JP2001093339A - Litz wire and its manufacturing device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a litz wire with less power consumed by heat generation if a high frequency current flows therein, and to provide its manufacturing device. SOLUTION: The rotational twisting direction and inclination of each layer of a litz wire formed with a plurality of layers are freely set in the procedure of a litz wire manufacturing device which has a rotational twisting plate consisting of an outer periphery element wire placement table 15, a center clustered wire placement table 16, an outer periphery element wire bobbin 17 and a center clustered wire bobbin 18.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a litz wire used for winding of a high-frequency transformer or the like and an apparatus for manufacturing the litz wire.

[0002]

2. Description of the Related Art Heretofore, there has been a deflection coil which uses an electric wire for flowing a high-frequency current as a winding and a coil.

[0003] The electric wire has a central conductor of copper, aluminum,
A wire having a wire diameter of 0.02 to 0.5 mm, which is made of a metal such as iron or brass, and whose outer skin is covered with an insulating coating of a polymer synthetic material such as polyesterimide enamel or polyester urethane is used.

FIG. 13 is an external view of a conventional electric wire, where 1 is a central conductor and 2 is an insulating coating.

[0005] The electric wire is a single wire, and generally, a plurality of such electric wires are bundled and used. One such electric wire is called a strand. Therefore, the electric wire shown in FIG.

FIG. 14 shows a conventional litz wire, which shows a litz wire made by bundling and twisting element wires. In this case, 3 is a strand, and 19 litz wires shown in FIG.

FIG. 15 is a view showing a conventional twisting machine. The conventional process of making a litz wire is performed by the twisting machine shown in FIG. The twisting machine shown in this figure is called a double buncher that twists twice at a time, where 4 is a perforated plate for arranging each wire when litz wire is used, and 5 is a wire 3 A first nozzle for applying a first twist, a bow for rotating a wire, a second nozzle for applying a second twist, a litz wire which is more twisted, and a twist processing This is a winding bobbin for winding the litz wire 8 having the shape shown in FIG.

Hereinafter, a litz wire processed by such a twisting machine will be described.

Each of the wires 3 is guided to the first nozzle 5 through the determined hole of the eye plate 4, and the wires are fixed and bundled at the determined positions. Next, the bundled wires are guided to the bow 6, and the bundled wires are changed by rotating the bow.

[0010] The bundled strands 3 are swept by the first nozzle 5 and the second nozzle 7 fixed to the movable part of the bow 6 by rotating the bow 6, so that the bow 6 It is turned twice in one revolution, and this turning becomes twisting.

FIG. 16 is an external view of a litz wire twisted in such a process. FIG. 16 is a diagram showing a litz wire processed by a conventional twisted wire, and the litz wire is a left-hand twisted product called 19 strands called Z twist.

When a switching transformer is made using the litz wire, a loss characteristic occurs, but an eddy current loss as a copper loss occurs as a loss caused when a high-frequency current flows in the switching transformer. The eddy current loss is divided into a skin effect loss caused by the self-magnetic flux of the flowing current itself and a proximity effect loss caused by the magnetic flux of the other winding due to the current flowing through another electric wire.

Among the eddy current losses, regarding the skin effect loss, the ratio of the surface area to the sectional area of the flowing current is preferably increased. That is, generally, an electric wire is thinned.

FIG. 1 shows a graph of the wire diameter and the rate of increase in resistance.
FIG. FIG. 17 is a graph showing the wire diameter and the rate of increase in resistance for explaining the skin effect.

That is, it shows an increase in resistance to a change in frequency when the conductor cross-sectional area is constant.
As the frequency increases, the resistance generally increases,
It can be seen that the ratio is reduced by making the wires thinner.

On the other hand, since the proximity effect loss is affected by the current flowing through the other winding, it is necessary to consider the current density distribution as a coil.

Hereinafter, the current density distribution will be described.

FIG. 18 is a coil diagram in which element wires are bundled and wound in a substantially circular shape. FIG. 19 is a diagram for explaining a current density distribution.
8 is a partial cutaway view, FIG. 20 is a current density distribution diagram, and FIG. 18 is a coil formed by bundling 19 strands 3 and winding them in a substantially circular shape to explain the current density. FIG. 19 is a partial view in which a certain portion of the coil is cut out. In this figure, a cross-sectional portion 10 is cut out and a current density distribution diagram of this portion is shown in FIG.
0 is shown.

The current density distribution means that the current flowing in the electric wire is distributed depending on how the current flowing in the other winding intersects. In this case, the electric wire located at the center is most often the other winding. Most current does not flow because it is affected by the line.

That is, the electric current density of the electric wire located at the center is the lowest, and the electric current density increases as it goes outward. Then, the current flowing through the outermost electric wire is the largest.

This tendency becomes more remarkable as the flowing current becomes higher in frequency. Generally, 100 kHz
At about z, in the case of about 19 litz wires, the ratio between the current flowing through the outermost wire and the current density of the wire located at the center is 10: 0.5, that is, about 1/20. Become.

That is, the resistance of the electric wire at the center increases when a high-frequency current flows, and almost no current flows.

For these reasons, in the winding of a high-frequency transformer or the like, even if the cross-sectional area and the total surface area of the electric wire are ensured, it is because only the heat generated by the resistance increases and the transformer effect cannot be expected due to the efficiency. It has become.

[0024]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has been developed in consideration of high-frequency current.
An object of the present invention is to provide an efficient litz wire and an apparatus for manufacturing the litz wire, which consume less heat and the like.

[0025]

In order to achieve this object, the present invention relates to a method for twisting a litz wire, wherein the litz wire is made by a litz wire manufacturing apparatus having a twist rotating plate for each of different twisting directions between the layers. The first layer of the litz wire is to use a bundled strand, and the twist pitch of the litz wire is different between the layers, The twist rotating plate of the adjacent layer of the litz wire is obtained by inserting gears between the adjacent twist rotating plates and reversing the twist direction.

[0026]

BEST MODE FOR CARRYING OUT THE INVENTION The invention according to claim 1 of the present invention is a method for twisting a litz wire composed of a plurality of layers and having different twisting directions between at least one adjacent layer for each different twisting direction between the layers. It is made with a litz wire manufacturing device having a rotating plate, and the invention according to claim 2 is:
The first layer of the litz wire uses a bundled strand, and the invention according to claim 3 is such that the twist pitch is different between layers, and the invention according to claim 4 is ,
The twist rotating plate of the adjacent layer inserts gears between the adjacent twist rotating plates to reverse the twist direction.

An embodiment of the present invention will be described below with reference to FIGS. The same components as those described in the related art are denoted by the same reference numerals, and description thereof will be omitted.

(Embodiment 1) FIG. 1 is an external structural view of a litz wire according to a first embodiment of the present invention, and is an external structural view of a litz wire using 19 strands 3 for explaining the first invention. is there.
The litz wire is formed by twisting seven wires near the center in a right-handed twist and twelve wires located on the outer periphery in a left-handed twist.

The characteristics of the litz wire will be described below.

FIG. 2 is a perspective view of the litz wire according to the first embodiment of the present invention as viewed from the side.

In the figure, when the wires 11 located at the central portion and the wires 12 located at the outer peripheral portion shown by hatching are in contact with each other, they are intersected. When these two wires are taken out, they are as shown in FIG. FIG. 3 is a diagram showing two hatched wires of FIG. 2 taken out.

That is, assuming that the wire 11 located at the center and the wire 12 located at the outer periphery are in contact with each other at an angle of 120 °, the wire 11 located at the outer periphery of the wire 11 located at the center is located. The degree of influence on the strand 12 also affects the angle as a relative angle of 120 °.

That is, the current 14 generated by the back electromotive force generated in the wire 12 located in the outer peripheral portion by the magnetic flux 13 excited by the current flowing through the wire 11 located in the central portion is changed to the wire 12 located in the outer peripheral portion. Has an angle of 120 ° with respect to the current flowing therethrough.

This impedes the current flowing through the element wire 12 located at the outer peripheral portion to a lower degree by the angle.

That is, in the prior art, the wires are arranged in parallel (in this case, the relative angle is 180 °). In the present invention, since the relative angle of the wires is 120 °, the difference is calculated as follows. It becomes as follows.

Assuming that the current due to the back electromotive force is I, the current due to the back electromotive force when the wires are arranged in parallel is Ia, and the current due to the back electromotive force according to the present invention is Ib, Ia = I × sin ( 180-90) = I Ib = I × sin (120-90) = 0.5I As a result, in the case of the present invention, the disturbed current is smaller than that of the conventional technology in which the wires are arranged in parallel. It can be seen that is about halved.

That is, it may be considered that the proximity effect loss is reduced accordingly. FIG. 4 is a current density distribution diagram by the litz wire according to the first embodiment of the present invention. Is halved as compared with the prior art as shown in FIG.

Next, a description will be given of an apparatus for manufacturing the litz wire.

FIG. 5 is an enlarged view of a main part of the litz wire manufacturing apparatus according to the first embodiment of the present invention. Here, reference numeral 15 denotes an outer peripheral wire holder, 16 denotes a central bundle holder, 17 denotes an outer peripheral wire bobbin, 18 denotes a central bundle bobbin, 19 denotes an eye plate serving as a twist rotary plate, 20 Denotes a nozzle, and 21 denotes a litz wire according to the present invention.

The method of manufacturing a 19-lit wire in the litz wire manufacturing apparatus configured as described above will be described in detail. First, the wire 12 is wound around an outer wire bobbin 17 and placed on an outer wire holder 15. Next, in the inner peripheral portion, the bundled bundle of the seven strands is wound around the central bundle bobbin 18 and disposed on the central bundle stand 16. That is,
The electric wires that form the basis of the litz wire are arranged such that seven inner peripheral portions are placed on the central bundle holder 16 and 12 outer peripheral portions are placed on the outer strand holder 15. The central bundling holder 16 and the outer strand holder 15 arranged as described above are structured so that the holder itself can be rotated. FIG. 6 is a diagram showing the rotation direction of the central bundled wire holder and the outer peripheral wire holder. For example, as shown by an arrow in FIG.
Rotates clockwise, and the outer wire strand holder 15 rotates counterclockwise.

That is, the rotation directions of the central bundled wire placing table 16 and the outer peripheral element wire placing table 15 are reversed.

Next, the enameled electric wire on which the litz wire thus arranged is based is led to the eye panel 19. This eye plate 19
Is also designed to rotate.

That is, it is designed to rotate in the same direction and at the same rotational speed as the outer periphery strand holder 16.
Therefore, even if the outer peripheral portion strand holder 15 is rotated due to the rotation of the eye panel 19, the strands are not entangled between the eye plate and the outer peripheral strand holder.

On the other hand, the rotation of the basal plate portion of the center-bundling stand 16 also rotates in the direction of rotation of the center-bundling stand 16.

That is, the rotation of the eye plate 19 also rotates in the opposite direction at the central portion and the outer peripheral portion.

Next, the eye panel 19 will be described.

FIG. 7 is a detailed external view of the eye plate of the litz wire manufacturing apparatus according to the first embodiment of the present invention, and FIG. 8 is a plan view of the eye plate of the litz wire manufacturing apparatus of the first embodiment of the present invention. here,
Reference numeral 22 denotes an outer peripheral element wire hole through which the enamel electric wire supplied from the outer peripheral element holder 15 passes. In the case of the first embodiment, twelve holes are provided. Reference numeral 23 denotes a central binding wire hole through which a binding wire supplied from the central binding wire placing table 16 passes. In addition, between the outer peripheral element hole 22 and the central bundling line hole 23, a roller bearing 24 for preventing rotation around the circumference is provided for preventing rotation of both holes. I have.

The enameled electric wire that has passed through the eye panel 19 thus arranged is next led to a nozzle 20, where it is twisted.

Hereinafter, the twisting method will be described in detail.

First, the twisting process of the central bundled wire is as follows.
FIG. 9 is a diagram showing a twisting process of the central bundled wire.

In this case, the process of twisting seven bundles will be described.

First, as shown in FIG. 9 (a), seven pieces are gathered in a plane and wound on a central bundle bobbin 18. That is, the bundle drawn from the central bundle bobbin 18 is in this state. When the extracted bundled wires pass through the central bundled wire holes 23, they are arranged in a circular shape which is the shape of the central bundled wire holes 23. This is the state shown in FIG.

The rotation of the central bundle bobbin 18 and the fixing of the central bundle hole 23 of the eye plate allow rotation of the seven bundles. This state is shown in FIG.

That is, the seven bundled wires arranged in a plane are drawn out from the bobbin being wound, and when the bobbin is pulled out, the bobbin being wound is rotated, and the take-out opening is circular. Therefore, the bundled wire is formed into a substantially circular shape while being twisted.

Next, the bundle that has passed through the hole of the perforated plate 19 is guided to the nozzle 20.

Since the nozzle 20 is completely fixed, the rotation of the bobbin for winding the bundled wire appears as the nozzle transfer twist. Further, since the nozzle 20 also serves to determine the size of the outer diameter of the litz wire, the seven bundled wires are adjusted to a fixed size. That is, FIG.
(D).

The seven bundled wires that have been planar in the above process become substantially circular litz wires.

In the case of this litz wire, the twist pitch depends on the number of rotations of the central bundled wire placing table. That is, when the length of the bundle to be drawn is 10 mm and the number of rotations is 5, the pitch is 2 mm.

Next, the process of twisting the outer strand will be described.

The outer strands are set on the outer strand holder 15 and the eye panel 19 which rotate in the same direction.

That is, if the outer periphery strand holder 15 rotates 20 times per minute in the counterclockwise direction, the rotation of the eye plate 19 is also in the left direction.
20 revolutions per minute. By rotating in the same direction in two sections at the same time, the tangling of the individual wires in the section between the outer peripheral strand placing table 15 and the eye plate 19 is eliminated.

Each wire passing through the hole of the eye plate 19 is then guided to the nozzle 20, but the nozzle 20 is fixed without rotating. The entanglement between the fixed portion and the preceding rotating portion is performed. The cause twist processing is performed.

The manufacturing process of the nineteen double-layer stranded litz wires has been described above.

(Embodiment 2) Next, 37 litz wires of three layers will be described.

FIG. 10 is an external view of a litz wire according to Embodiment 2 of the present invention. Seven center layers are right-handed, the second layer is left-handed, and the outermost layer is a layer adjacent to right-handed. Is a three layer 37 litz wire which is inconsistent.

FIG. 11 is a diagram showing a configuration of a litz wire according to the second embodiment of the present invention.

Here, an explanation will be added for representing the configuration of a general litz wire.

The litz wire is generally represented by using the twist ratio of each of the constituent layers and the twist angle of the twist wire.

First, the twisting ratio, which represents a ratio to be added to the length of the central axis of the stranded wire, is as follows: l = length of the central axis of the stranded wire x = element wire constituting the stranded wire D ′ = layer core diameter D = outer diameter of stranded wire P = pitch of stranded wire, expressed by (Equation 1).

[0070]

(Equation 1)

In this case, when the twisted wire inclination angle is θ, it is expressed by (Equation 2).

[0072]

(Equation 2)

FIG. 12 shows a general configuration of the stranded wire. FIG. 12 is a configuration diagram of a general stranded wire.

When the litz wire of FIG. 11 of the present invention is viewed, the stranded wire inclination angle θ of each layer is such that the stranded wire inclination angle of the center layer is θ 1, the stranded wire inclination angle of the second layer is θ 2, Assuming that the inclination angle of the stranded wire of the layer is θ3, l is constant irrespective of each layer, but x is different because the finished outer diameter of each layer is different. Therefore, the stranded wire inclination angle of each layer also differs.

In the case of FIG. 11, the result is as shown in (Equation 3).

[0076]

(Equation 3)

That is, the stranded wire inclination angle gradually increases toward the outside from the center layer.

In this case, since the rotation speeds of the central bundled wire placing table and the outer peripheral element wire placing table in which the outer periphery is arranged are the same during the twisting process for the first to third layers. In addition, the stranded wire inclination angle of each layer is different.

In the present invention, since the center bundling stand and the outer periphery strand stand are separately set, the respective rotation speeds can be set separately. That is, the above-described twist wire inclination angle can be freely set for each layer.

[0080]

As described above, according to the present invention, since the twist rotation direction of each layer composed of a plurality of layers and the twist inclination angle of each layer can be freely set, even if a high-frequency current is handled, it is consumed by heat and the like. It can supply litz wire with little wasted power.

[Brief description of the drawings]

FIG. 1 is an external structural view of a litz wire according to a first embodiment of the present invention.

FIG. 2 is a perspective view of the litz wire according to the first embodiment of the present invention when viewed from the side.

FIG. 3 is a view showing two hatched wires of FIG. 2 taken out;

FIG. 4 is a current density distribution diagram using a litz wire according to the first embodiment of the present invention.

FIG. 5 is an enlarged view of a main part of the litz wire manufacturing apparatus according to the first embodiment of the present invention.

FIG. 6 is a diagram showing a rotation direction of a central bundled wire holder and an outer peripheral wire holder.

FIG. 7 is a detailed external view of a face plate of the litz wire manufacturing apparatus according to the first embodiment of the present invention.

FIG. 8 is a plan view of an eye plate of the litz wire manufacturing apparatus according to the first embodiment of the present invention.

FIG. 9 is a view showing a twisting process of a central bundled wire;

FIG. 10 is an external view of a litz wire according to a second embodiment of the present invention.

FIG. 11 is a diagram showing a configuration of a litz wire according to a second embodiment of the present invention.

FIG. 12 is a configuration diagram of a general stranded wire

FIG. 13 is an external view of a conventional electric wire.

FIG. 14 shows a conventional litz wire.

FIG. 15 is a diagram showing a conventional twisting machine.

FIG. 16 is a diagram showing a litz wire processed by a conventional twisting machine.

FIG. 17 is a graph showing the wire diameter and the rate of increase in resistance explaining the skin effect.

FIG. 18 is a coil diagram in which element wires are bundled and wound into a substantially circular shape.

FIG. 19 is a partial cutaway view of FIG. 18 for illustrating a current density distribution.

FIG. 20 is a current density distribution diagram

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Center conductor 2 Insulating coating 3 Element wire 4 Eyeboard 5 First nozzle 6 Bow 7 Second nozzle 8 Litz wire 9 Litz wire winding bobbin 10 Coil cross section 11 Element wire located at the center part 12 Located at the outer peripheral part Wire 13 Excited magnetic flux 14 Current due to back electromotive force 15 Outer peripheral wire holder 16 Central bundled wire holder 17 Outer peripheral wire bobbin 18 Central bundled bobbin 19 Eye plate 20 Nozzle 21 Litz wire 22 Outer peripheral portion Hole for wire 23 Hole for central bundled wire 24 Roller bearing

Claims (5)

[Claims] 1. A litz wire comprising a plurality of layers, wherein a twist direction between at least one adjacent layer is different. 2. The litz wire according to claim 1, wherein the twist pitch of the litz wire differs between layers. 3. A litz wire manufacturing apparatus comprising a plurality of layers, wherein a litz wire having a different twist direction between at least one adjacent layer has a twist rotating plate for each different twist direction between the layers. 4. The litz wire manufacturing apparatus according to claim 3, wherein the first layer of the litz wire uses a bundled strand. 5. The litz according to claim 3, wherein the twisted rotating plates of the adjacent layers of the litz wire have a twisting direction reversed by inserting a gear between the adjacent twisted rotating plates. Wire manufacturing equipment.