JP2002093654A - Multiple main line trapezoidal coil and method and device for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve the problem due to the fact that a conventional coil causes a large eddy current when a gap with an adjacent coil is made small, if the coils are arranged into an arc shape. SOLUTION: Ten optical fibers whose cross sectional areas differ are substantially bundled in a band shape, so that the cross sectional areas sequentially become large and the cross sections are arranged in a line, without being tangled. The bundled optical fibers are positioned, so that they are not pressed on a pair of the confronted sides of a core metallic mold in a square pole shape. A part of the optical fibers is pressed on the other pair of confronted sides in the core metallic mold and is positioned. It is wound by the core metallic mold, and at least the partial cross face of the coil 100 is made to be the cross section in a trapezoidal shape. Thus, the gap with the adjacent coil becomes small, when the coils are arranged in the arc shape, and the large eddy current will not occur since the coil 100 is formed of the optical fibers.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil, a method for manufacturing a coil, and an apparatus for manufacturing a coil.

[0002]

2. Description of the Related Art A coil used in a conventional motor will be described with reference to FIG. FIG. 12 is a plan view of a conventional motor coil device. Ten block iron cores 11a to 11j are provided inside the ring of the ring iron core 10, and each of the block iron cores 11 has a cross section. A coil 12 formed by winding one circular element wire is fitted therein. Incidentally, in the conventional motor coil device, for example, a large gap 13 is provided between the coil 12a and the coil 12b.
As described above, there is a large gap between the adjacent coils 12, and there is a problem that the performance of the motor coil device is reduced when such a gap exists.

In order to solve the problem, FIG.
As shown in FIG. 3, a plate-shaped coil material having a trapezoidal cross section and a monotonically increasing thickness in the width direction is prepared, and the coil material is wound up to form a trapezoidal pyramid shown in FIG. The coil 14 is manufactured, and the bottom of the coil 14 is press-formed so as to be along the inner periphery of the ring iron core 10 to produce the coil 15 shown in FIG. 14B, and as shown in FIG. There has been proposed a motor coil device which is formed by being fitted in each block iron core 11 of a ring iron core 10 and which does not cause a large gap between adjacent coils.

[0004]

However, FIG.
The coil 15 obtained by press forming the truncated quadrangular pyramid-shaped coil 14 described with reference to (b) is obtained by winding a plate-shaped coil material having a trapezoidal cross section shown in FIG. Therefore, there is a problem that a large eddy current is generated.

The present invention has been made in consideration of the above-described problems, and has been made in consideration of the above-described problems. A coil which can reduce a gap between adjacent coils when arranged in an arc and does not generate a large eddy current, and a method of manufacturing the coil And a manufacturing apparatus.

[0006]

Means for Solving the Problems The first invention (claim 1)
Is a coil in which a plurality of wires are bundled without being entangled, wherein at least a part of the plurality of wires has a different cross-sectional area and / or a cross-sectional shape, and at least a part of the coil is The vertical cross section is a substantially trapezoidal cross section, or a substantially pentagonal cross section formed such that a substantially rectangular shape and a substantially trapezoidal shape having one side of the rectangle as a short side are in contact with one side of the rectangle. A multi-line trapezoidal coil characterized by the following.

A second aspect of the present invention (corresponding to claim 2) is that the number of the element wires constituting each longitudinal section of the coil in a direction substantially perpendicular to a height direction of the coil is equal to that of the coil. The same number at any height position, the cross-sectional area and cross-sectional shape of each of the strands in a direction substantially perpendicular to the height direction of the coil, constituting the respective longitudinal cross-sections, The cross-sectional area in the height direction of the coil of at least a part of each of the strands, which are substantially the same at the height position and constitute the vertical cross section of the substantially trapezoidal shape or the substantially pentagonal shape, is the platform. The first aspect of the present invention, wherein the size of the shape increases in order from the short side to the long side, or from the short side to the long side of the substantially trapezoidal shape forming the substantially pentagonal shape. Many of the described in A trapezoidal shape coil.

According to a third aspect of the present invention (corresponding to claim 3), the inner diameter of the coil is substantially a polygon, and the plurality of strands on at least one side constituting the polygon are formed. The multi-wire trapezoidal coil according to the first or second aspect of the present invention, wherein the coil portion to be formed has a substantially rectangular parallelepiped shape.

According to a fourth aspect of the present invention (corresponding to claim 4), the polygon means a quadrangle, and at least one side of the polygon is a pair of two sides opposite to each other. In other words, the coil portion formed by the plurality of strands bundled on the other pair of the two sides facing each other of the square is substantially a prismatic shape having a substantially trapezoidal cross section, or A multi-wire trapezoidal coil according to a third aspect of the present invention, wherein the coil has a substantially prismatic shape having an upper cross section of the pentagonal shape.

According to a fifth aspect of the present invention (corresponding to claim 5), the height of the substantially rectangular parallelepiped coil portion is higher than the height of the substantially rectangular columnar coil portion, and the substantially rectangular parallelepiped coil portion is provided. A part of the part is protruding on the long side of the trapezoid in one longitudinal section of the substantially prismatic shape, or on the long side of the trapezoid forming the pentagon in the one longitudinal section. It is a multi-line trapezoidal coil according to the third or fourth aspect of the present invention.

According to a sixth aspect of the present invention (corresponding to claim 6), the multi-wire according to any one of the first to fifth aspects of the invention, wherein each of the strands is covered with an insulating material. It is a trapezoidal coil.

A seventh aspect of the present invention (corresponding to claim 7) is that the wires are taken out from each of a plurality of bobbins around which the wires are wound, and the plurality of wires are cross-sectioned without being entangled. Are bundled in a substantially band shape so that they are arranged in a line, and the bundled plurality of strands are wound up with a predetermined core mold to produce a coil, wherein the plurality of strands are wound. At least a part of the cross-sectional area is different, and when arranging the plurality of wires in the band shape, the cross-sectional area of at least a part of the plurality of wires is different from one end side in the width direction in the width direction of the band. So that it becomes larger in the order of the end side,
A method for manufacturing a coil, comprising arranging the plurality of strands in a strip shape.

An eighth aspect of the present invention (corresponding to claim 8) is that, when arranging the plurality of strands in the band shape, the plurality of predetermined wires from the one end side in the width direction of the band have a sectional area and a sectional shape. Are substantially equal, and the cross-sectional area and the cross-sectional shape are substantially the same from the cross-sectional area of the plurality of strands from the part adjacent to the line where the strands are substantially equal to the other end. A plurality of large strands are arranged, and the cross-sectional area of at least a part of the plurality of strands increases in the order from the side adjacent to the portion where the plurality of strands having substantially the same cross-sectional area are arranged in order from the other end. A seventh aspect of the present invention is the method of manufacturing a coil according to the present invention, wherein the plurality of strands are arranged in a strip shape.

According to a ninth aspect of the present invention (corresponding to claim 9), after the plurality of strands are bundled in the band shape, the bundled strands are wound up by the winding core mold. Before, at least a part of the plurality of strands bundled in the strip is pressed in the thickness direction of the strip, and the thickness in the thickness direction of each of the plurality of strands in the width direction of the strip is substantially reduced. A seventh aspect of the present invention is the method of manufacturing a coil according to the seventh or eighth aspect of the present invention.

[0015] A tenth aspect of the present invention (corresponding to claim 10) is:
When performing the press, the width of the band when the plurality of strands are bundled into the strip after the press is performed, the plurality of strands are formed into the strip when the press is not performed. The ninth aspect of the present invention is the method of manufacturing a coil according to the ninth aspect, wherein the pressing is performed so as to be substantially equal to the length of the width of the band when the bundle is bundled.

The eleventh invention (corresponding to claim 11) provides:
The wound core mold is substantially a polygonal pillar, and at least one side of the polygonal pillar is the pressed, and the plurality of element wires bundled in the band shape are positioned. A ninth or tenth method of manufacturing a coil according to the present invention, wherein the pressing and the winding are performed.

The twelfth invention (corresponding to claim 12) provides:
The polygonal prism means a quadrangular prism, and at least one side surface constituting the polygonal prism means a pair of two side surfaces facing each other of the square prism, and another pair of two opposite side surfaces of the square prism. In the coil according to the eleventh aspect of the present invention, wherein the pressing and the winding are performed so that the plurality of strands bundled in the band shape are not pressed. It is a manufacturing method.

A thirteenth aspect of the present invention (corresponding to claim 13) is:
A method for manufacturing a coil according to any one of the seventh to twelfth aspects, wherein each of the strands is covered with an insulating material.

The fourteenth invention (corresponding to claim 14) is:
A convergence means provided with a hole for bundling a plurality of strands from each of the plurality of bobbins around which the strands are wound, without tangling them, so that the cross-sections are arranged in a line substantially in a line. A winding core die for winding up the plurality of wires bundled by the convergence means, wherein at least some of the cross-sectional areas of the plurality of wires are different, and Passing through the hole of
The cross-sectional area of at least a part of the plurality of strands in the longitudinal direction of the hole is increased from one end side to the other end side in the longitudinal direction, so that the plurality of strands pass through. This is a coil manufacturing device.

According to a fifteenth aspect of the present invention (corresponding to claim 15),
Arranged between the converging means and the wound core mold, at least a part of the plurality of strands bundled in the band shape,
A fourteenth aspect of the present invention, further comprising pressing means for pressing in the thickness direction of the strip and for substantially unifying the thickness in the thickness direction of each of the plurality of strands in the width direction of the strip. 2. A coil manufacturing apparatus according to item 1.

According to a sixteenth aspect of the present invention (corresponding to claim 16),
A columnar body in which the pressing means is in contact with a lower side of the plurality of strands bundled in the strip shape; a pressurizing unit for applying pressure to at least a part of the plurality of strands from above; a width of the strip; When the pressure is applied to the plurality of strands bundled in the band shape, the stretch regulating portion that regulates the extension of the plurality of strands in the width direction of the band, and the columnar shape. A coil manufacturing apparatus according to a fifteenth aspect of the present invention, characterized in that the coil manufacturing apparatus comprises one or a plurality of flat-plate-shaped rings having a predetermined thickness and fitted into a body.

The seventeenth invention (corresponding to claim 17) is:
A medium carrying a program and / or data for causing a computer to execute all or some of all or some of the steps of the coil manufacturing method according to any one of the seventh to thirteenth aspects of the present invention. A medium that can be processed by a computer.

The eighteenth invention (corresponding to claim 18) is:
A program and / or data for causing a computer to execute all or part of all or part of the steps of the coil manufacturing method according to any one of the seventh to thirteenth aspects of the present invention. Information aggregate.

According to a nineteenth aspect of the present invention (corresponding to claim 19),
The wires are taken out from each of the plurality of bobbins around which the wires are wound, and each of the plurality of wires is bundled in a substantially band shape so that the cross sections are arranged in a line without being tangled,
The bundled plurality of wires are wound up by a square pillar-shaped wound core mold, and at least one pair of outer sides of at least one pair of side faces of the square pillar-shaped wound core mold with respect to the wound wire. And producing a coil by pressing the coil.

According to a twentieth aspect of the present invention (corresponding to claim 20),
A cross-sectional area of at least a part of the plurality of wires is different, and when arranging the plurality of wires in the band shape, a cross-sectional area of at least a part of the plurality of wires is the width direction in the width direction of the band. The plurality of strands are arranged in a strip shape so as to increase in order from one end side to the other end side, and each longitudinal section of the coil shape after being wound by the wound core mold is substantially (1) substantially trapezoidal. Or (2) the substantially rectangular shape and the substantially trapezoidal shape having one side of the rectangle as a short side are formed into a substantially pentagonal shape formed so that one side of the rectangle is in contact with the rectangle, and the pressing is performed during the pressing. (A) has a substantially rectangular parallelepiped shape, or (B) has a substantially prismatic shape having a substantially trapezoidal cross section. Or (C) substantially rectangular It is characterized by being pressed so that a substantially trapezoidal shape having one side of the rectangle as a short side has a substantially prismatic shape having a substantially pentagonal cross-section formed so as to be in contact with one side of the rectangle. A nineteenth aspect is a method for manufacturing a coil according to the present invention.

According to a twenty-first aspect of the present invention (corresponding to claim 21),
Before winding with the wound core mold, the cross-sectional area and the cross-sectional shape of the plurality of wires are substantially equal, and each longitudinal section of the coil shape after winding with the wound core mold is substantially rectangular, At the time of the pressing, the coil portion composed of the wire wound on the pressed core die on the pressed side is (A) substantially rectangular parallelepiped, or (B) substantially trapezoidal. Or (C) a substantially pentagon formed such that a substantially rectangular shape and a substantially trapezoidal shape having one side of the rectangle as a short side are in contact with one side of the rectangle. A method for manufacturing a coil according to the nineteenth aspect of the present invention, wherein the coil is pressed so as to have a substantially prismatic shape having a cross section of the shape.

According to a twenty-second aspect of the present invention (corresponding to claim 22),
A convergence means provided with a hole for bundling a plurality of strands from each of the plurality of bobbins around which the strands are wound, without tangling them, so that the cross-sections are arranged in a line substantially in a line. A square pillar-shaped core for winding the plurality of strands bundled by the converging means, and a square pillar-shaped core for the strand wound by the wound core. And a pressing means for pressing from at least both sides of a pair of opposed side surfaces of the mold.

According to a twenty-third aspect of the present invention (corresponding to claim 23),
A cross-sectional area of at least a part of the plurality of strands is different, and when the plurality of strands are arranged in the band shape by the converging means, a cross-sectional area of at least a part of the plurality of strands is a width of the band. In a direction, the plurality of strands are arranged in a band shape so as to increase in order from one end side to the other end side in the width direction, and the pressing unit is on the pressed side.
The coil portion composed of the wire wound by the wound core mold is (A) so as to have a substantially rectangular parallelepiped shape, or (B) so as to have a substantially prismatic shape having a substantially trapezoidal cross section. Or (C) a substantially rectangular shape having a substantially pentagonal cross section formed such that a substantially rectangular shape and a substantially trapezoidal shape having one side of the rectangle as a short side are in contact with one side of the rectangle. Thus, the coil manufacturing apparatus according to the twenty-second aspect of the present invention is a means capable of being pressed.

According to a twenty-fourth aspect of the present invention (corresponding to claim 24),
Before being wound by the wound core mold, the plurality of strands have substantially the same cross-sectional area and cross-sectional shape, and the pressing means is wound by the wound core mold on the side to be pressed. The coil portion composed of the element wire is (A) substantially rectangular parallelepiped, (B) substantially prismatic having a substantially trapezoidal cross section, or (C) substantially rectangular. By means that can be pressed so that a substantially trapezoidal shape having one side of the rectangle as a short side has a substantially prismatic shape having a substantially pentagonal cross section formed so as to be in contact with one side of the rectangle. A twenty-second aspect of the present invention is the coil manufacturing apparatus according to the twenty-second aspect.

According to a twenty-fifth aspect of the present invention (corresponding to claim 25),
A coil in which a plurality of N strands are wound up and having a plurality of M layers, wherein in each layer of the coil, a plurality of L partial lines constituting the same strand are adjacent to each other. Coil.

According to a twenty-sixth aspect of the present invention (corresponding to claim 26),
A twenty-fifth aspect of the present invention is that the cross-sectional area of at least a part of the plurality of N strands increases in the height direction of the coil in order from one end face side to the other end face side of the coil. 3 is a coil according to the present invention.

According to a twenty-seventh aspect of the present invention,
The coil according to the twenty-fifth or twenty-sixth aspect of the present invention, wherein the inner diameter of the coil is substantially polygonal.

According to a twenty-eighth aspect of the present invention (corresponding to claim 28),
The coil according to any one of the twenty-fifth to twenty-seventh aspects, wherein each of the strands is covered with an insulating material.

According to a twenty-ninth aspect of the present invention (corresponding to claim 29),
The wire is taken out from each of the plurality of N bobbins around which the wire is wound, and each of the plurality of N wires is arranged in a row at a predetermined interval without being entangled, A method for manufacturing a coil, comprising: winding a plurality of N strands having a cross section arranged in a line at a predetermined interval with a predetermined core mold to manufacture a coil; When winding up the strands, each of the plurality of N strands is substantially simultaneously shifted in substantially the same direction each time the strands are wound by the winding core mold to form the same strands. A method of manufacturing a coil, comprising winding up the plurality of N element wires so that a plurality of L partial lines adjacent to each other substantially fill the gap.

According to a thirtieth aspect of the present invention (corresponding to claim 30),
A cross-sectional area of at least a part of the plurality of N strands is different, and when arranging the plurality of N strands in the row, a cross-sectional area of at least a part of the plurality of N strands is the same as that of the one row. The method for manufacturing a coil according to a twenty-ninth aspect of the present invention, wherein the plurality of N element wires are arranged in the row so that the wires become larger in order from one end side to the other end side in the width direction. is there.

According to a thirty-first aspect of the present invention (corresponding to claim 31),
A method according to the twenty-ninth or thirtieth aspect of the present invention, wherein the wound core mold is substantially a polygonal pillar.

According to a thirty-second aspect of the present invention (corresponding to claim 32),
A method of manufacturing a coil according to any one of the twenty-ninth to thirty-first aspects, wherein each of the strands is covered with an insulating material.

According to a thirty-third aspect of the present invention (corresponding to claim 33),
A predetermined hole is provided for aligning the cross section of the plurality of N wires from the plurality of N bobbins around which the wires are wound in a line at a predetermined interval without being tangled. And a winding core mold for winding the plurality of N wires, the cross sections of which are arranged in a line at predetermined intervals by the wire aligning means. When a plurality of M wires are wound up, in each layer where the wires are wound up, each of the wires is so formed that a plurality of L partial lines constituting the same wire can be adjacent to each other. An apparatus for manufacturing a coil, characterized in that each of the plurality of M strands is substantially simultaneously shifted in substantially the same direction each time one turn is performed by a wound core mold.

A thirty-fourth aspect of the present invention (corresponding to claim 34) is:
A medium carrying a program and / or data for causing a computer to execute all or some of all or some of the steps of the coil manufacturing method according to any one of the twenty-ninth to thirty-second inventions. A medium that can be processed by a computer.

According to a thirty-fifth aspect of the present invention (corresponding to claim 35),
A program and / or data for causing a computer to execute all or some of all or some of the steps of the coil manufacturing method according to any one of the twenty-ninth to thirty-second inventions. Information aggregate.

[0041]

Embodiments of the present invention will be described below with reference to the drawings.

(Embodiment 1) First, a coil 100 according to Embodiment 1 of the present invention will be described with reference to FIGS. FIG. 1A is a top view of a coil 100 according to the first embodiment, and the coil 100 has six bundles bundled in a belt shape without being entangled with each other by making ten strands substantially parallel. FIG. 1 (b) is a side view of the entire coil when the coil 100 is viewed from the x direction, which is a coil formed by winding and having a substantially square inner diameter, when viewed from the y direction. FIG. 1C is a side view of the entire coil of FIG.

FIG. 2A is a sectional view taken along a line AA ″ in FIG.
As shown in FIG. 2, the cross section is a cross section of a substantially rectangular parallelepiped coil portion composed of ten strands having different cross sectional areas and cross sectional shapes, and the height direction of the coil is the horizontal direction in FIG. is there. Similarly, the cross section taken along the line BB ″ in FIG.
As shown in the figure, the cross-sectional shape is substantially circular and the same shape, but is a cross-section of a prismatic coil portion having a substantially trapezoidal bottom surface composed of ten strands having different cross-sectional areas and having the same cross-sectional area. The height direction of the coil is the vertical direction in FIG.

As shown in FIGS. 2A and 2B, the number of element wires in a direction substantially perpendicular to the "height direction" is the same as six. The same number of six coils means that the coils 100 of the first embodiment are
This is because the coil is formed by winding six element wires. As shown in FIGS. 2A and 2B,
The cross-sectional area and cross-sectional shape of the wires in a direction substantially perpendicular to the “height direction” are substantially the same at any position in the “height direction”, but 10 wires in the “height direction” Or the cross-sectional area and the cross-sectional shape are different. As described above, the configuration of the coil 100 of the first embodiment
The cross-sectional areas and / or cross-sectional shapes of the strands are not uniform.

Note that the ten strands arranged in the “height direction” shown in FIGS. 2A and 2B are bundles bundled in a band without being entangled with each other. .

Next, in order to further describe the coil according to the first embodiment, an apparatus and a method for manufacturing the coil according to the first embodiment will be described with reference to FIGS. FIG.
FIG. 2 is a plan view of the coil manufacturing apparatus according to the first embodiment,
FIG. 4 is a side view of the coil manufacturing apparatus.

As shown in FIGS. 3 and 4, the coil manufacturing apparatus according to the first embodiment includes a bobbin 1 and a rotating roller 2a.
And 2b, a converging plate 3, a pressing mechanism 4, a wound core mold 5, and a winding machine base 6.

The bobbin 1 has a predetermined wire wound thereon, and the outer surface of the wire is covered with an insulating material. 3 and 4, for convenience of explanation, the bobbin 1
Although only two are described, in the first embodiment
In this example, ten wires are arranged in parallel, and the cross-sectional shape of each wire wound on each bobbin 1 is substantially circular, and the cross-sectional area of each wire is different. The ten bobbins 1 are arranged in parallel so that are arranged in ascending order.

The rotating rollers 2a and 2b are means for guiding the strand wound on the bobbin 1 to the converging plate 3 side.

As shown in FIG. 5, the converging plate 3 is a plate provided with a horizontally long trapezoidal hole 3a having a short side on the left side and a long side on the right side. Is a means for converging element wires from each of the bobbins 1 substantially in a band shape. When the strands from each bobbin 1 are passed through the trapezoidal holes 3a, the cross sections are arranged in a line in order from the one having the smallest cross-sectional area as shown in FIG. Pass through the trapezoidal hole 3a while keeping it.

As described above, the holes provided in the converging plate 3 are arranged such that the short side is located on the left side and the long side is located on the right side in order to arrange the element wire sections in order from the one having the smallest sectional area.
It has a long trapezoidal hole on the side.

As shown in FIG. 7 (b), the pressing mechanism 4 presses a part of the ten strands bundled in a band shape, which have passed through the trapezoidal holes 3a of the converging plate 3, and This is a means capable of substantially unifying the thickness of each of the strands in the thickness direction of the band, and comprises displacing the lower press part 4a, the upper press part 4b displaceable in the vertical direction, and the upper press part 4b in the vertical direction. 2
And four gear motors 4c.

FIG. 7 (a) shows the band-shaped 1
It is a front view of the lower press part 4a and the upper press part 4b when not pressing 0 strand, FIG.7 (b) presses a part of ten strands bundled in the band shape, FIG. 7C is a front view of the press mechanism 4 when the thicknesses of the individual wires in the thickness direction of the band are substantially unified, and FIG. 7C is a side view of the press mechanism 4.

The wound core mold 5 is a means for winding up ten strands bundled in a belt shape, which have passed through the press mechanism 4, and as shown in FIG. Divided tapered wedge type mold 5b and mold 5c
, A right side plate 5d, a winding core 5e surrounded by the coil inner diameter mold, a left side plate fixing pin 5f for fixing the left side plate 5a to the winding core 5e, and a right side plate 5
5g of right side plate fastening bolt for fixing d to winding core 5e
It is composed of

The left side of the coil inner diameter mold is inserted into the concave portion of the left side plate 5a, and the right side of the coil inner diameter mold is inserted into the concave portion of the right side plate 5d, and the winding core 5e and the left side plate 5a are fixed by the left side plate fixing pin 5f. When the winding core 5e and the right side plate 5d are fixed by the right side plate tightening bolts 5g, the respective components are integrated with the winding core 5e, and no idle rotation occurs.
When the coil is manufactured, the winding core 5e and the other winding core molds 5 are used.
It is assumed that the above-mentioned components are integrated. Further, it is assumed that the coil inner diameter mold composed of the mold 5b and the mold 5c is a square pillar-shaped mold.

The winding machine base 6 is a table on which the converging plate 3, the press mechanism 4, and the winding core mold 5 are placed.

Next, the operation of the coil manufacturing apparatus described above and the coil manufacturing method according to the first embodiment will be described.

As shown in FIG. 3 and FIG.
The wire is taken out from each of the bobbins 1, and the trapezoidal holes 3 of the converging plate 3 are passed through the rotating rollers 2a and 2b while keeping the wires in a substantially parallel relationship without being entangled.
Pass through a. At that time, as shown in FIG. 6, ten strands are passed through the trapezoidal hole 3a so that the cross sections are arranged in a line in order from the one with the smallest cross sectional area and become substantially strip-shaped.

Next, a part of the ten strands bundled in a band shape is pressed by the press mechanism 4 to substantially unify the thicknesses of the respective strands in the thickness direction of the band into the wound core mold 5. As shown in FIG. 3, the leading of the guided and bundled strands is bent substantially at right angles to the traveling direction and fixed to the opening of the left side plate 5a of the wound core mold 5 (the fixing mechanism is not shown). Omitted), FIG.
As shown in, the winding core 5e of the winding core mold 5 is rotated,
The ten core wires bundled in a belt shape by the winding core mold 5 are wound up.

Then, the winding core 5e is rotated substantially 90 degrees from the initial position, and the ten elements bundled in a belt shape are positioned on the next side view of the square-pillar-shaped coil inner diameter mold appearing by the rotation. Regarding the wires, the bundled strands are positioned on the side without being pressed by the press mechanism 4, and the winding core 5 e is rotated to wind the ten strands bundled in a band shape by the winding core mold 5. take.

As described above, every time the winding core 5e rotates 90 degrees, the band including the strand pressed by the press mechanism 4 and the band including only the unpressed strand are alternately formed. Then, the winding core 5e is rotated six times to wind up the ten strands bundled in a band shape so as to be positioned on the side surface of the square pillar-shaped coil inner diameter mold.

Therefore, by controlling the rotation speed of the winding core 5e and the timing of pressing and not pressing the ten strands bundled in the belt shape in the press mechanism 4, the belt-like portion including the pressed strands is controlled. And the band-shaped portion formed only of the unpressed element wires are alternately positioned on the side surface of the square pillar-shaped coil inner diameter mold.

Next, the final winding wire after the completion of the winding wire is subjected to a springback measure with a bond or the like, and a lead wire portion at the end of winding is secured and the element wire is cut. Then, the right side plate tightening bolt 5g is loosened and taken out, and the coil inner diameter die is taken out from the winding core 5e. As described above, the coil inner diameter mold has two molds 5b and 5 which are tapered wedge molds.
Since the coil is composed of c, the coil can be easily taken out by pushing the thinner wedge.

The coil manufactured in this manner is the coil described with reference to FIGS. This coil is placed so that the bottom surface is along the inner circumference of the ring iron core 10 in FIG.
As shown in FIG. 16, when the press-formed coil is inserted into each block iron core 11 of the ring iron core 10 so that the coil portions having trapezoidal cross-sections are adjacent to each other, the adjacent coil is formed. A large eddy current can be generated because the gap can be made small and each coil is not a coiled plate-shaped coil material but a strip of 10 strands wound up. It is possible to bring about the effect of not being allowed to do so.

FIG. 16 (a) is a configuration diagram of a coil R shaping mold 8 for press-shaping the coil so that the bottom surface is along the inner periphery of the ring iron core 10 of FIG. The R shaping die 8 is composed of a shaping press receiving die 8a having an R-shaped concave portion and a shaping press upper surface die 8b having an R-shaped convex portion. Then, as shown in FIG. 16 (b), the coil is arranged on the shaping press receiving mold 8a, and as shown in FIG. 16 (c), the coil is pressed from above by the shaping press upper mold 8b. 16 (d)
As shown in FIG. 16 (e), the coil before pressing shown in (1) is shaped so that the bottom surface is along the inner periphery of the ring iron core 10.

In the above-described embodiment, when the ten strands bundled in a band are wound up,
A part of the wire was pressed or not pressed by the press mechanism 4 in accordance with each side surface of the rectangular pillar-shaped coil inner diameter mold, but this was applied to each block iron core 11 of FIG. On the ring iron core 10 with the coil fitted,
This is for laminating similar ring iron cores 10. When such lamination is not performed, it is not necessary to press any of the strands.

Such a coil manufactured without pressing any of the strands is illustrated in FIG. FIG.
(A) shows a coil 10 formed by winding six 10 strands bundled in a band without pressing any strands.
FIG. 9B is a top view of FIG. 9, and FIG. 9B is a side view of the entire coil when viewed from the x direction, and FIG. 9C is a side view of the entire coil when viewed from the y direction. It is. Therefore, in the case of the coil in this case, any longitudinal section is shown in FIG.
A substantially trapezoidal shape as shown in FIG. Note that FIG.
(A), (b), and (c) correspond to FIGS.
(B) and (c) respectively.

Further, in the above-described embodiment, each of the wire cross sections has a circular shape.
As shown in FIGS. 0 (a) and (b), the shape may be rectangular or square. In short, the wire cross-sectional shape is not limited. By the way, one longitudinal section of the trapezoidal portion of the coil when the strand cross section is rectangular is as shown in FIG. 10C, and shows a longitudinal section of the coil formed by the strand having a circular cross section. The space factor can be improved as compared with FIG.

FIG. 10D shows a longitudinal section of the trapezoidal portion of the coil when the cross section of the element wire is square, as in FIG. 10C. ), The space factor can be improved. Note that FIG.
FIG. 2B shows a case in which a wire having a square wire cross-sectional shape as shown in FIG. 2B is partly bundled in a band shape to substantially unify the wire thickness in the thickness direction of the band. FIG. 10 shows a cross section of a substantially rectangular parallelepiped coil portion corresponding to FIG.
(E).

A wire having a rectangular or square cross section as shown in FIGS.
As shown in (b), it may be produced by a press mechanism 7 for pressing a wire having a circular cross section. Further, the press mechanism 7 may be incorporated in the coil manufacturing apparatus shown in FIGS. FIG. 11A is a front view of the lower press portion 7a and the upper press portion 7b of the press mechanism 7 when a wire having a circular cross-sectional shape is not pressed.

In the above-described embodiment, FIG.
As shown in (a), the lower press part 4a of the press mechanism 4
States that the ends of the ten strands bundled in a band are regulated, that is, the width of the band is regulated. However, the width of the band need not be completely regulated.

In the case where the width of the band is not completely restricted as described above, the height of the left end wire among the ten wires bundled in the band shape in FIG. Pressing these nine wires to match the height of
As shown in FIG. 17A, the width of the band after pressing is longer than the width of the band when the strand is not pressed (see FIG. 17B). Then, there arises a problem that the height of the coil portion formed by the band in which the pressed wires are bound is different from the height of the coil portion formed by the band in which the unpressed wires are bound.

Therefore, the height of the strand after pressing (press height) is determined as follows. First, as shown in FIG. 18, paying attention to one cross section of a coil portion constituted by unpressed strands, the width of the innermost ten strip-shaped strands is defined as one side, and a predetermined diameter is defined. The cross section is divided by a rectangle having the length between the outermost and innermost sides of the strand as the other side.

Then, the area of the portion (space A) where no wires are present in the rectangle, the area of the wire portion (protruding portion B) protruding from the rectangle in the above wire cross section, and the respective wires In consideration of the area of the space between the wires (inter-wire space C), the height of the coil portion composed of the band where the pressed wires are bundled, and the coil composed of the band where the unpressed wires are bundled The height of the strand after pressing (press height) is determined so that the height of the part is substantially equal.

In FIG. 18, the length between the outermost and innermost portions of the fourth strand from the left in FIG. 17 is defined as the short side, and the width of the ten innermost strips is defined as the long side. The case where the cross section of the coil is divided by a rectangle is shown.

As described above, the height of the coil portion constituted by the band obtained by binding the pressed wires is substantially equal to the height of the coil portion constituted by the band obtained by binding the unpressed wires. Then, a press mechanism 20 as shown in FIG. 19 is used.

The press mechanism 20 includes a columnar body 21 that comes into contact with the lower side of a bundle of strands, a pressurizing unit 22 that applies pressure to the strand from above, and a columnar body 21. Stretching restricting portions 23a and 23b for restricting stretching of a bundle of element wires in a width direction by a predetermined length or more, and four plate-shaped rings 24 fitted to the columnar body 21 and having a predetermined thickness. It is composed of In addition, the stretching control section 23
a and 23 b are fixed to the columnar body 21.

In the case where the wire is not pressed, FIG.
As shown in FIG. 9A, the wires bundled by the pressing unit 22 are not pressed. On the other hand, when the strand is pressed, as shown in FIG. 19 (b), pressure is applied to, for example, the six strands on the right side of the band by the pressing unit 22. Then, since the six strands are regulated on the right side by the extension regulating portion 23b, the six strands extend to the left and push the ring 24 to the left, whereby pressure is applied to the three strands on the left side of the band. .

By the way, since the ring 24 is a plate-like body, that is, has substantially a flat surface, when pressed to the left, sufficient pressure is applied to the three strands on the left side of the band. As a result, the three strands extend toward the pressing portion 22, and the heights of all the strands are substantially equal.

At that time, the thickness of the ring 24 is adjusted so that the width of the band when the ten wires are bundled into a band after pressing is substantially equal to the width of the band when the wires are not pressed. I do. Then, the height of the ten strands after pressing becomes equal, and the width of the band when the ten strands are bundled after the pressing is substantially equal to the width of the band when the strand is not pressed. Equal, and the coil height becomes uniform.

When the press mechanism 20 shown in FIG. 19 is used in place of the press mechanism 4 shown in FIG. 7, the converging plate 3 as shown in FIG. The separated wires are bundled in a band.

The ring 24 is formed using, for example, mirror-polished steel. In this case, pressure can be applied to the strand with reduced frictional resistance. Ring 2
The number of 4 is not limited.

As shown in FIG. 20, the above-described press mechanism 20 and press mechanism 7 may be used in combination. At that time, the converging plate 3 as shown in FIG. 5 is disposed between the press mechanism 20 and the press mechanism 7 and on the downstream side of the press mechanism 7 or between the press mechanism 20 and the press mechanism 7. Is preferred. 20A is a plan view of a coil manufacturing apparatus including the press mechanism 20 and the press mechanism 7, and FIG. 20B is a plan view of the coil manufacturing apparatus including the press mechanism 20 and the press mechanism 7. FIG.

Note that, as described above with reference to FIG. 7A, when not limiting the ends of the ten strands bundled in a band but not completely restricting the width of the band, as described above,
Pressing these nine strands so that the height of the other nine strands matches the height of the leftmost strand in FIG. 6 of the ten strands bundled in a belt shape As shown in FIG. 17 (a), the width of the band after pressing is longer than the width of the band when the wire is not pressed (see FIG. 17 (b)), and as shown in FIG. Height of the coil portion (FIG. 21)
(See FIG. 21 (a)) is substantially higher than the height of a prismatic coil portion having a substantially trapezoidal cross section (see FIG. 21 (b)).

The height of such a substantially rectangular parallelepiped coil portion is different from the height of a substantially rectangular prismatic coil portion having a substantially trapezoidal cross section. As shown in FIG. The upper surface and the upper surface of the prismatic coil portion having a substantially trapezoidal cross section are substantially coplanar, and a part of the substantially rectangular parallelepiped coil portion has a prismatic shape having a substantially trapezoidal cross section. The coil 102 protruding below the lower surface of the coil portion also belongs to the present invention.

FIG. 22A is a top view of a coil 102 in which the height of a substantially rectangular parallelepiped coil portion and the height of a prismatic coil portion having a substantially trapezoidal cross section are different. FIG. 22B is a side view of the entire coil when viewed from the x direction, and FIG. 22C is a side view of the entire coil when viewed from the y direction.

In the above-described embodiment, the ten strands having different cross-sectional areas are arranged in a line in order from the one having the smaller cross-sectional area, and the belt-like shape is maintained without being entangled. The coil is wound and manufactured, but the number of strands is not limited to 10.
Further, the cross-section and the cross-sectional shape of all of the plurality of strands bundled in a band shape are not limited to different ones, and strands having substantially the same shape and substantially the same cross-section are arranged in a part. You may. In short, the cross-sections of each of the plurality of bundled strands are arranged in a line so that the cross-sectional area of at least a part of the plurality of strands of the strands is at least partly smaller, and are substantially parallel without being entangled. All that is required is that the relationship be maintained.

Therefore, as shown in FIG. 6, the cross sections are not lined up in order from the one having the smaller cross sectional area.
As shown in FIG. 3, four strands having substantially the same cross-sectional area and cross-sectional shape are arranged, and six strands are arranged next to each other so that the cross-sectional areas become substantially equal and the cross-sectional area increases in order, and bundled into a band shape. Is also good.

A coil obtained by winding the bundled wires as shown in FIG. 23 with a wound core mold 5 without pressing with a press mechanism 4 also belongs to the present invention. As shown in FIG. 24, the longitudinal section of the coil has a substantially pentagonal cross section including a rectangular portion and a substantially trapezoidal portion having one side of the rectangular portion as a short side. More specifically, the prism-shaped coil portion having a substantially pentagonal cross section has a shape in which a prism portion having a substantially trapezoidal cross section is located below the quadrangular prism portion.

Such a coil is illustrated as in FIG. FIG. 25A is a top view of the coil 103,
FIG. 25B is a side view of the entire coil 103 when viewed from the x direction, and FIG. 25C is a side view of the entire coil when viewed from the y direction.

It is not necessary that all the longitudinal sections of the coil have a substantially pentagonal cross section as shown in FIG. 24. As shown in FIG. The cross section of the coil portion located on the side may be a substantially pentagonal cross section shown in FIG. 24, and the shape of the coil portion located on the other pair of two opposite sides may be a rectangular parallelepiped shape.
Further, in that case, the height of the rectangular parallelepiped coil portion is higher than the height of the prismatic coil portion having a substantially pentagonal cross section, and the upper surface of the rectangular prismatic coil portion and the upper surface of the rectangular parallelepiped coil portion May be substantially on the same plane, and a part of the substantially rectangular parallelepiped coil portion may protrude below the lower surface of the prismatic coil portion.

The strand is not a round wire having a circular cross section.
The cross section may be a square line, or a round line may be compressed into a square line. FIG. 26 shows a cross section of the coil portion when the vertical cross section is made substantially pentagonal using such a square line.

Further, in the above-described embodiment, the coil is manufactured by winding six strands of ten strands bundled in a band shape, but the number of windings is not limited to six.

Further, in the above-described embodiment, the shape of the coil inner diameter mold is a square pole, but the shape of the coil inner diameter mold may be a polygonal pillar such as a hexagonal pillar or an octagonal pillar. , May be cylindrical. That is, the inner diameter of the coil is not limited to a square.

Further, in the present embodiment, the hole provided in the converging plate 3 is a trapezoidal hole 3a that is long in the lateral direction, but may be a rectangular hole, for example. In short, the holes provided in the converging plate 3 only need to be such that at least a part of the plurality of strands can be arranged in a line in cross section in ascending order of cross section.

A medium carrying a program and / or data for causing a computer to execute all or a part of the operations of all or some of the steps of the coil manufacturing method according to the above-described embodiment. A medium which is readable and in which the read program and / or data cooperates with the computer to execute the operation also belongs to the present invention.

Therefore, the timing for pressing a part of the ten strands bundled in the band shape in the above-described embodiment and the rotation speed for winding up the strands bundled in the band shape by the winding core mold 5 are described. Is a recording medium that records a program and / or data for causing a computer to execute the operation of controlling the computer, and is readable by a computer, and the read program and / or data is read in cooperation with the computer. A recording medium that executes the above operation also belongs to the present invention.

The medium includes a recording medium such as a ROM, a transmission medium such as the Internet, and a transmission medium such as light, radio waves, and sound waves. The carried medium includes, for example, a recording medium on which a program and / or data is recorded, a transmission medium for transmitting the program and / or data, and the like.

Also, the fact that processing can be performed by a computer means that
For example, in the case of a recording medium such as a ROM, it means that the program can be read by a computer.
Or it means that the data can be handled by a computer as a result of the transmission.

Further, the present invention is an information aggregate which is a program and / or data for causing a computer to execute all or a part of operations of all or a part of the steps of the coil manufacturing method according to the above-described embodiment. An information set that is readable and in which the read program and / or data cooperates with the computer to execute the operation also belongs to the present invention.

The information aggregate includes, for example, software such as programs and / or data.

The data in the medium and the information aggregate described above includes a data structure, a data format, a data type, and the like.

Further, when the wire is pressed, the insulating film covering the outer surface of the wire becomes thin. Is used, there is no problem in using the coil even if the conductor is deformed by about 30%, for example. When a problem such as a layer short occurs, the coil performance can be obtained by inserting insulating paper between the layers.

(Embodiment 2) A coil manufacturing apparatus and method according to Embodiment 2 of the present invention will be described with reference to the drawings. A part of the coil manufacturing apparatus according to the second embodiment is the same as that described in the first embodiment with reference to FIGS. 3 and 4, and the remaining configuration of the coil manufacturing apparatus according to the second embodiment is shown in FIG. Shown in The coil manufacturing apparatus according to the second embodiment includes a portion shown in FIGS. 3 and 4 and a portion shown in FIG. Note that FIGS. 3 and 4 have been described in the first embodiment, and a description thereof will be omitted.

Next, the remainder of the coil manufacturing apparatus according to the second embodiment shown in FIG. 27 will be described. The remainder of the coil manufacturing apparatus includes a coil compression base plate 27a, a coil inner diameter mold 27b attached to the coil compression base plate 27a, and rectangular parallelepiped forming press plates 27c and 27d.
, Trapezoidal portion pressing plates 27e and 27f, coil upper surface suppressing plate 27g, and upper surface suppressing plate tightening bolt 27h. FIG. 27A shows the upper surface of the remaining part of the coil manufacturing apparatus, and FIG. 27B shows the side surface thereof.

The coil compression base plate 27a is made up of a coil inner diameter mold 27b and rectangular parallelepiped forming pressure plates 27c and 27c.
d, and a trapezoidal portion pressing plate 27e and 27f are mounted thereon, and the coil inner diameter mold 27b is a square pillar-shaped mold attached to the coil compression base plate 27a,
This is a mold similar to the coil inner diameter mold composed of the mold 5b and the mold 5c described above.

The rectangular parallelepiped forming pressure plates 27c and 27d
As shown in FIG. 27 (a), a plane portion arranged outside a pair of opposed side surfaces of a rectangular column-shaped coil inner diameter mold 27b so as to satisfy a positional relationship substantially parallel to the side surface. The distance between the plate and the side surface can be changed. When the intermediate product coil 106 is arranged in the coil inner diameter mold 27b,
This is means for applying pressure from the outside to the intermediate product coil 106, and pressing the coil to a substantially rectangular parallelepiped shape at the portion where the pressure is applied. The configuration of the rectangular parallelepiped portion forming pressing plate 27c is also illustrated in FIG. 27C, and the configuration of the rectangular parallelepiped portion forming pressing plate 27d is also illustrated in FIG. 27D.

The trapezoidal pressure plates 27e and 27f are connected to the
As shown in FIGS. 7 (a) and 7 (b), the plate is a plate disposed outside the other set of opposing side surfaces of the square pillar-shaped coil inner diameter mold 27b, as shown in FIG. 3 (e). , And has a trapezoidal cross section. Further, the distance between the opposing side surface of the coil inner diameter mold 27b can be changed. Then, the intermediate product coil 1 is placed in the coil inner diameter mold 27b.
06 is arranged, pressure is applied to the intermediate product coil 106 from the outside, and the coil shape of the portion where the pressure is applied is pressed so as to have a substantially prismatic shape having a substantially trapezoidal cross section. It is a means that can be done.

The coil upper surface suppressing plate 27g is shown in FIG.
As shown in FIG.
7b, when the pressure is applied from the outside to the side surface of the intermediate product coil 106 disposed around the coil inner diameter mold 27b, the height of the coil is prevented from increasing. Is a means for suppressing the upward extension of the intermediate product coil 106 so that the height of the intermediate product coil 106 is not substantially changed. The upper surface suppression plate tightening bolt 27h is a means for fixing the coil upper surface suppression plate 27g to the coil inner diameter mold 27b (see FIG. 27 (g)).

Next, the operation of the above-described coil manufacturing apparatus and the method of manufacturing a coil according to the present embodiment will be described.

As shown in FIG. 3 and FIG.
The wire is taken out from each of the bobbins 1, and the trapezoidal holes 3 of the converging plate 3 are passed through the rotating rollers 2a and 2b while keeping the wires in a substantially parallel relationship without being entangled.
Pass through a. At that time, as shown in FIG. 6, ten strands are passed through the trapezoidal hole 3a so that the cross sections are arranged in a line in order from the one with the smallest cross sectional area and become substantially strip-shaped.

Next, the ten strands bundled in a belt shape are passed through without being pressed by the press mechanism 4 and guided to the wound core mold 5, and the leading ends of the bundled strands are shown in FIG. Then, it is bent substantially at right angles to the running direction and fixed to the opening of the left side plate 5a of the wound core mold 5 (the fixing mechanism is not shown), and as shown in FIG. Core 5e of die 5
Is rotated to wind up ten strands bundled in a belt shape by the winding core mold 5. The winding is performed so that the winding core 5e is rotated six times so that the ten strands bundled in a band form six layers.

Next, the final winding wire after the winding is completed is subjected to a springback measure with a bond or the like, and a lead wire portion at the end of winding is secured and the element wire is cut. Then, the right side plate tightening bolt 5g is loosened and taken out, and the coil inner diameter die is taken out from the winding core 5e. As described above, the coil inner diameter mold has two molds 5b and 5 which are tapered wedge molds.
The coil as an intermediate product can be easily taken out by extruding the thinner wedge type because it is composed of c.

The intermediate product coil 1 manufactured as described above
06 is illustrated as in FIG. FIG. 9A is a top view of a coil formed by winding six ten strands bundled in a belt shape, and FIG. 9 is a side view of the entire coil when the coil is viewed from the x direction. FIG. 9B is a side view of the entire coil when viewed from the y direction, as shown in FIG. Therefore, in the case of the coil in this case, any longitudinal section is shown in FIG.
A substantially trapezoidal shape as shown in FIG.

Then, the intermediate product coil 106 shown in FIG. 9 is set around the coil inner diameter mold 27b described with reference to FIGS. 27 (a) and 27 (b). FIG. 28 shows a state in which the intermediate product coil 106 is set around the coil inner diameter mold 27b.

Next, a coil upper surface suppressing plate 27g is arranged above the coil inner diameter mold 27b, and the coil inner diameter mold 27b and the coil upper surface suppressing plate 27g are connected to the upper surface suppressing plate tightening bolt 27g.
h (see FIG. 29). The distance between the coil compression base plate 27a and the coil upper surface suppression plate 27g is
The distance between them is such that the rectangular parallelepiped portion forming pressing plates 27c and 27d and the trapezoidal portion pressing plates 27e and 27f can be inserted.

Thereafter, the trapezoidal portion pressing plates 27e and 27f are moved to the coil inner diameter mold 27b side, and the intermediate product coil 10
6, the intermediate product coil 106 is pressed by the trapezoidal portion pressing plates 27e and 27f, and the rectangular parallelepiped portion forming pressing plates 27c and 27d are held in the coil inner diameter mold 27b while maintaining the pressed state.
Side and sandwich the intermediate product coil 106. Then, the intermediate product coil 106 is pressed by the rectangular parallelepiped portion forming pressing plates 27c, 27d, and the rectangular parallelepiped portion forming pressing plates 27c, 27d are pressed.
The coil portion opposed to is substantially in the shape of a rectangular parallelepiped (see FIG. 2).
9).

At the same time, the trapezoidal pressure plates 27e, 27
f, while maintaining the prismatic shape having a substantially trapezoidal cross section, the size thereof is smaller than the size of the portion of the intermediate product coil 106 having the prismatic shape having a substantially trapezoidal cross section. I do.

As described above, by pressing the side surface of the intermediate product coil 106 from the outside, the size of the space in the coil is reduced, and the space factor is improved. In other words,
A round wire that is cheaper than a square wire (a square wire has a square cross-sectional shape and a round wire means that the cross-sectional shape has a round shape) can be used to improve the conductor space factor of the coil. That's what it means.

Thereafter, the pressure applied to the coil is released, and the rectangular parallelepiped portion forming pressure plates 27c and 27d and the trapezoidal portion pressing plate 27c are released.
e, 27f are retracted outward from the coil inner diameter mold 27b, the coil upper surface suppressing plate 27g is removed, and the coil is taken out.

The coil taken out in this way is shown in FIG.
(A) is a coil having a substantially quadrangular inner diameter as shown in (a), a substantially rectangular parallelepiped coil portion is located on one pair of two sides of the quadrilateral opposing, and the other opposing pair of coils A coil in which a prismatic coil portion having a substantially trapezoidal cross section is located on two sides. FIG. 1A corresponds to a top view of the coil taken out of the coil inner diameter mold 27b after pressurization, and FIG. 1B is a side view of the entire coil when the coil is viewed from the x direction. The side view of the entire coil as viewed from the y direction is as shown in FIG.

Finally, the removed coil was placed on the bottom surface as shown in FIG.
Press forming is performed as shown in FIG. 16 along the inner periphery of the ring iron core 10 of FIG. 2 and the coil formed by pressing is formed so that coil portions having trapezoidal cross sections are adjacent to each other. When inserted into the block iron core 11, the gap between adjacent coils can be reduced, and each coil is not a coiled plate-shaped coil material but is a bundle of ten strands. Is wound up, an effect of not generating a large eddy current can be obtained.

In the above-described embodiment, when the intermediate product coil 106 is pressed from the side surface, the coil portions located on the pair of two side surfaces facing each other of the coil inner diameter mold 27b have a substantially rectangular parallelepiped shape. The intermediate product coil 10 is formed in such a manner that the coil portions located on the two side surfaces of the other pair facing each other have a substantially prismatic shape with a trapezoidal cross section.
6 was pressed from the side, but a pair of 2
The coil portion located on the side surface side has a prismatic shape having a substantially trapezoidal cross section, and the coil portion located on the other pair of two opposite side surfaces also has a prismatic shape having a substantially trapezoidal cross section. Alternatively, the intermediate product coil 106 may be pressed from its side.

Even if the intermediate product coil 106 is pressurized so that the coil portions on all four sides of the coil whose inner diameter is substantially square are formed into a prism having a substantially trapezoidal cross section, even if the coil This has the effect of improving the space factor.

Further, the intermediate product coil may be pressurized so that the coil portions on all four sides of the coil have a substantially rectangular parallelepiped shape, in which case the space factor is also improved.

Further, in the above-described embodiment, the coil portions on two opposing sides of the four sides of the coil, or the coil portions on all four sides are formed into a prismatic shape having a substantially trapezoidal cross section. Alternatively, the intermediate product coil was pressurized so as to have a substantially rectangular parallelepiped shape, but the coil portions on two opposing sides of the four sides of the coil, or the coil portions on all four sides, are shown in cross section in FIG. The intermediate product coil may be pressurized from its side so as to have a pentagonal prism shape formed by such a rectangular portion and a trapezoidal portion.

Further, in the above-described embodiment, the ten strands bundled in a band shape are passed through without being pressed by the press mechanism 4, and the strands bundled in the belt shape by the winding core mold 5 are wound up. However, all or a part of the ten strands bundled in a belt shape are pressed by the press mechanism 4 to substantially unify the thicknesses of the respective strands in the thickness direction of the belt. It is led to the core mold 5, which is wound up and wound up by the core mold 5,
The intermediate product coil may be manufactured such that all the coil portions located on the four sides of the intermediate product coil whose inner diameter shape is substantially quadrangular have a substantially rectangular parallelepiped shape.

Alternatively, the timing of pressing by the press mechanism 4 and the timing of winding by the winding core mold 5 are adjusted so that, of the coil portions located on the four side surfaces, a pair of opposed two side surfaces is disposed. The intermediate product coil is manufactured such that the coil portions located are substantially prismatic with a trapezoidal cross section and the coil portions located on the other pair of two side surfaces facing each other have a substantially rectangular parallelepiped shape. You may.

In any case, thereafter, all or some of the coil portions on the four side surfaces of the coil are formed into a prismatic shape having a substantially trapezoidal cross section, or a rectangular portion as shown in FIG. The intermediate product coil is pressed so as to have a prismatic shape having a pentagonal cross section formed by a trapezoidal shape or a substantially rectangular parallelepiped shape. By doing so, the conductor space factor of the coil can be improved.

When manufacturing the intermediate product coil by making all the coil portions located on the four side surfaces of the intermediate product coil substantially in the shape of a rectangular parallelepiped, the thickness of all the strands bundled in a belt shape is determined in advance. You can keep it unified.
In that case, the press by the press mechanism 4 becomes unnecessary. However, it may be pressed.

Further, by adjusting the timing of pressing by the press mechanism 4 and the timing of winding by the winding core mold 5, a coil portion located on the four side surfaces of a coil having a substantially square inner diameter is formed. Among them, a pair of opposed coil portions located on the two side surfaces have a prismatic shape having a substantially trapezoidal cross section, and another opposed pair of coil portions located on the two side surfaces have a substantially rectangular parallelepiped shape. When an intermediate product coil is manufactured in such a way that the width of the band of the pressed product is reduced by 1
As shown in FIG. 21, the height of the substantially rectangular parallelepiped coil portion of the intermediate product coil is longer than the width when the zero strands are arranged, and the prismatic coil portion having a substantially trapezoidal cross section is provided. May be higher than the height. Note that FIG.
21A shows a cross section of a substantially rectangular parallelepiped coil portion, and FIG. 21B shows a cross section of a prismatic coil portion having a substantially trapezoidal cross section.

A top view of the intermediate product coil at that time is shown in FIG.
FIG. 22B shows a side view of the entire coil when viewed from the x direction, as shown in FIG. 22A, and a side view of the entire coil when viewed from the y direction. 22
(C). Then, as shown in FIG. 22 (b), when the top surface positions of the substantially rectangular parallelepiped coil portion and the rectangular coil portion having a substantially trapezoidal cross section substantially coincide with each other, a substantially rectangular parallelepiped coil is formed. A portion of the portion projects below the lower surface of the prismatic coil portion having a substantially trapezoidal cross section.

Also for such an intermediate product coil, all or some of the coil portions on the four sides of the intermediate product coil are formed into a prismatic shape having a substantially trapezoidal cross section.
Alternatively, as shown in FIG. 26, a pentagonal shape composed of a rectangular portion and a trapezoidal shape has a pentagonal cross section,
Alternatively, when the intermediate product coil is pressed so as to have a substantially rectangular parallelepiped shape, the conductor space factor of the coil is improved.

In this case, since a part of the substantially rectangular parallelepiped coil portion protrudes below the lower surface of the prismatic coil portion having a substantially trapezoidal cross section, the coil manufacturing apparatus shown in FIG. The remaining coil compression base plate 27
a, as shown in FIG. 30, is replaced with a recess provided with a concave portion 27x corresponding to the protruding portion,
The coil portions of both the protruding portion and the non-protruding portion are stably arranged on the coil compression base plate 27a, and the pressure plate of the pressing plate is adjusted according to the height of the protruding portion of the coil portion. Change the height. Note that FIG.
FIG. 3A is a top view of a coil pressing unit having a coil compression base plate 27a provided with a concave portion 27x, and FIG.
0 (b) is a side view, and FIG. 30 (c) is a side view when an intermediate product coil is arranged around the coil inner diameter mold 27b of the coil pressing portion.

Further, around the coil inner diameter mold 27b of the coil pressing portion having the coil compression base plate 27a provided with the concave portion 27x shown in FIG. When an intermediate product coil having substantially the same height of the coil portion is arranged and pressed from the outside of each side surface of the intermediate product coil, the extension to the coil upper surface side is regulated by the coil upper surface suppressing plate 27g. Recess 2
The coil portion arranged in the portion where 7x is provided extends to the concave portion 27x side, and the coil after pressurization has the shape of the coil protruding downward described with reference to FIG. The shape becomes as small as possible.

In the above embodiment, the converging plate 3
When ten strands are bundled in a band shape and passed through the hole 3a, the cross-sections are arranged in a line in order from a small cross-sectional area as shown in FIG. However, as shown in FIG. 23, the cross-sectional areas of the four wires on the left side are substantially equal, and the six wires on the right side are larger than the cross-sectional areas of the four wires on the left side. , The cross-sectional area may be increased in order, and the cross-sections may be arranged in a line to pass through the hole 3 a of the converging plate 3.

In this case, when ten strands are bundled in a belt shape and wound up by the wound core mold 5 without being pressed by the press mechanism 4, the longitudinal section of the intermediate product coil becomes as shown in FIG.
The cross section is a pentagonal shape composed of a rectangular portion and a trapezoidal portion.

All or some of the coil portions on the four sides of the intermediate product coil are formed so as to have a prismatic shape having a substantially trapezoidal cross section, or a rectangular portion and a trapezoidal shape as shown in FIG. When the intermediate product coil is pressurized so as to have a prism shape having a cross section of a pentagonal shape composed of the following, or a substantially rectangular parallelepiped shape, the conductor space factor of the coil is improved.

Further, in the above-described embodiment, each of the wire cross-sections is circular, but the wire cross-section may be rectangular or square. In short, the wire cross-sectional shape is not limited. By the way, the coil in the case where the strand cross section is rectangular can improve the space factor as compared with the coil formed by the strand having a circular cross section.

Further, in the above-described embodiment, the ten strands having different cross-sectional areas are arranged in a line in order from the one having the smaller cross-sectional area, and are formed in a belt shape while maintaining a substantially parallel relationship without being entangled. To produce an intermediate product coil, but the number of strands is not limited to ten. In addition, there is no limitation that the cross-sectional area and the cross-sectional shape of all of the plurality of strands bundled in a band shape are different.
Elements having substantially the same shape and substantially the same cross-sectional area may be partially arranged.

In the above-described embodiment, a coil is manufactured by winding six strands of ten strands bundled in a belt shape. However, the number of windings is not limited to six.

In the present embodiment, the holes provided in the converging plate 3 are trapezoidal holes 3a which are long in the lateral direction, but may be rectangular holes. Alternatively, a horizontally long pentagonal hole formed by a rectangular portion and a trapezoidal portion may be used. In short, the holes provided in the converging plate 3 only need to be such that the cross sections of the plurality of strands can be arranged in a line.

Lastly, when the wire is pressed, the insulating film covering the outer surface of the wire becomes thin. However, since a material having a good insulating film performance is widely used, a material having such a good insulating film performance is used. If a wire is used, for example, even if the conductor is deformed by about 30%, there is no problem in using the coil. When a problem such as a layer short occurs, the coil performance can be obtained by inserting insulating paper between the layers.

(Embodiment 3) Next, a coil 104 according to Embodiment 3 of the present invention will be described with reference to FIGS. FIG. 31A shows a coil 104 according to the third embodiment.
FIG. 9 is a top view of the coil 104. The coil 104 has a circular cross section and has nine strands having different cross sectional areas at predetermined intervals and made substantially parallel, and fills the interval each time the coil is turned. 9 is a coil having ten layers formed by the staggered winding method by shifting nine wires substantially simultaneously in substantially the same direction, and a side view of the entire coil when the coil 104 is viewed from the x direction. FIG. 31 (b) is a side view of the entire coil when viewed from the y direction, and FIG. 31 (c).

The longitudinal section of the coil 104 shown in FIG. 31 is a substantially trapezoidal section, as shown in FIG. 32, and the sectional shapes are substantially circular and have the same shape but different sectional areas. , And the cross section is composed of nine element wires, and two lines constituting the same element wire are adjacent to each other in each layer.

The cross-sectional area of the nine strands is
The larger the number, the larger. Further, the coil of the third embodiment is a coil having ten layers as described above. However, focusing on the element wire, the layers will be described. As shown in FIG. The layer containing the numbers “1” and “2” is the first layer, and the layer containing the numbers “3” and “4” is the second layer.

Next, in order to further describe the coil 104 according to the third embodiment, a device and a method for manufacturing the coil according to the third embodiment will be described with reference to FIGS. The coil manufacturing apparatus according to the third embodiment has almost the same functions as the coil manufacturing apparatus according to the first embodiment described with reference to FIG. 3 and the like. Since the number of strands to be formed and the shape of the wound core mold are different, in the third embodiment, different parts will be mainly described.

First, the number of element wires is nine (9 types) in the third embodiment. These are the nine strands from the above, which will be described later.
As shown in FIG. 33, when passing through the holes 3a, the cross-sections are arranged in a line so that the cross-sectional area increases in order, and are arranged so that a predetermined interval is provided between adjacent strands. In the third embodiment as well, each element wire is covered with an insulating material as in the first embodiment.

Next, as shown in FIG. 34, the wound core mold according to Embodiment 3 includes a left side plate 50a, a coil mold 50b, a first wedge 50c, a second wedge 50d, and a third wedge 50e. A tapered wedge type coil inner diameter mold formed by four components, a right side plate 50f, a winding core 50g surrounded by the coil inner diameter mold, and a left side plate fixing for fixing the left side plate 50a to the winding core 50g. Pin 50h
And a right side plate fastening bolt 50i for fixing the right side plate 50f to the winding core 50g.

The left side of the coil inner diameter mold is inserted into the concave portion of the left side plate 50a, and the right side of the coil inner diameter mold is inserted into the concave portion of the right side plate 50f, and the winding core 50g and the left side plate 50a are fixed by the left side plate fixing pin 50h. When the winding core 50g and the right side plate 50f are fixed by the right side plate fastening bolt 50i, the respective components are integrated with the winding core 50g, and do not run idle. When manufacturing the coil, the winding core 50
It is assumed that g and other components of the wound core mold are integrated. Also, it is assumed that the coil inner diameter mold is a square pillar-shaped mold. The coil mold 50b has a hook pin 51 for hooking a wire at the beginning of winding.

Next, a coil manufacturing method according to the third embodiment will be described.

First, in the same manner as in the first embodiment described with reference to FIGS. 3 and 4, strands are taken out from each of the nine bobbins 1 and substantially parallel relationships are established without tangling the strands. It is passed through the trapezoidal hole 3a of the converging plate 3 while keeping it. At this time, as shown in FIG. 33, the cross-sections are arranged in a line so that the cross-sectional area increases in order, and a predetermined interval is provided between adjacent strands, so that nine strands are mounted on the base. Through the hole 3a.

Here, the spacing between adjacent strands will be described with a specific example. The distance between the element wire and the element wire is the distance at which the element wire can enter the distance, and the distance between the element wire and the element wire can enter the distance. The interval. The intervals between the other strands are the same as the intervals between the adjacent two strands so that the strand having the larger cross-sectional area of the two adjacent strands can enter between the adjacent two strands. .

Next, the nine strands that have passed through the converging plate 3 are allowed to pass without being pressed by the press mechanism 4, guided to a wound core mold shown in FIG. 34, and winding is started. At the start of the winding, the leading ends (lead wire portions) of the nine strands are shown in FIG.
5 (a), it is bent substantially at right angles to the running direction, and the bent corner portion is
1 and hold the lead wire portion with the left side plate 50a to prevent the lead wire portion (a detent mechanism is not shown). FIG. 35 (a) shows a state in which the wire is wound by a quarter from the beginning.

As described above, after the lead wire portion is stopped, the winding core die is rotated to wind up the element wire. By the way, as shown in FIG. 35 (b), the second wedge 50d and the third wedge 50e are provided with nine types of grooves according to the diameter (cross-sectional area) of the wire, and have substantially the same size. The two grooves are adjacent to each other. Therefore, there are a total of 18 grooves. The size of the groove is gradually reduced from the right side plate 50f side to the left side plate 50a side.

Then, when the winding core mold is rotated to wind up the strands, as shown in FIG. 35 (a), each strand is inserted into the corresponding groove, and the nine strands which have passed through the converging plate 3 are further moved. Are wound so as to substantially maintain the distance between the strands, and after one turn, nine strands are shifted substantially simultaneously in substantially the same direction, and two partial lines constituting the same strand are adjacent to each other. Then, the individual wires are wound up so that the gap generated during the first winding is substantially filled.

Thus, the first layer of the coil described with reference to FIG. 32 is created. In the longitudinal section of the coil shown in FIG. 32, the numbers of "1" to "20" are given to the wires, which indicate the order in which the wires are wound up. As for the layer, it is shown that the portion "1" is wound first, and then the portion "2" is wound between the element wire and the portion "1".

Similarly, for each of the second and subsequent layers,
In the first winding, the distance between each of the nine wires is substantially the same as the distance between the nine wires that have passed through the converging plate 3, and each wire is wound up. Each strand is wound up so that the resulting spacing is substantially filled. However, FIG.
As shown in the figure, the "3" part of the wire of the first turn of the second layer is located above the "2" part of the wire, and the "2" is located above the "1" part of the wire. Each wire is wound by the staggered winding method so that the “4” portion of the wire of the second winding of the layer is located. In the present embodiment, the zigzag winding is 20 turns.

When the element wire is wound in this way, a coil having 10 layers wound by nine element wires is adjacent to two partial wires constituting the same element wire in each layer. it can.

Next, as in the first embodiment, the final wound wire after the completion of the wound wire is subjected to a springback measure with a bond or the like to secure a lead wire portion at the end of winding and cut the element wire. I do. Thereafter, the right side plate fastening bolt 50i is loosened and taken out, and the coil inner diameter die is taken out from the winding core 50g.

Then, the first wedge 50c is slid out in the depth direction with respect to the paper surface of FIG. 34, and is pulled out. Further, the coil mold 50b is slid to the right, and the winding is started, and the lead wire is released from the pin 51. Next, the coil mold 50
b is slid to the left and taken out, and finally the second wedge 50d and the third wedge 50e are taken out. Thereby, the coil can be taken out from the coil inner diameter mold without damaging the inner diameter of the coil.

Thereafter, the coil taken out from the coil inner diameter mold is, like in the first embodiment, subjected to the coil R shaping mold 8 shown in FIG. Press molding along the circumference. When the coil formed by pressing as described above is inserted into each block iron core 11 of the ring iron core 10, a gap between adjacent coils can be reduced, and each coil is formed by winding a plate-shaped coil material. In this embodiment, since ten wires are wound up, there is an advantage that a large eddy current is not generated as in the first embodiment.

The nine wires are circular in cross section, and each of the wires is wound while a tension is applied. For example, as shown in FIG. The line of “4” is located above the element, the element of “3” is located above the element of “2”, and “1”, “4”,
, "17", "20", the lines formed by the respective cross-sections of the partial strands, and "2", "3", ..., "18", "1"
The line formed by the cross section of each of the 9 "partial strands is
Both may not be substantially straight.

That is, as shown in FIG. 36, the strand of “3” is not located directly above the strand of “2”,
Drops between the line formed by the first wound part of the element wire with the element wire of "2" and is stably located at that part,
Similarly, the strand of “4” does not lie directly above the strand of “1”, but falls between the lines formed by the strand of “1” and the strand of “2”. May be stably located in some parts. Therefore, the vertical section in that case becomes a trapezoidal shape close to a pentagonal shape as shown in FIG. However, also in this case, in each layer, two partial lines constituting the same element wire are adjacent to each other and belong to the present invention.

Press forming in the height direction and the side direction of the coil having a trapezoidal shape in which each vertical section is substantially a pentagonal shape results in a coil 105 having a shape shown in FIG.

In the above embodiment, the converging plate 3
Are passed through the nine wires that have passed through without pressing by the press mechanism 4, but as in the first embodiment,
A part of the wire is pressed to substantially unify the thickness of the pressed portion of the wire, and as shown in FIG. An upper rectangular parallelepiped coil portion may be located, and a prismatic coil portion having a trapezoidal cross-section formed in a zigzag pattern may be located on another pair of two side surfaces facing each other. FIG.
Is a coil 10 having the substantially rectangular parallelepiped coil portion and a prismatic coil portion having a trapezoidal cross section.
FIG. 5 is a top view of FIG.

Further, in the above-described embodiment, each of the wire cross sections is circular, but the wire cross section may be rectangular or square. That is, the wire cross-sectional shape is not limited. By the way, in the case of a coil formed by a rectangular or square wire cross-sectional shape, the space factor can be improved more than in the case of a coil formed by a wire having a circular cross-section.

Further, in the above-described embodiment, nine wires having different cross-sectional areas are arranged in a line so that the cross-sectional areas increase in order, and a predetermined interval is set between adjacent wires. The coil is manufactured by winding the coil while keeping a substantially parallel relationship without being entangled, but the number of wires is not limited to nine. Further, the cross-sectional area and the cross-sectional shape of all of the plurality of strands are not limited to those different from each other, and strands having substantially the same shape and substantially the same cross-sectional area may be partially arranged, The cross-sectional shapes and cross-sectional areas of all the strands may be substantially the same.

Further, in the above-described embodiment, the case of manufacturing a coil having ten layers has been described, but the number of layers of the coil is not limited to ten. Further, in the above-described embodiment, in each layer, two partial lines constituting the same strand are adjacent to each other, but three or more partial lines constituting the same strand may be adjacent to each other. .

In the above-described embodiment, the shape of the coil inner diameter mold is a quadratic prism, but the shape of the coil inner diameter mold may be a polygonal column such as a hexagonal column or an octagonal column. , May be cylindrical. In short, the shape of the inner diameter of the coil is not limited to a square.

A medium carrying a program and / or data for causing a computer to execute all or a part of the operations of all or some of the steps of the coil manufacturing method according to the above-described embodiment, and A medium which is readable and in which the read program and / or data cooperates with the computer to execute the operation also belongs to the present invention.

Note that the medium includes a recording medium such as a ROM, a transmission medium such as the Internet, and a transmission medium such as light, radio waves, and sound waves. The carried medium includes, for example, a recording medium on which a program and / or data is recorded, a transmission medium for transmitting the program and / or data, and the like.

Also, the processing by the computer means that
For example, in the case of a recording medium such as a ROM, it means that the program can be read by a computer.
Or it means that the data can be handled by a computer as a result of the transmission.

[0174] Furthermore, an information aggregate that is a program and / or data for causing a computer to execute all or a part of the operations of all or a part of the steps of the coil manufacturing method of the above-described embodiment is provided. An information set that is readable and in which the read program and / or data cooperates with the computer to execute the operation also belongs to the present invention.

The information aggregate includes, for example, software such as programs and / or data.

The data in the medium and the information aggregate described above includes a data structure, a data format, a data type, and the like.

[0177]

As is apparent from the above description, the present invention provides a coil which can reduce a gap between adjacent coils when arranged in an arc and does not generate a large eddy current. A method and an apparatus for manufacturing the coil can be provided.

Further, the present invention can provide a method and an apparatus for manufacturing a coil having a high space factor.

[Brief description of the drawings]

FIG. 1 is a configuration diagram of a coil according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view of the coil of FIG.

FIG. 3 is a plan view of the coil manufacturing apparatus according to the embodiment of the present invention.

FIG. 4 is a side view of the coil manufacturing apparatus according to the embodiment of the present invention.

FIG. 5 is a configuration diagram of a converging plate 3 of the coil manufacturing apparatus according to the embodiment of the present invention.

FIG. 6 is a configuration diagram of ten strands bundled in a belt shape according to the first embodiment of the present invention.

FIG. 7 is a configuration diagram of a press mechanism 4 of the coil manufacturing apparatus according to the first embodiment of the present invention.

FIG. 8 is an explanatory diagram of a wound core mold 5 of the coil manufacturing apparatus according to the first embodiment of the present invention.

FIG. 9 is a configuration diagram of a coil according to the first embodiment of the present invention.

FIG. 10 is an explanatory diagram of a coil wire cross section and the like according to the first embodiment of the present invention;

FIG. 11 is a press mechanism 7 according to the first embodiment of the present invention.
Configuration diagram

FIG. 12 is a plan view of a conventional motor coil device.

FIG. 13 is a configuration diagram of a conventional plate-shaped coil material.

FIG. 14 is a configuration diagram of a conventional truncated conical coil.

15 is a plan view of a conventional motor coil device in which the motor coil device of FIG. 12 is improved.

FIG. 16 is a configuration diagram of a coil R shaping mold.

FIG. 17 is a diagram for explaining a difference in the width of ten element wires bundled in a band shape depending on the presence or absence of a press in the first embodiment of the present invention.

FIG. 18 is an explanatory diagram of a method for determining a press height according to the first embodiment of the present invention.

FIG. 19 is a press mechanism 2 according to the first embodiment of the present invention.
Configuration diagram of 0

FIG. 20 is a configuration diagram of a coil manufacturing apparatus according to the first embodiment of the present invention.

FIG. 21 is a longitudinal sectional view of the coil according to the first embodiment of the present invention.

FIG. 22 is a configuration diagram of a coil according to the first embodiment of the present invention.

FIG. 23 is a configuration diagram of ten strands bundled in a belt shape according to the first embodiment of the present invention.

FIG. 24 is a longitudinal sectional view of the coil according to the first embodiment of the present invention.

FIG. 25 is a configuration diagram of a coil according to the first embodiment of the present invention.

FIG. 26 is a longitudinal sectional view of the coil according to the first embodiment of the present invention.

FIG. 27 is a configuration diagram of the remaining part of the coil manufacturing apparatus according to the second embodiment of the present invention.

FIG. 28 is a view showing a state where an intermediate product coil is set around the coil inner diameter mold 27b of FIG. 27;

FIG. 29 is a view showing a state in which an intermediate product coil is set around a coil inner diameter mold 27b in FIG. 27, and then a coil upper surface suppressing plate 27g is disposed above the coil inner diameter mold 27b.

FIG. 30 is a view showing a recess 27x according to the second embodiment of the present invention.
Of a pressurizing unit having a coil compression base plate 27a provided with a coil

FIG. 31 is a configuration diagram of a coil according to a third embodiment of the present invention.

FIG. 32 is a longitudinal sectional view of a coil according to the third embodiment of the present invention.

FIG. 33 is a diagram showing an arrangement of nine element wires when passing through the converging plate 3 in the third embodiment of the present invention.

FIG. 34 is an explanatory diagram of a wound core mold according to the third embodiment of the present invention.

FIG. 35 is an enlarged view of a main part of a wound core mold according to Embodiment 3 of the present invention.

FIG. 36 is a longitudinal sectional view of a coil according to the third embodiment of the present invention.

FIG. 37 is a top view of the coil according to the third embodiment of the present invention.

[Explanation of symbols]

 Reference Signs List 1 bobbin 2a, 2b rotating roller 3 converging plate 3a trapezoidal hole 4 press mechanism 4a lower press portion 4b upper press portion 4c geared motor 5 wound core mold 5a left side plate 5b coil inner diameter mold 5c coil inner diameter mold 5d right side plate 5e Winding core 5f Left side plate fixing pin 5g Right side plate tightening bolt 6 Winding machine base 7 Press mechanism 7a Lower press section 7b Upper press section 7c Cylinder 10 Ring iron core 11 Block iron core 12 Coil 13 Gap 14 Coil 15 Coil 100 Coil

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) H02K 3/28 H02K 3/28 M 3/34 3/34 B 3/52 3/52 Z 15/04 15 / 04 ZF term (reference) 5E002 AA06 AA14 AA25 AA27 5H603 AA03 AA07 AA09 BB01 BB09 BB12 CA01 CB02 CB03 CB05 CB17 CB22 CB26 CC11 CD01 CD04 CD14 CD21 CE01 5H604 AA05 AA08 BB01 BB01 BB14 P01 BB01 BB14 P01 PP01 PP12 PP13 PP14 QQ02 QQ19 QQ20 SS03 SS11

Claims (35)

[Claims] 1. A coil in which a plurality of strands are bundled without being entangled, wherein at least a part of the plurality of strands has a different sectional area and / or a sectional shape, and at least a part of the coil has a different shape. The vertical cross section is a substantially trapezoidal cross section, or a substantially pentagonal cross section formed such that a substantially rectangular shape and a substantially trapezoidal shape having one side of the rectangle as a short side are in contact with one side of the rectangle. A multi-line trapezoidal coil characterized by the following. 2. The number of wires in a direction substantially perpendicular to the height direction of the coil, which constitutes each longitudinal section of the coil, is the same at any height position of the coil, The cross-sectional area and cross-sectional shape of each of the strands in a direction substantially perpendicular to the height direction of the coil, constituting each of the longitudinal sections, are substantially the same at any height position of the coil, The cross-sectional area in the height direction of the coil of at least a part of each of the strands forming the substantially trapezoidal or substantially pentagonal longitudinal section is in order from the short side to the long side of the trapezoid, 2. The multi-wire trapezoidal coil according to claim 1, wherein the trapezoidal coil has a larger shape in an order from a shorter side to a longer side of the substantially trapezoidal shape constituting the substantially pentagonal shape. 3. 3. The method according to claim 1, wherein the inner diameter of the coil is substantially a polygon, and a coil portion formed by the plurality of bundled wires on at least one side constituting the polygon is substantially a rectangular parallelepiped. The multi-wire trapezoidal coil according to claim 1 or 2, wherein: 4. The polygon refers to a quadrangle, and at least one side of the polygon refers to a pair of opposing sides of the rectangle, and another pair of opposing sides of the rectangle. The coil portion formed by the plurality of strands bundled on two sides is substantially a prism having a trapezoidal cross section, or a substantially prism having a substantially pentagonal cross section. The trapezoidal coil according to claim 3, wherein: 5. The height of the substantially rectangular parallelepiped coil portion is higher than the height of the substantially rectangular prismatic coil portion, and a part of the substantially rectangular parallelepiped coil portion is a portion of the substantially rectangular parallelepiped coil portion. 5. The multi-portion according to claim 3, wherein the projection protrudes to a long side of the trapezoid in one longitudinal section or to a long side of the trapezoid forming the pentagon in the one vertical section. 6. Main line trapezoidal coil. 6. The multi-wire trapezoidal coil according to claim 1, wherein each of said strands is covered with an insulating material. 7. The wire is taken out from each of a plurality of bobbins around which the wire is wound, and each of the plurality of wires is bundled in a substantially band shape so that the cross sections are arranged in a line without being entangled. A coil manufacturing method for manufacturing a coil by winding the bundled plurality of strands with a predetermined wound core mold, wherein a cross-sectional area of at least a part of the plurality of strands is different. When arranging the wires in the band shape, the cross-sectional area of at least a part of the plurality of wires is increased in the width direction of the band from one end side in the width direction to the other end side, so that the plurality of A method for manufacturing a coil, comprising arranging strands in a band. 8. When arranging the plurality of strands in the band shape, the predetermined plurality of strands from the one end side in the width direction of the band are arranged with strands having substantially equal cross-sectional areas and cross-sectional shapes. From the portion next to the portion where a plurality of strands having substantially the same cross-sectional shape are arranged to the other end, a plurality of strands having a cross-sectional area larger than the cross-sectional area of the plurality of strands are arranged, and the plurality of strands are arranged. Arranging the plurality of strands in a band shape such that at least a part of the cross-sectional area of the strand increases in the order from the side adjacent to the portion where the plurality of strands having substantially the same cross-sectional area are arranged from the side adjacent to the other end The method for manufacturing a coil according to claim 7, wherein: 9. After the plurality of strands are bundled in the band shape, and before the bundled strands are wound by the winding core mold, the plurality of strands are bundled in the belt shape. At least part of the line
9. The method according to claim 7, wherein the pressing is performed in the thickness direction of the band, and the thickness of the plurality of strands in the width direction of the band is substantially unified in the thickness direction of the band.
3. The method for producing a coil according to item 1. 10. When the pressing is performed, when the plurality of strands are bundled into the strip after the pressing, the width of the band is equal to the length of the plurality of strands when the pressing is not performed. The method of manufacturing a coil according to claim 9, wherein the pressing is performed so that the width of the band when the wires are bundled is substantially equal to the length of the band. 11. The wound core mold is substantially a polygonal pillar, and the plurality of strands bundled in the band shape are pressed at least partially on at least one side surface of the polygonal pillar. The press and the winding are performed so that is positioned.
0. The method for manufacturing a coil according to item 0. 12. The polygonal prism refers to a quadratic prism, and at least one side surface of the polygonal prism refers to a pair of two side surfaces of the quadratic prism facing each other. The method according to claim 11, wherein the pressing and the winding are performed such that the plurality of strands, which are not pressed and are not bundled, are positioned on a pair of two side surfaces. Manufacturing method of coil. 13. The method for manufacturing a coil according to claim 7, wherein each of said strands is covered with an insulating material. 14. A hole is provided for bundling a plurality of wires from a plurality of bobbins around which the wires are wound, so that the cross-sections are aligned in a line without being tangled. And a winding core die for winding up the plurality of wires bundled by the convergence device, wherein at least some of the plurality of wires have different cross-sectional areas, and When passing the line through the hole of the converging means, the cross-sectional area of at least a part of the plurality of strands in the longitudinal direction of the hole is increased in order from one end side to the other end side in the longitudinal direction. A coil manufacturing apparatus, wherein the plurality of strands are passed through. 15. At least a part of the plurality of element wires arranged between the converging means and the wound core mold and bundled in the band shape is pressed in a thickness direction of the band.
15. The coil manufacturing apparatus according to claim 14, further comprising press means for substantially unifying the thickness of each of the plurality of strands in the width direction of the strip in the thickness direction. 16. A columnar body in which the pressing means contacts a lower side of the plurality of strands bundled together, and a pressurizing unit for applying pressure to at least a part of the plurality of strands from above. A stretching regulation that regulates stretching of the plurality of strands in the width direction of the strip when the pressure is applied to the plurality of strands bundled in the strip and located on both sides of the width of the strip. The coil manufacturing apparatus according to claim 15, characterized in that the coil manufacturing apparatus comprises a portion and one or a plurality of flat-plate-shaped rings which are fitted into the columnar body and have a predetermined thickness. 17. A medium carrying a program and / or data for causing a computer to execute all or part of all or part of the steps of the method for manufacturing a coil according to claim 7. A medium which can be processed by a computer. 18. A program and / or data for causing a computer to execute all or part of all or part of the steps of the method for manufacturing a coil according to claim 7. Information aggregate to be characterized. 19. The wire is taken out from each of a plurality of bobbins around which the wire is wound, and each of the plurality of wires is bundled in a substantially band shape so that the cross sections are lined up without being entangled, The bundled plurality of wires are wound up with a square pillar-shaped wound core mold, and the outside of at least one pair of side faces of the square pillar-shaped wound core mold facing at least the wound wire. A method for manufacturing a coil, comprising manufacturing a coil by pressing from a coil. 20. The cross-sectional area of at least a part of the plurality of strands is different, and when arranging the plurality of strands in the band shape, the cross-sectional area of at least a part of the plurality of strands is the width of the band. The plurality of strands are arranged in a band shape so as to increase in order from one end side to the other end side in the width direction, and each longitudinal section of the coil shape after being wound by the winding core mold is defined as (1 (2) a substantially trapezoidal shape, or (2) a substantially pentagonal shape formed such that a substantially rectangular shape and a substantially trapezoidal shape having one side of the rectangle as a short side are in contact with one side of the rectangle. In the meantime, the coil portion constituted by the element wire wound by the wound core mold on the pressed side,
(A) Substantially rectangular parallelepiped, (B) Substantially prismatic having a substantially trapezoidal cross section, or (C) Substantially rectangle and one side of the rectangle as a short side 20. The method of manufacturing a coil according to claim 19, wherein pressing is performed so that the upper trapezoidal shape has a substantially pentagonal cross section formed so as to be in contact with one side of the rectangle. . 21. A cross-sectional area and a cross-sectional shape of the plurality of strands are substantially equal to each other before being wound by the wound core mold, and each of the longitudinal sections of the coil shape after being wound by the wound core mold is When substantially pressed into a rectangle, a coil portion composed of a wire wound by the wound core mold on the side to be pressed during the pressing,
(A) Substantially rectangular parallelepiped, (B) Substantially prismatic having a substantially trapezoidal cross section, or (C) Substantially rectangle and one side of the rectangle as a short side 20. The method of manufacturing a coil according to claim 19, wherein pressing is performed so that the upper trapezoidal shape has a substantially pentagonal cross section formed so as to be in contact with one side of the rectangle. . 22. A hole is provided for bundling a plurality of strands from a plurality of bobbins around which the strands are wound, so that the cross-sections are aligned in a line without being tangled. Converging means, a square pillar-shaped wound core mold for winding up the plurality of strands bundled by the converging means, and a square with respect to the strand wound by the wound core mold. Pressing means for pressing from at least both outer sides of at least one pair of side faces of the column-shaped wound core mold, the coil manufacturing apparatus comprising: 23. A cross-sectional area of at least a part of the plurality of strands is different, and when the plurality of strands are arranged in the band shape by the convergence means, a cross-sectional area of at least a part of the plurality of strands is changed. In the width direction of the band, the plurality of strands are arranged in a band shape so as to increase in order from one end side to the other end side in the width direction, and the pressing means is the winding core on the side to be pressed. The coil part consisting of the element wire wound up by the mold,
(A) Substantially rectangular parallelepiped, (B) Substantially prismatic having a substantially trapezoidal cross section, or (C) Substantially rectangle and one side of the rectangle as a short side 23. The means according to claim 22, wherein the upper trapezoidal shape is a means capable of being pressed so as to have a substantially prismatic shape having a substantially pentagonal cross section formed so as to be in contact with one side of the rectangle. An apparatus for manufacturing the coil described in the above. 24. A cross-sectional area and a cross-sectional shape of the plurality of strands are substantially equal before being wound up by the rolled-up core die, and the pressing means may be configured such that the pressed core-side die is on the pressed side. The coil part composed of the strand wound up in
(A) Substantially rectangular parallelepiped, (B) Substantially prismatic having a substantially trapezoidal cross section, or (C) Substantially rectangle and one side of the rectangle as a short side 23. The means according to claim 22, wherein the upper trapezoidal shape is a means capable of being pressed so as to have a substantially prismatic shape having a substantially pentagonal cross section formed so as to be in contact with one side of the rectangle. An apparatus for manufacturing the coil described in the above. 25. A method in which a plurality of N wires are wound and a plurality of M wires are wound.
A coil having layers, wherein in each layer of the coil, a plurality of L partial lines constituting the same element wire are adjacent to each other. 26. A cross-sectional area of at least a part of the plurality of N strands increases in the height direction of the coil in order from one end face side of the coil to the other end face side. The coil according to claim 25, wherein 27. The coil according to claim 25, wherein the inner diameter of the coil is substantially polygonal. 28. The coil according to claim 25, wherein each of said strands is covered with an insulating material. 29. The wire is taken out from each of the plurality of N bobbins around which the wire is wound, and each of the plurality of N wires is not entangled,
The cross sections are arranged in a line at a predetermined interval, and the plurality of N wires whose cross sections are arranged in a line at the predetermined interval are wound up by a predetermined core mold, and the coil is wound. Wherein the plurality of N strands are substantially wound each time the plurality of N strands are wound by the wound core mold when winding up the plurality of N strands. A coil which is simultaneously shifted in substantially the same direction, and winds up the plurality of N wires so that a plurality of L adjacent wires constituting the same wire are adjacent to each other and substantially fill the gap. Manufacturing method. 30. A cross-sectional area of at least a part of the plurality of N strands is different, and when arranging the plurality of N strands in the line, at least a part of a cross-sectional area of the plurality of N strands 30. The coil according to claim 29, wherein the plurality of N element wires are arranged in the row so that the width increases in the width direction from one end to the other end in the width direction. Production method. 31. The method for manufacturing a coil according to claim 29, wherein the wound core mold is substantially a polygonal pillar. 32. The method for manufacturing a coil according to claim 29, wherein each of said strands is covered with an insulating material. 33. A method for aligning cross sections of a plurality of N wires from a plurality of N bobbins around which the wires are wound at predetermined intervals without being entangled. A wire alignment means provided with a hole; and a wound core die for winding up the plurality of N wires, the cross sections of which are arranged in a line at predetermined intervals by the wire alignment means. When the plurality of M strands are wound, in each layer where the strand is wound, a plurality of L partial lines constituting the same strand can be adjacent to each other. An apparatus for manufacturing a coil, wherein each of the plurality of M strands is substantially simultaneously shifted in substantially the same direction each time each strand is wound by the wound core mold. 34. A medium carrying a program and / or data for causing a computer to execute all or part of all or part of the steps of the coil manufacturing method according to claim 29. A medium which can be processed by a computer. 35. A program and / or data for causing a computer to execute all or part of all or part of the steps of the coil manufacturing method according to claim 29. Information aggregate to be characterized.