JP2005327926A - Coil winding device and method for winding split type coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a technology capable of automatically forming a split type coil in a short period of time without a collapse of the coil. <P>SOLUTION: The method for forming the coil comprises the steps of winding a conductor to a first region with its width regulated by a first member, forming a first unit coil, then holding the both sides of the first unit coil in the coil axis direction by a second member, moving the first member with itself held from the width-regulated position of the first unit coil to the predetermined position in the coil axis direction, getting over the cnductor at the wound-up-end side of the first unit coil within a second region which is newly width-regulated by the first member, and forming a second unit coil by laminating a plurality of layers by winding the conductor within the second region. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a winding technique for a split coil, and more particularly to a technique for preventing line breakage in a unit coil during winding work.

  In relation to the present invention, conventional techniques for preventing the unit coil from breaking are disclosed in, for example, Japanese Patent Publication No. 6-12648 (Patent Document 1), Japanese Patent Application Laid-Open No. 6-61086 (Patent Document 2), and the like. And registered utility model No. 2500966 (patent document 3). In Japanese Patent Publication No. 62-12648, an insulated wire having a self-bonding layer formed on the surface is used as a conducting wire, and after the winding is completed as a unit coil, the unit coil is heated to produce the self-bonding layer. Japanese Patent Application Laid-Open No. 6-61086 describes a U-shaped insulating spacer made of the same material as that used for casting a mold coil. A technique is described in which a unit coil is formed by attaching a conductor around a frame at a predetermined interval, winding the conductor inside the U-shaped insulating spacer, and forming a unit coil. A configuration in which a non-resin impregnated interlayer insulator coated with an adhesive is provided over the entire wound layer of a coil wire (conductive wire) is described.

Japanese Examined Patent Publication No. 62-12648

JP-A-6-61086 Registered Utility Model No. 2500966

  Among the above-mentioned conventional techniques, the technique described in Japanese Patent Publication No. 61-2648 requires heating every time the winding operation of the unit coil is completed, which complicates the apparatus configuration and increases the time for heating. And time for cooling is required. Insulated coated electric wires provided with a self-bonding layer are relatively expensive and lead to an increase in material costs. In the technique described in Japanese Patent Laid-Open No. 6-61086, it is difficult to automate the operation of providing the U-shaped insulating spacer. In addition, the technique described in the registered utility model No. 2500966 discloses a relatively expensive interlayer insulation because a non-resin impregnated interlayer insulator coated with an adhesive on both sides is provided over the entire wound layer of the coil wire. It consumes a lot of things and takes time.

The problem of the present invention is that, in view of the state of the prior art described above, as a coil winding technique, a split type coil can be manufactured in a short time and at low cost by an automatic operation in a state where the unit coil is not broken. Is to do.
An object of the present invention is to solve the above-described problems and provide a winding technique suitable for mass production of split-type coils.

  In order to solve the above-described problems, in the present invention, as a winding technique for a split-type coil, after a conductor is wound around a first region whose width is restricted by a first member to form a first unit coil, Both side surfaces of the first unit coil in the coil axis direction are held by the second member, and in the held state, the first member is moved from the width regulating position of the first unit coil to a predetermined position in the coil axis direction. And moving the conductor on the winding end side of the first unit coil into the second region newly width-controlled by the first member, and winding the conductor in the second region. Thus, the second unit coil is formed by stacking in a plurality of layers. The second member holds both side surfaces of the wound unit coil to prevent the unit coil from being broken.

  According to the present invention, it is possible to manufacture the split coil at a low cost by an automatic operation in a state where the unit coil is not broken.

Hereinafter, the best embodiment of the present invention will be described with reference to the drawings.
1-5 is explanatory drawing of embodiment of this invention. 1 is an overall configuration diagram of a coil winding device as an embodiment of the present invention, FIG. 2 is a configuration example diagram of a coil winding portion in the coil winding device of FIG. 1, and FIG. 3 is a coil of FIG. FIG. 4 is a diagram illustrating an example of the appearance of a wound split-type coil, and FIG. 5 is a diagram illustrating an example of a procedure for winding the split-type coil. 1 to 4, the same components are denoted by the same reference numerals.

  In FIG. 1, 1 is a coil winding device, 10 is a conductor for a coil, 21 is a bobbin of a split coil, and 14 is a unit coil for guiding the conductor 10 when winding a unit coil of the split coil. A guide 15 serving as a first member for regulating the width in the coil axial direction of the second coil 15 holds both side surfaces in the coil axial direction of a unit coil in which the conductor 10 is wound around the bobbin 21 and laminated in a plurality of layers. 30 is a winding final roller for supplying the conductor 10 to the region of the surface of the bobbin 21 whose width is restricted by the guide 14, and 40 is a guide drive as a drive mechanism for moving the guide 14. , 41 is a hand drive unit as a drive mechanism for moving and driving the hand, 50 is a roller movement drive unit that moves the position of the final roller in the direction of the coil axis of the split coil, and 60 is an operation table. That. In the operation table 60, the rotational drive state of the bobbin 21, the tension state of the conductor 10 supplied from the final roller 30, the operation state of the guide drive unit 40, the operation state of the hand drive unit 41, and the like are controlled by computer control. To do.

  With the above configuration, the bobbin 21 is rotationally driven by a motor or the like at a predetermined speed, and the conductor 10 supplied from the final roller 30 is aligned in the first region on the surface of the bobbin 21 whose width is regulated to a predetermined value by the guide 14. The first unit coil is formed by sequentially stacking. Both side surfaces of the formed first unit coil in the coil axis direction are held by being held by the hand 15 that is moved and driven by the hand drive unit 41. In the holding state, the guide 14 is moved from the current width regulation position to a predetermined position in the coil axis direction by the guide driving unit 40. At this time, the final roller 30 is also moved by the roller movement drive unit 50, and the conductor on the winding end side of the unit coil formed in the second region on the surface of the bobbin 21, the width of which is newly regulated by the guide 14. To cross. When the crossing operation is finished, the conductor 10 supplied from the final roller 30 is wound in an aligned manner in the second region in which the width of the conductor 10 is regulated to a predetermined value by the guide 14, and is sequentially laminated to form the second layer. A unit coil is formed. Both side surfaces of the second unit coil are also held by the hand 15 moved by the hand driving unit 41. The hand 15 holds both side surfaces of the wound unit coil in order to prevent breakage of the unit coil, particularly when the conductor on the winding end side is crossed.

FIG. 2 is a configuration example diagram of a coil winding portion in the coil winding apparatus of FIG. (A) is when winding the first unit coil, (b) is the state when the winding of the first unit coil is finished and the second unit coil is wound. Show.
In FIG. 2, 20a is a first unit coil, 20b is a second unit coil, 14a and 14b are guides, 15a and 15b are hands, 40a is a guide drive unit for driving the guide 14a, and 40b is for driving the guide 14b. It is a guide drive part. The hand drive unit 41 drives the hands 15a and 15b. The guide driving units 40a and 40b move the guides 14a and 14b in the directions of arrows X and Y, respectively. In addition, the roller movement drive unit 50 moves the final roller 30 in the directions of arrows a and b.

  In the state of FIG. 2A, the guides 14a and 14b regulate the width of the predetermined position on the surface of the bobbin 21 by a predetermined value in the coil axis direction (X direction) to form the first region. The conductor 10 supplied from the final roller 30 is wound in an aligned manner in the first region by rotating the bobbin 21 and moving the final roller 30 at a predetermined speed in the direction b. When the layers reach the predetermined number of layers, the first unit coil 20a is formed. In the case of (a) in which the first unit coil 20a is in a winding state, the hands 15a and 15b are separated from the first unit coil 20a at positions moved in the Y direction.

  When the first unit coil 20a is formed, the first unit coil 20a is sandwiched between the hands 15a and 15b which are moved from the separated position by the hand drive unit 41 on both side surfaces in the coil axial direction. It is held in a pressed state. While being held by the hands 15a and 15b, the guides 14a and 14b are moved from the current width regulation position to a predetermined position in the coil axis direction, that is, a position where the second unit coil 20b is wound by the guide driving portions 40a and 40b. Moved. At this time, the final roller 30 is also moved in the direction b by the roller movement driving unit 50, and the width of the end-of-winding end conductor of the first unit coil 20a is newly restricted by the guides 14a and 14b. The bobbin 21 is passed over the second region on the surface.

  When the moving operation is finished, the conductor 10 supplied from the final roller 30 is driven to rotate the bobbin 21 in the second region in which the width of the conductor 10 is regulated to a predetermined value by the guides 14a and 14b and the final roller 30. Are moved in the b direction at a predetermined speed so as to be wound in alignment (FIG. 2B) and sequentially stacked to form the second unit coil 20b. Both side surfaces of the second unit coil are also held by the hands 15a and 15b moved by the hand driving unit 41. In the holding state, the guides 14a and 14b are moved from the current width regulation position to the winding position of the third unit coil (not shown) by the guide driving units 40a and 40b. At this time, the final roller 30 is also moved in the direction b by the roller movement driving unit 50, and the width of the end-of-winding end conductor of the second unit coil 20b is newly regulated by the guides 14a and 14b. In the third region of the surface of the formed bobbin 21. Thereafter, winding is performed to form a third unit coil. Further, the holding by the hands 15a and 15b, the movement of the guides 14a and 14b, the crossing operation of the end-of-winding side conductor, and the winding are repeated, and a predetermined plurality of unit coils are formed as divided coils formed on the bobbin 21 Finalize.

FIG. 3 is an explanatory view of side holding of the unit coil in the coil winding portion of FIG.
In FIG. 3, reference numeral 10a denotes a transition portion of the winding end side conductor of the first unit coil 20a, and 100 denotes a first unit coil 20a formed by windings, the width of which is regulated by the guides 14a and 14b. Region 200 is also the second region. With the first unit coil 20a being held by the hands 15a and 15b on both sides in the coil axis direction, the guides 14a and 14b leave the both sides and move to the winding position of the second unit coil. The second region is formed. In this state, the final roller 30 causes the end-of-winding end side conductor of the first unit coil 20a to move across the second region 200 to form the transition portion 10a. At this time, since the first unit coil 20a is held on both sides by the hands 15a and 15b, the line breakage does not occur.

  FIG. 4 is an external view of a wound divided coil. In this configuration, the first unit coil 20a, the second unit coil 20b, the third unit coil 20c, the fourth unit coil 20d, and the fifth unit coil 20e are formed on the bobbin 21. is there. The split coil is further molded, for example, with a resin or the like to form a molded coil for a transformer.

FIG. 5 is a diagram illustrating an example of a procedure for winding a split coil.
In FIG.
(1) The bobbin 21 is set at a predetermined position (step S501).
(2) The guides 14a and 14b for guiding the winding of the conductor 10 to the bobbin 21 are moved by the guide driving units 40a and 40b and set in a predetermined state (step S502).
(3) The conductor 10 is set at a predetermined position by the final roller 30 or the like (step S503).
(4) The winding of the first unit coil 20a is started, and the first layer winding is performed on the bobbin 21 (step S504).
(5) Winding the second layer is performed (step S505).

(6) Further, the third and subsequent windings are performed by repeating the above steps S503 and S504.
(7) It is determined whether or not the number of layers has reached a predetermined value, that is, whether or not the winding of the first unit coil 20a has been completed (step S506).
(8) If the result of determination in step S506 is that the winding of the first unit coil 20a has been completed, the first unit coil 20a is held by the hands 15a and 15b (step S507). As a result of the determination in step S506, if the winding of the first unit coil 20a is not completed, the process returns to step S505 to perform further winding.
(9) After holding the first unit coil 20a with the hands 15a and 15b in step S507, the guides 14a and 14b are moved to the position of the next second unit coil 20b along the coil axis direction, 2 region 200 is formed (step S508).
(10) The terminal 10a at the end of winding of the first unit coil 20a that has been wound is moved to the second region 200 side (step S509). The transition part 10a is a terminal at the beginning of winding of the second unit coil 20b.

(11) Similarly to the case of the first unit coil 20a, the second unit coil 20b is operated in a series of steps from step S504 to step S507 (referred to as A). The second unit coil 20b is wound (step S510).
(12) Furthermore, the third unit coil 20c and the fourth unit can be obtained by repeating the series of procedures A by holding the coil side surfaces by the hands 15a and 15b, moving the guides 14a and 14b, moving the winding end terminals, and performing a series of procedures A. Winding of the coil 20d, the fifth unit coil 20e,... Is performed.
(13) It is determined whether or not the predetermined number of unit coils has been reached (step S511).
(14) If the number of unit coils has reached a predetermined value as a result of the determination in step S511, the winding operation is completed. For example, in the case of a molded coil, the coil is molded with resin (step S512). If the result of determination in step S511 is that the number of unit coils has not yet reached the predetermined value, processing returns to step S508 and winding is performed.

  According to the embodiment, the split coil can be automatically manufactured in a short time in a state where the unit coil is not broken.

  In addition to holding both side surfaces with the hands 15a and 15b, the wound unit coil may be configured such that an adhesive tape piece is provided on a part of the coil circumference or an adhesive is applied. Good. In the above embodiment, the bobbin 21 is used for the winding. However, the winding may be performed using a mold or the like.

1 is an overall configuration example diagram of a coil winding apparatus as an embodiment of the present invention. It is a structural example figure of the coil winding part in the coil winding apparatus of FIG. It is explanatory drawing of the side surface holding | maintenance of the unit coil in the coil winding part of FIG. It is an external view example of a split type coil. It is a figure which shows the example of a procedure of the winding operation | work of a split type coil.

Explanation of symbols

1 ... Coil winding device,
10 ... conductor,
10a ... Crossover part,
21 ... Bobbin,
14, 14a, 14b ... guide,
15, 15a, 15b ... hand,
30 ... last roller,
40, 40a, 40b ... guide drive unit,
41 ... hand drive unit,
50. Roller movement drive unit,
60: Operation console.

Claims (3)

A coil winding device for winding a split type coil in which a plurality of unit coils in which conductors are laminated in a plurality of layers are coaxially arranged,
A first member that guides the conductor and regulates the width of the unit coil in the coil axis direction when winding the unit coil;
A second member that holds both side surfaces in the coil axis direction of a unit coil wound around the conductor and laminated in a plurality of layers;
A drive mechanism for driving the first and second members;
And holding the both side surfaces of the first unit coil, the width of which is restricted and wound by the first member, with the second member, and after the holding, the first member is attached to the first unit coil. The coil is moved from the width regulation position to a predetermined position in the coil axis direction, and the conductor on the winding end end side of the first unit coil is moved into the area where the width is newly regulated by the first member. A coil winding apparatus characterized in that the conductor is wound and laminated in a plurality of layers to wind the second unit coil.   The coil winding device according to claim 1, wherein the unit coil has a structure in which an odd number of layers of conductors are laminated. A winding method for a split coil comprising a plurality of unit coils arranged coaxially,
Winding the conductor in an aligned manner by regulating the winding width by the first member, and laminating a plurality of layers to form the first unit coil;
Holding both side surfaces of the first unit coil in the coil axial direction at the position by the second member;
Moving the first member from a width regulating position of the first unit coil to a predetermined position in the coil axis direction while being held by the second member;
Passing the conductor on the winding end side of the first unit coil into a region regulated by the first member;
Winding the conductor in the region with the first member to regulate the winding width in an aligned manner, and laminating a plurality of layers to form a second unit coil;
And then splitting the split coil by winding the split coil.

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