heating the adhered fine particles. It is characterized by having.

According to a fifth aspect of the present invention, there is provided an apparatus for manufacturing an electromagnetic coil, comprising:
A preheater is provided for preheating thermosetting resin, powder resin, or fine particles of the conductor.

According to a sixth aspect of the present invention, there is provided an apparatus for manufacturing an electromagnetic coil, comprising: an end face processing section for forming an end face of a continuously fed conductor into an arc shape; and a foreign matter adhering to the conductor coming out of the end face processing section. A foreign matter removing unit for supplying a conductor to a resin tank, a powder tank, or an adhesion tank is provided.

According to a seventh aspect of the present invention, there is provided an electromagnetic coil manufacturing apparatus which is wound around an outer periphery of a bobbin to form an insulating inner cylinder,
An insulating sheet drum is provided, which supplies an insulating sheet wound around the outer periphery of the conductor wound on the insulating inner cylinder to form an outer peripheral insulating layer to the reel.

According to an eighth aspect of the present invention, there is provided an apparatus for manufacturing an electromagnetic coil, wherein both sides of an insulating inner cylinder and an outer peripheral insulating layer protrude from both sides of a wound conductor, and an end portion is formed on the outer periphery of the conductor between the projecting portions. An insulating layer is formed.

According to the first to fourth aspects of the present invention, a thin and uniform insulating film in close contact with the conductor is formed on the surface of the conductor of the coil. Further, in the invention corresponding to claim 5, in particular, the fluidity of the insulating resin attached to the conductor to be wound is increased to facilitate the formation of a thin film, and the curing time after forming the coil is shortened.

In the invention corresponding to claim 6, the thickness of the insulating film formed on the end face of the coil is made uniform, and
The concentration of the stress applied to the insulating film in this portion is reduced. In the invention corresponding to claim 7, molding of the coil including the insulating inner cylinder and the outer peripheral insulating layer is performed continuously. Further, in the invention corresponding to claim 8, the insulation at the end of the coil, which is only the insulating film, is strengthened, and the rigidity of the entire coil is increased.

[0029]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a layout explanatory view showing a first embodiment of a method and an apparatus for manufacturing an electromagnetic coil according to the present invention, and corresponds to claim 1; FIG. 2 is similar to FIG.
It is a partial expanded sectional view of the electromagnetic coil manufactured by the arrangement explanatory view shown by.

In FIG. 2, the outer circumference of the insulating cylinder 1A made of epoxy glass prepreg tape is
Sheet-shaped conductor 3A provided with insulating coating 2 as described later
The outer peripheral insulating layer 4A made of an epoxy glass prepreg tape is formed on the outside thereof in the same manner as in the related art.

In FIG. 1, a coil 5 is formed by winding an aluminum or copper hoop conductor cut to the width of the coil.
Is inserted into the roller 6 of the winding machine equipped with a feed mechanism, and the sheet-shaped conductor 3A is sequentially fed out.

Since both end surfaces of the sheet-shaped conductor 3A are in a sheared state, they have a return or a sharp cut.
First, it is passed through the end face processing portion 7. In this end surface processing section 7, the end surface of the sheet-shaped conductor 3A is pressed by a roller to flatten the return and the like and to process the circular and smooth end surface with a die.

Next, the foreign matter adhering to the sheet-like conductor 3A is passed through a foreign matter removing section 8 for removing the foreign matter with a brush, a magnet, vacuum suction, or the like, and the sheet-like conductor 3A from which the foreign matter has been removed is passed through rollers 9A and 9B.
After passing through a resin tank 11 in which the resin 10 is stored, the coating film thickness is adjusted by a coating film thickness adjusting unit 12 such as a roller, and then, through a roller 9C, a winding die 14 to which a winding core 13 is attached is formed. Wind a predetermined number of times.

As shown in FIG. 1, an insulating cylinder 1A on which an insulating tape 15 such as an epoxy glass prepreg tape is wound is formed on the former 14 in advance. In the winding part as a coil, a heating device 16 such as infrared rays is provided,
It promotes curing of the resin adhered to the insulating cylinder 1A and the sheet-shaped conductor 3A.

The insulating tape 15 is wound when forming the insulating cylinder 1A and the outer peripheral insulating layer 4 of FIG. Further, in the coil winding portion, the pressure roller 17 is used by moving up and down as shown by arrows in order to uniformly and densely wind between the sheet-shaped conductors 3A of each layer.

Next, the operation of the method and the apparatus for manufacturing the electromagnetic coil of the first embodiment will be described. In the present embodiment, since the insulating tube 1A is wound while applying heat and pressure to the insulating tape 15, a strong and dense insulating layer is formed after winding, and the insulating tape 1A is excellent in thermal, mechanical, and electrical properties. It becomes a thin insulating layer.

The sheet-shaped conductor 3A is wound thereon. The sheet-shaped conductor 3A is wound while applying heat and pressure to the resin 10 applied to the surface at the time of winding. Is firmly adhered, the rigidity of the electromagnetic coil is increased, and the electromagnetic coil becomes mechanically excellent.

Further, since a thin resin layer is formed between the sheet-shaped conductors 3A, heat conduction is improved, and the layer can withstand a voltage of several tens of volts between layers. After the thin film is formed, it is integrated as a coil and there is no processing to bend it in the state of a cured film like an enameled wire, so not only does not cause crazing or damage the insulating layer, but also in a continuous process Since it is completed, work efficiency can be increased.

In the present invention, the hoop material cut and coiled is set in a winding machine, and the end face is processed in the winding process, so that there is no conventional rewinding operation. Since the thin insulating coating film is uniformly adhered and the stress is not concentrated by the end face processing, it is possible to prevent a short circuit between the conductors at the end face due to meandering or pressing during winding.

The foreign matter removal is generally not attached to a winding machine because the winding operation is performed in a dust-proof room, but in the present invention, the end face processing is performed during the winding operation and it becomes an insulating layer of a thin film. In addition, the quality is improved.

As a method for removing foreign matter, there are methods of removing foreign matter on the surface with a brush, removing iron-based foreign matter with a magnet, and sucking by vacuum suction, and these are used alone or in combination.

The resin can be attached to the conductor by passing it through a resin layer containing an epoxy resin or a varnish for an enamel film. The thickness of the coating can also be adjusted by the conductor's passing speed and the viscosity of the resin, etc. Deploy.

Since the conductor having a constant coating thickness is wound around the outer periphery of the inner cylinder while being heated and pressurized, the conductor is joined to the insulating cylinder, and the conductors are also joined. At this time, due to the heating and pressurization, an insulating layer of several microns to several tens of microns is formed, and a coil having excellent heat conductivity and a small external shape as compared with a method in which interlayer paper is inserted is obtained.

Since the outer periphery of the conductor is wound while being heated and pressed with an epoxy glass prepreg tape or the like in the same manner as the insulating cylinder, a strong integral coil is formed as a whole. Because the outer periphery is covered with resin, it can be used for dry transformers, oil-filled transformers, and gas-insulated transformers.

Further, since the conductors are firmly and integrally fixed to each other with the insulating coating film 10, the coil has high rigidity and has a high overcurrent strength, which is coupled with an improvement in thermal conductivity. To increase the current capacity.

In the case of an aluminum material, in this embodiment, if a peroxidation treatment is performed in a post-process of the foreign substance removing section 8 to form an aluminum oxide film on the surface of the aluminum conductor, the aluminum oxide film is made of an insulator. Because of this, the resin layer only needs to be coated on one side for bonding, and the insulating layer between conductors can be made thinner. In addition, since the application surface is on one side, it is possible to directly heat with a heating device, and it is possible to further shorten the curing time.

FIG. 3 is a layout explanatory view showing a second embodiment of the method and apparatus for manufacturing an electromagnetic coil according to the present invention.
FIG. 13 is a diagram corresponding to another example of FIG. 1 shown in the above-described embodiment. In FIG. 3, the difference from FIG.
2 is the same as FIG. 2 except that the resin 10 attached to the conductor 3A is preheated at 18.

That is, between the winding frame 14 and the roller 9C on the upstream side of the winding frame 14, a heating device 18 having the same shape as the heating device 16 in the final step is provided below the sheet-shaped conductor 3A. . In this method, the resin and the conductor are heated before winding on the coil, so that the curing of the resin can be promoted and the winding speed of the coil can be increased. By heating before winding, voids formed in the resin layer can be prevented.

That is, depending on the type of the resin 10, it is better to gradually heat the resin 10 and raise the temperature while curing the resin 10 in order to form a uniform thin film. For example, when forming a thin coating film by lowering the viscosity of the resin, a diluent or a solvent is used for the resin.

This diluent or solvent foams when rapidly heated to form voids that reduce thermal conductivity and insulation. Therefore, by heating before winding, the solvent and the like are vaporized and released, thereby forming voids. Prevent formation.

Further, even when the film is thickened, it can be cured by heating before coil winding to prevent the flow of the coating resin at the time of coil winding. Can be prevented.

In the case of a resin that cures slowly, the resin is brought into a fluid state only by heating at the time of coil winding, and is extruded from an end face by the pressure at the time of coil winding to form a thin film. Accelerates curing and efficiently manufactures coils with uniform film thickness.

In this case, in the case of using a catalyst which promotes the reaction by ultraviolet rays as the resin, the same effect can be obtained if the heating device is a light source of ultraviolet rays. That is, the heating device may select either heat or light depending on the type of reaction for curing the resin.

FIG. 4 is a layout explanatory view showing a third embodiment of the method and apparatus for manufacturing an electromagnetic coil according to the present invention, and corresponds to FIGS. 1 and 3 shown in the above-described embodiment.
FIG. 4 differs from FIG. 3 shown in the above-described embodiment in that the resin tank 11 shown in FIG.
Instead, a powder tank 19 was installed.

That is, the conductor 3A from which foreign matter on the surface has been removed by the foreign matter removing unit 8 is passed from the roller 9B to the conductor 3A through the powder tank 19 in which the powdered epoxy resin powder 22 is stored.
Powder 22 is adhered to the surface of.

In the powder tank 19, the epoxy powder resin 22 is blown up with compressed air 21 toward the positively charged wire mesh electrode 20 to charge the powder 22 positively. The sheet-shaped conductor 3A is negatively charged via a roller or the like, and the sheet-shaped conductor 3A is
The powder 22 is electrostatically attached to the substrate.

While the powder 22 on the sheet-like conductor 3 is melted and hardened by the heating device 18 with the powder 22 adhered, the winding frame 14 is heated and pressed by the heating device 16 and the pressing roller 17. Wrap.

In order to apply the powder 22 to the sheet conductor 3A, the heating device 18 is disposed in front of the powder tank 19 to heat the sheet conductor 3A and put the powder 22 in the air in a dusty state. The powder that has been sprayed and touched the surface of the conductor may be melted and adhered by heat. This method using powder is suitable for forming a film having a thickness of about 100 μm, and suitable for forming a thick film on a thick strip or sheet conductor.

In this case, when the coil is wound,
The stress applied to the adhesion layer is different between the inner circumference and the outer circumference of the bent part,
When the film is completely cured and hard, a hair crack occurs on the outer peripheral side. However, in the present invention, the curing is in progress at the time of winding and the film layer is elongated, so that the hair crack does not occur.

FIG. 5 is a layout explanatory view showing a fourth embodiment of the method and apparatus for manufacturing an electromagnetic coil according to the present invention, and corresponds to FIGS. 1 to 4 shown in the aforementioned embodiment. FIG.

FIG. 5 is different from FIG. 4 shown in the above-described embodiment in that an adhering tank 24 into which a solution described below is injected is provided instead of the powder tank 19 shown in FIG. .

That is, the sheet-like conductor 3A from which the foreign matter on the surface has been removed by the foreign matter removing unit 8 passes directly through the adhesion tank 24,
The winding process is started from the rollers 9B and 9C and above the heating device 18. An epoxy resin solution 23 in which gel fine particles are dispersed is injected into the adhesion tank 24, and an electrode 25 whose lower end is opposed to above the roller is vertically provided at the center.

A conductor 3 is provided between the electrode 25 and the conductor 3A.
A DC voltage is applied, with the A side as the positive electrode side and the electrode 25 side as the negative electrode side. The application of this voltage charges the fine particles in the solution 23, and the charged fine particles move toward the sheet conductor 3A by the electrophoresis phenomenon, so that the fine particles adhere to the sheet conductor 3A.

The electrode 25 in the container 23 is arranged to make the gap between the electrode 25 and the sheet conductor 3A as small as possible and to easily generate the electrophoresis phenomenon, and the adhesion tank 24 is also on the negative electrode side. In the subsequent steps, as in the embodiment shown in FIG. 3 and FIG.
In the winding step by step 16, an electromagnetic coil with no step paper is formed.

According to the present embodiment, a thin resin layer is formed on the surface of the conductor by continuously attaching the gel-like fine particles in the solution to the surface of the conductor in the adhesion tank 14. Similarly to the above, it is possible to obtain a method and apparatus for manufacturing an electromagnetic coil capable of forming a thin and uniform interstage insulating layer, having excellent heat transfer, and having a small outer shape. In addition, by using an epoxy resin mixed with a filler of fine particles for the solution, an electromagnetic coil having flame retardancy and excellent heat resistance can be obtained.

FIG. 6A is a partial cross-sectional view showing a fifth embodiment of the method and apparatus for manufacturing an electromagnetic coil of the present invention, and particularly corresponds to FIG. 2 shown in the first embodiment. FIG. 14 is a diagram corresponding to item 8.

In FIG. 6A, the difference from FIG. 2 described above is that the width of the insulating cylinder 1B and the outer peripheral insulating layer 4B is wider than the width of the sheet conductor 3A, and thick insulating layers are formed on both sides. That is.

That is, the insulating cylinder 1 shown in FIG.
A and the outer peripheral insulating layer 4B are formed between the insulating cylinder 1B and the outer peripheral insulating layer 4B formed of the prepreg material to have a width larger than the width of the sheet-like conductor 3A therebetween. The recesses 26 and 27 formed between both sides of the formed sheet conductor 3A are filled with a compound obtained by mixing an inorganic filler in epoxy resin.

In this case, since the deformation can be prevented by the compound insulating layers formed on both sides where the stress received by the electromagnetic force due to the fault current is maximized, the overcurrent strength of the electromagnetic coil can be further increased. . FIG.
The electromagnetic coil shown in (a) may be manufactured not only in the steps shown in FIG. 2 but also in the steps shown in FIGS. 3, 4 and 5.

FIG. 6B is a partial sectional view showing a sixth embodiment of the method and apparatus for manufacturing an electromagnetic coil according to the present invention.
FIG. 6C is an enlarged detailed view of the block coil 28 shown in FIG. 6B, corresponding to the primary coil of FIG. 7 shown in the prior art.

In the electromagnetic coil shown in FIG. 6B, a release material is applied to the outer periphery of the insulating cylinder 1B in the process of manufacturing the electromagnetic coil shown in FIG. 6 in which the step of forming the outer peripheral insulating layer 4 is omitted.
After six block coils 28 shown in (c) are overlapped and connected to a casting mold via a not-shown interval piece inserted between them, epoxy resin is injected between and around these block coils 28. Thus, an insulating layer 29 is formed.

In this case, if the primary voltage of the step-down transformer having a high primary voltage and a large primary / secondary turns ratio is adopted as the primary coil 42 shown in the prior art of FIG. 7, excellent mechanical and electrical characteristics are obtained. In addition, an electromagnetic coil having a small external shape can be obtained.

In the above embodiment, the case where the material of the coil is a sheet-like conductor has been described, but the same applies to a material manufactured as a strip. However, in this case, in the case of a material whose both end surfaces are formed into a curved surface, the end surface processed portion 7 can be omitted. In the heating device 16 in the final step, the heating may be performed to such an extent that the shape is not lost, and may be completely cured in a heating furnace common to other electric devices.

[0074]

As described above, according to the invention corresponding to claim 1, an end face processing step of processing the end face of a continuously supplied conductor into a curved surface, and an adhering step of adhering the resin to the surface through the conductor through the resin tank. And a molding process of winding the conductor around the bobbin while heating the resin on the surface of the conductor, and a curing process of heating and curing the resin of the molded conductor, thereby providing a thin and uniform insulating film that is in close contact with the conductor. Formed on the surface of the conductor of the coil, it is possible to obtain a method of manufacturing an electromagnetic coil capable of obtaining a compact electromagnetic coil having excellent strength.

According to a second aspect of the present invention,
A resin tank in which a thermosetting resin is stored by being immersed in a conductor continuously fed from a wound and rotated coil, and a bobbin for winding the conductor to which the thermosetting resin adheres while passing through the resin tank, By providing a heater that heats the thermosetting resin attached next to the winding frame, a thin and uniform insulating film that adheres to the conductor is formed on the surface of the coil conductor, so it is small and has excellent strength. An electromagnetic coil manufacturing apparatus capable of obtaining an improved electromagnetic coil can be obtained.

According to the third aspect of the present invention,
A powder tank in which a conductor continuously fed from a wound and rotated coil passes, and a powder tank in which the powder resin is stored, and a winding frame that passes through the powder tank and winds the conductor to which the powder resin is attached, By providing a heater that is attached to the winding frame and heats the adhered powder resin, a thin and uniform insulating film that adheres to the conductor and is formed on the surface of the coil conductor is small and has excellent strength. An electromagnetic coil manufacturing apparatus capable of obtaining an electromagnetic coil can be obtained.

In particular, the apparatus for manufacturing an electromagnetic coil according to the present invention is characterized in that a conductor continuously fed from a wound and rotated coil is immersed, a solution in which resin fine particles are dispersed and suspended is stored, and fine particles are collected. An adhesion tank in which a voltage to be charged is applied between the conductor, a bobbin that winds up the conductor to which the fine particles adhere through the adhesion tank, and a heater that is adjacent to the bobbin and heats the adhered fine particles. By providing a thin and uniform insulating film which is in close contact with the conductor and formed on the surface of the conductor of the coil, it is possible to obtain an electromagnetic coil manufacturing apparatus capable of obtaining a small and high-strength electromagnetic coil.

In particular, according to the invention corresponding to claim 5,
By providing a preheater for preheating the thermosetting resin, powder resin, or fine particles of the conductor between the resin tank, powder tank, or adhesion tank and the bobbin, the fluidity of the insulating resin attached to the conductor to be wound And the hardening time after forming the coil is shortened, so that it is possible to obtain an electromagnetic coil manufacturing apparatus capable of obtaining an electromagnetic coil having a small size and excellent strength.

In particular, according to the invention corresponding to claim 6,
An end processing section for forming an end face of a continuously fed conductor in an arc shape, and a foreign substance removing section for removing foreign substances adhering to the conductor coming out of the end processing section and supplying the conductor to a resin tank, a powder tank, or an adhesion tank. Is provided, the thickness of the insulating film formed on the end face of the coil is made uniform, and the concentration of the stress applied to the insulating film in this portion is also reduced, so that it is possible to obtain a small electromagnetic coil having excellent strength. An apparatus for manufacturing an electromagnetic coil can be obtained.

In particular, according to the invention corresponding to claim 7,
Insulation that is wound around the outer periphery of the bobbin and the conductor is wound around the outer periphery to form an insulating inner tube, and is wound around the outer periphery of the wound conductor and forms an outer peripheral insulating layer. By providing the sheet drum, since the molding of the coil including the outer peripheral insulating layer in the insulating inner cylinder was performed continuously, it is possible to obtain an electromagnetic coil manufacturing apparatus capable of obtaining a small and excellent electromagnetic coil. .

Further, according to the invention corresponding to claim 8, both sides of the insulating inner cylinder and the outer peripheral insulating layer protrude from both sides of the wound conductor, and the outer periphery of the conductor between the protruding portions is provided with an end insulating material. By forming a layer, the insulation at the end of the coil, which is only an insulating film, was strengthened, and the rigidity of the entire coil was increased.
An electromagnetic coil manufacturing apparatus capable of obtaining a compact electromagnetic coil having excellent strength can be obtained.

[Brief description of the drawings]

FIG. 1 is a layout explanatory view showing a first embodiment of a method and an apparatus for manufacturing an electromagnetic coil of the present invention.

FIG. 2 is a partially enlarged sectional view showing a first embodiment of the method and apparatus for manufacturing an electromagnetic coil of the present invention.

FIG. 3 is a layout explanatory view showing a second embodiment of the method and apparatus for manufacturing an electromagnetic coil of the present invention.

FIG. 4 is a layout explanatory view showing a third embodiment of the method and apparatus for manufacturing an electromagnetic coil of the present invention.

FIG. 5 is a layout explanatory view showing a fourth embodiment of the method and apparatus for manufacturing an electromagnetic coil of the present invention.

FIG. 6A is a partially enlarged detailed cross-sectional view showing a fifth embodiment of the method and apparatus for manufacturing an electromagnetic coil of the present invention,
(B) is a partially enlarged detailed sectional view showing a sixth embodiment of the method and apparatus for manufacturing an electromagnetic coil of the present invention, (c).
3 is a partially enlarged detailed view of FIG.

FIG. 7 is a partially enlarged cross-sectional view showing an example of a conventional method of manufacturing an electromagnetic coil and an apparatus therefor.

[Explanation of symbols]

1A: insulating cylinder, 2: insulating coating, 3A: sheet conductor, 4A
... peripheral insulating layer, 5 ... coil, 6, 9A, 9B, 9C, 9
D: roller, 7: end surface processing section, 8: foreign matter removing section, 10: resin, 11: resin tank, 12: coating film thickness adjusting section, 13: winding core, 14 ...
Winding form, 15… insulating tape, 16, 18… heating device, 19… powder tank, 20… wire mesh electrode, 21… air, 22… powder resin, 23… solution, 24… adhesion tank, 25… electrode, 26 , 27 ... recess, 28 ... block coil, 29 ... casting resin.

Claims (8)

[Claims] 1. An end face processing step of processing an end face of a continuously supplied conductor into a curved surface, an attaching step of passing the conductor through a resin tank and attaching a resin to the surface, and heating the resin on the surface of the conductor. A method for manufacturing an electromagnetic coil, comprising: a molding step of winding the conductor around a winding frame while heating and curing the resin of the molded conductor. 2. A resin bath in which a conductor continuously drawn out from a wound and rotated coil is immersed to store a thermosetting resin, and the conductor which passes through the resin bath and to which the thermosetting resin adheres. And a heater for heating the thermosetting resin adhered to the winding frame. 3. A powder tank in which a conductor continuously fed from a wound and rotated coil passes and in which a powder resin is stored, and the conductor which passes through the powder tank and to which the powder resin adheres. An apparatus for manufacturing an electromagnetic coil, comprising: a winding frame for winding a resin; and a heater disposed adjacent to the winding frame for heating the adhered powder resin. 4. A deposition in which a conductor continuously fed from a wound and rotated coil is immersed, a solution in which resin fine particles are dispersed and suspended is stored, and a voltage for charging the fine particles is applied between the conductor and the conductor. An apparatus for manufacturing an electromagnetic coil, comprising: a tank; a winding form that winds the conductor having the fine particles adhered through the adhesion tank; and a heater adjacent to the winding form and heating the adhered fine particles. 5. A preheater for preheating the thermosetting resin, the powder resin, or the fine particles of the conductor is provided between the resin tank, the powder tank or the adhesion tank and the winding frame. The apparatus for manufacturing an electromagnetic coil according to any one of claims 2 to 4, wherein: 6. An end processing portion for forming an end face of the continuously fed conductor in an arc shape, and removing foreign matter adhering to the conductor coming out of the end processing portion and removing the conductor from the resin bath or the powder. The apparatus for manufacturing an electromagnetic coil according to any one of claims 2 to 5, further comprising a foreign matter removing unit for supplying the foreign matter to the tank or the adhesion tank. 7. An insulating member wound around the outer periphery of the winding frame and the conductor wound around the outer periphery to form an insulating inner cylinder, and wound around the outer periphery of the wound conductor to form an outer peripheral insulating layer. The apparatus for manufacturing an electromagnetic coil according to any one of claims 2 to 7, further comprising an insulating sheet drum that supplies a sheet to the reel. 8. An end insulating layer is formed on both sides of the insulated inner cylinder and the outer peripheral insulating layer from both sides of the wound conductor, and an outer peripheral portion of the conductor is formed between the protruding portions. An apparatus for manufacturing an electromagnetic coil according to any one of claims 2 to 7.