JP2009147275A - Method of manufacturing rectangular edge wise coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a rectangular edge wise coil that is manufactured at low cost without using any device called a winding machine with a high space factor of a coil and a satisfactory heat dissipation. <P>SOLUTION: The method of manufacturing a rectangular edge wise coil by using a plurality of rod wires 1 includes a composite rectangular line working step of working a composite rectangular wire 2 configured of cross-sectional almost rectangular wires having arcs with small diameters at four corners which are adhered to each other in parallel by supplying a plurality of rod wires 1 in parallel, and making them pass through an extraction dice such as a roller dice 20; and a roller bending step of working the composite rectangular wire 2 into a linear side section and a curved corner part by supplying the obtained composite rectangular lines 2, and making them meander through rollers adjusted to fixed non-parallel clearances in every prescribed distance. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a flat edgewise winding, and more particularly to a method for manufacturing a flat edgewise winding using a plurality of round wires.

A winding wound such that the short side of a line having a rectangular cross section is parallel to the axial direction of the winding is called an edgewise winding. This edgewise winding can obtain a coil having a generally higher space factor than a round wire.
In general, a rectangular wire is often used for the edgewise winding. However, when edgewise winding is performed using this rectangular wire, the radius of curvature of the corner portion of the winding becomes large, and a magnetic core or the like. When wound around, there is a problem that the gap between the coil end portion and the core becomes large. Moreover, when a curvature radius becomes large, the air insulating layer of the part will increase and there exists a problem that heat dissipation becomes bad.
In addition, when edgewise winding is performed using a single rectangular wire having a large cross-sectional area, there is a problem that the eddy current loss of the coil increases and it is difficult to obtain a skin effect against high-frequency current.
In such a background, Japanese Utility Model Laid-Open No. 4-134822 (Patent Document 1) uses a plurality of insulated conductors as a high-frequency transformer, and winds them edgewise around a winding shaft in a state where they are aligned in parallel. A high-frequency transformer is disclosed.
Similarly, in Japanese Patent Application Laid-Open No. 2005-209916 (Patent Document 2) and Japanese Patent Application Laid-Open No. 2005-327834 (Patent Document 3), a plurality of electric wires are stacked in parallel and edged by a winding machine or the like. A manufacturing method for finishing a wise winding is disclosed.
Japanese Utility Model Publication No. 4-134822 JP 2005-209916 A JP 2005-327834 A

However, all of those disclosed in Patent Documents 1 to 3 are merely windings in which a plurality of electric wires are bundled in parallel and wound together. That is, the cross-sectional shape of each used electric wire remains as it is, and is merely a bundled wire existing in a part of the edgewise winding. For this reason, when the original electric wire is a round wire, the circular cross section is carried over as a part of the cross section of the winding as it is, so that the coil has a large gap and a low space factor. In addition, there is a problem in heat dissipation because the gap between the wires is large and the air insulating layer increases.
In addition, in the disclosures in Patent Documents 1 to 3, any method using a winding shaft or a winding machine is employed to bend the wire edgewise.

  Accordingly, the present invention solves the above-mentioned problems in the prior art, has a high winding space factor, good heat dissipation, and can be manufactured at low cost without using a device called a winding machine. An object is to provide a method for manufacturing an edgewise winding.

  A method for manufacturing a flat edgewise winding according to the present invention is a method for manufacturing a flat edgewise winding using a plurality of round wires, and a plurality of round wires are supplied in parallel to draw a drawing die such as a roller die. By passing through, a synthetic rectangular wire machining process that forms and forms a synthetic rectangular wire in which each line having a substantially rectangular cross section with small-diameter arcs at the four corners is in close contact with each other, and the obtained synthetic rectangular wire is supplied While bending through a roller adjusted to a constant non-parallel gap for each predetermined distance, a roller bending process for forming a composite flat wire into a straight side and a curved corner It has the 1st characteristic to have.

According to the first feature of the present invention described above, a synthetic rectangular wire machining step is used to combine a plurality of round wires in parallel with each other having a substantially rectangular cross section having small-diameter arcs at the four corners. A flat wire is obtained. The obtained composite rectangular wire has a structure in which each of the lines constituting it is transformed from a circular cross section into a rectangular cross section having a small-diameter arc at the four corners, so that the space factor of the composite rectangular wire itself is simply a plurality of round lines. This is sufficiently improved as compared with those bundled individually, and the gaps between the constituent lines are reduced to improve heat dissipation.
In addition, the synthetic rectangular wire is passed through the roller adjusted at a constant non-parallel gap by the roller bending process at every constant distance, so that the synthetic rectangular wire can be bent at a constant distance while moving straight. Is possible.
As a result, as a method using a roller, it is possible to make the composite rectangular wire an edgewise winding composed of a straight side portion and a curved corner portion.
The composite rectangular wire to be bent is one in which a plurality of wires are in close contact with each other in parallel, but also possesses independence as individual lines, so compared to the case of a flat wire consisting of a single line, The obtained edgewise winding can reduce the radius of curvature of the outer periphery of the corner. That is, a more compact edgewise winding can be obtained.

  In addition to the operation and effect of the first feature of the present invention, the manufacturing method of the flat edgewise winding according to the present invention includes a roller of the combined rectangular wire between the combined rectangular wire processing step and the roller bending processing step. A second feature is that it includes a composite rectangular wire thickness adjusting step in which a portion that is to be bent in the bending step to become a corner portion is processed in advance into a tapered cross-sectional shape in which the thickness of the cross section changes in the width direction of the cross section. It is said.

  According to the second feature of the present invention, the section of the synthetic rectangular wire that should be bent in the roller bending process and become the corner portion is processed into a tapered cross-sectional shape in advance by the synthetic rectangular wire thickness adjusting process. It becomes possible to keep. Therefore, the thick rectangular side of the tapered cross-sectional shape corresponds to the outer peripheral side of the corner portion, and the thin rectangular side of the tapered cross-sectional shape corresponds to the inner peripheral side of the corner portion. It is possible to absorb the decrease in the outer peripheral wall thickness and the increase in the inner peripheral wall thickness at the corner portion, and uniformize the thickness in the width direction at the corner portion after bending.

  In addition to the first feature described above, the method for manufacturing a flat edgewise winding according to the present invention has a shape of a die hole of a drawing die such as a roller die in the synthetic flat wire processing step, and the thickness of the drawn wire is The rectangular cross-sectional shape that is the same in the width direction and the tapered cross-sectional shape in which the thickness of the drawn line changes in the width direction are changed and adjusted, thereby forming a straight side portion of the edgewise winding. For the power part, a composite rectangular wire having a substantially rectangular cross-sectional shape with the same thickness in the width direction and a tapered cross-sectional shape in which the thickness changes in the width direction is processed for the part to be the corner part of the edgewise winding. This is a third feature.

  According to the third feature of the present invention, in addition to the function and effect of the first feature, when the composite rectangular wire is processed and formed from a plurality of round wires by the composite rectangular wire processing step, the edgewise winding is performed. The portion that should be the straight side portion is a synthetic rectangular wire having a substantially rectangular cross-section through a die hole having a rectangular cross-sectional shape, and the portion that should be the corner portion of the edgewise winding is a tapered cross-sectional shape. It is possible to obtain a synthetic rectangular wire having a tapered cross section through the die hole. That is, it is possible to simultaneously adjust the thickness depending on the location of the synthetic rectangular wire when processing and forming the synthetic rectangular wire. In this way, when the corner portion is processed and formed by bending the synthetic rectangular wire in the subsequent roller bending process, the decrease in the thickness on the outer peripheral side and the increase in the thickness on the inner peripheral side are absorbed. The thickness in the width direction can be made uniform.

  Moreover, in addition to any of the first to third features of the present invention, the fourth feature of the method for manufacturing a flat edgewise winding of the present invention is that the round wire to be used is an insulated coated wire. .

  According to the fourth feature of the present invention, in addition to the function and effect of any one of the first to third features of the present invention, a composite rectangular wire obtained by using a plurality of insulated wires, and The cross-section of the edgewise winding obtained by bending it can be divided into a plurality of states with an insulating coating film, and compared with the case of the edgewise winding with a single rectangular wire, Eddy current loss can be reduced.

  According to the method for manufacturing a flat edgewise winding of the present invention, a plurality of round wires are used, and the combined rectangular wires each having a substantially rectangular cross section having small-diameter arcs at the four corners are in close contact with each other in parallel. Since a flat rectangular edgewise winding is manufactured by bending a composite rectangular wire edgewise using a roller and then forming a flat rectangular edgewise winding with a roller, In comparison, the space factor of the winding can be improved, and the heat dissipation can be improved. Also, it is possible to manufacture a flat edgewise winding with less labor using a roller.

  With reference to the following drawings, a method of manufacturing a flat edgewise winding according to an embodiment of the present invention will be described for the understanding of the present invention. However, the following description is an embodiment of the present invention, and does not limit the contents described in the claims.

FIG. 1 is a diagram for explaining a synthetic rectangular wire processing step used in the method for manufacturing a flat edgewise winding according to the first embodiment of the present invention, and FIG. 2 is used for the synthetic rectangular wire processing step in the first embodiment. It is a figure explaining the process of process of the obtained several line, (A) is sectional drawing which shows the state in the middle of a process, (B) is sectional drawing of the obtained synthetic | combination rectangular wire. FIGS. 3A and 3B are diagrams illustrating a roller bending process used in the first embodiment. FIG. 3A is an explanatory diagram of the process, and FIGS. 3B and 3C are diagrams illustrating a roller gap.
FIG. 4 is a diagram for explaining a synthetic rectangular wire thickness adjusting process used in the method for manufacturing a flat edgewise winding according to the second embodiment of the present invention, wherein (A) is an explanatory diagram of the process, and (B), ( C) is a diagram for explaining a roller gap.

First, a first embodiment of a method for manufacturing a flat edgewise winding according to the present invention will be described with reference to FIGS.
FIG. 1 shows a process of forming a composite rectangular wire from a plurality of round wires. 10 is a bobbin, and 20 is a roller die. In addition, 1 is an insulation coating round wire, and 2 is a synthetic rectangular wire.
The composite rectangular wire 2 is processed and formed using a plurality of insulating coating round wires 1a, 1b, 1c, and 1d. The plurality of insulation-coated round wires 1a, 1b, 1c, and 1d are respectively drawn out from the bobbins 10a, 10b, 10c, and 10d, passed through the roller die 20, and drawn into a composite rectangular wire 2.
As said insulation coating round wire 1a, 1b, 1c, 1d, what coat | covered the surface of conducting wires, such as a copper wire, with a varnish, a prepreg, a synthetic resin, and another well-known insulating coating material can be used.

  In the roller die 20 shown in FIG. 1, a pair of longitudinal rollers 21 and a pair of lateral rollers 22 are combined and arranged in the front-rear direction. However, as shown in FIG. 2A, the longitudinal roller 21 and the lateral roller 22 may be combined at the same position. The roller die 20 may be a hole-type roller die in which a pair of lateral rollers is a grooved roller and a rectangular hole is formed between a pair of upper and lower rolls.

The shape of the extraction hole by the roller die 20 is a horizontally long rectangular shape with reference to FIG. However, the vertical and horizontal dimensions of the drawing hole are such that the combined rectangular wire 2 obtained by drawing has a cross-sectional shape of the rectangular wire as a whole, and each line 2a, 2b, 2c, 2d that combines the combined rectangular wire 2 is formed. The vertical and horizontal dimensions of the extraction hole are determined so that each has a substantially rectangular cross section with small-diameter arcs R at the four corners and is in close contact with each other. For the vertical and horizontal dimensions of the drawing hole of the roller die 20, referring to FIG. 2A, for example, the vertical gap h is slightly narrower than the diameter of the round wire 1, and the horizontal gap W Also, the diameter is slightly narrower than the diameter x the number of the round wires 1. By setting the vertical and horizontal dimensions of such a drawing hole, it is possible to obtain a synthetic rectangular wire in which lines having a substantially rectangular cross section having small-diameter arcs R at the four corners are in close contact with each other and arranged in parallel. That is, when a plurality of insulating coating round wires 1 pass through the roller die 20, each insulating coating round wire 1 is transformed into a substantially rectangular cross section having a small-diameter arc R, and the insulating coating rectangular wires 2a, 2b, In addition to 2c and 2d, they become a combined rectangular wire 2 having a rectangular cross section having a small-diameter arc R at four corners as a whole (see FIG. 2B).
The composite rectangular wire 2 according to the present invention has a small-diameter arc R, so that the gap between the parallel wires 2a, 2b, 2c, and 2d can be sufficiently reduced as compared with the original round wire 1. it can.

FIG. 3 shows a roller bending process. The synthetic rectangular wire 2 obtained through the above-described synthetic rectangular wire processing step is bent at a predetermined distance through the bending roller 30, and is a rectangular composed of a straight side portion 3a and a curved corner portion 3b. Edgewise winding 3 is obtained.
The bending roller 30 includes at least a pair of upper and lower rollers 31 and 32.
The gap between the pair of rollers 31 and 32 is adjusted to parallel gaps S ₁ and S ₁ and non-parallel gaps S ₁ and S ₂ .
That is, the parallel gaps S ₁ and S ₁ are used during the period corresponding to the straight side 3a of the flat edgewise winding 3 ((B) in FIG. 3). The parallel gaps S ₁ and S ₁ are set to be equal to or slightly smaller than the thickness of the synthetic rectangular wire 2 so that the synthetic rectangular wire 2 can be sent out without delay. The composite rectangular wire 2 goes straight while passing through the parallel gaps S ₁ and S ₁ . The straight side 3a of the flat edgewise winding 3 is formed by this straight advance.
On the other hand, the non-parallel gaps S ₁ and S ₂ are set while corresponding to the curved corner portion 3b of the flat edgewise winding 3 ((C) in FIG. 3). This non-parallel gap can be a tapered gap in which the gap varies continuously. In this case, the gap S ₂ corresponding to the outer peripheral side of the corner part 3 b of the flat edgewise winding 3 is made smaller than the thickness of the composite flat wire 2. Thus part of the synthetic flat wire 2 passing through the gap S ₂ is wrought is made. Clearance S ₁ which corresponds to the inner circumference side corner portion 3b of the rectangular edgewise winding 3 for the left as it gaps S ₁ corresponding to the linear side portions 3a, so that wrought is not performed. Therefore, the combined rectangular wire 2 that has passed through the non-parallel gaps S ₁ and S ₂ bends. By this bending, a curved corner portion 3b of the flat edgewise winding 3 is formed.
The obtained flat-angled edgewise winding 3 maintains a substantially rectangular cross section (indicated by reference character A in FIG. 3) in the side portion 3a, but the corner portion 3b has a taper in which the thickness of the outer peripheral portion is reduced. A cross-section (indicated by reference numeral in FIG. 3) is formed. Here, the reason why the cross section of the side portion 3a is a substantially rectangular cross section is that the shape of the plurality of lines constituting the side portion 3a is a substantially rectangular shape having a small-diameter arc R, and these are in close contact with each other. by.

The parallel gaps S ₁ and S ₁ and the non-parallel gaps S ₁ and S ₂ by the pair of rollers 31 and 32 can be adjusted by moving one side of one roller 31 up and down, for example. In other words, the parallel gaps S ₁ and S ₁ are maintained between the rollers 31 and 32 while the combined rectangular wire 2 passes a predetermined distance to be the linear side portion 3a of the rectangular edgewise winding 3. Distance and that for each of the range corresponding to the length of the side portion 3a is moved downward one side of the roller 31, to adjust the rollers 31, 32 gap constant non-parallel gap S _1, S _2, corresponding to the corner portion 3b Just turn the song forward. After a distance corresponding to the corner portion 3b, one side of the roller 31 is moved upward to return to the original parallel gaps S ₁ and S ₁ . By repeating the above, a flat edgewise winding 3 consisting of a straight side 3a and a curved corner 3b can be formed.

In order to restrict the width of the flat edgewise winding 3 to a fixed width with respect to the pair of upper and lower rollers 31 and 32, the pair of left and right rollers can be assisted. The axis of the auxiliary roller is perpendicular to the axis of the pair of rollers 31.
As the pair of upper and lower rollers 31, 32, it is also possible to use a roller such as a cam whose radius changes in the circumferential direction. That is, by using a roller in which the radius of the roller 31 increases in a taper shape in the width direction at a portion corresponding to the corner portion 3b of the flat edgewise winding 3, the vertical movement of the roller 31 is not adjusted. The parallel gaps S ₁ and S ₁ and the non-parallel gaps S ₁ and S ₂ can be adjusted.
Of course, the pair of rollers 31 and 32 may be rolling rollers or rollers constituting a drawing die.
In forming the corner portion 3b of the flat edgewise winding 3 by the bending roller 30, a bending correction means for correcting the bending state of the corner portion 3b to an accurate and constant bending radius is assisted. Can do. The bending correction means may be a winding shaft that winds a wire that has come out through the bending roller 30, for example. By making the winding shaft into a desired edge-wise winding shape, the wire that has passed through the bending roller 30 can be wound while being corrected to the desired winding shape. In addition, conventionally known bending means can be used as an auxiliary.

With reference to FIG. 4, the manufacturing method of the flat edgewise winding which concerns on the 2nd Embodiment of this invention is demonstrated. The manufacturing method according to the second embodiment is a manufacturing method in which a synthetic rectangular wire thickness adjusting step is added between the synthetic rectangular wire processing step and the roller bending step in the first embodiment. .
The adjustment of the composite rectangular wire thickness is performed using, for example, a wire thickness adjusting roller 40. By passing through the wire thickness adjusting roller 40, the synthetic rectangular wire 2 has a portion having a tapered cross-sectional shape in which the thickness of the cross section changes in the width direction in addition to a portion where the thickness of the cross section is constant in the width direction. Is done. That is, the portion of the composite flat wire 2 to be the side portion 3a of the flat edgewise winding 3 is maintained in a substantially rectangular cross-sectional shape in which the thickness of the cross section is constant in the width direction, and the corner portion of the flat edgewise winding. The portion to be 3b is adjusted by the wire thickness adjusting roller 40 into a tapered cross-sectional shape in which the thickness of the cross section changes in the width direction.

The wire thickness adjusting roller 40 is composed of, for example, a pair of upper and lower grooved rollers 41 and 42 constituting a hole type (caliber) in a roll gap, and this can be used as a rolling roll or a drawing roller die. . The wire thickness adjusting roller 40 may use a hole die regulated by each of these rollers as a roller die formed by a pair of horizontal (lateral) rollers and a pair of vertical (longitudinal) rollers. Good.
As shown in FIG. 4B, the gaps formed by the line thickness adjusting roller 40 are parallel gaps S ₃ and S ₃ that are constant in the width direction, and as shown in FIG. And non-parallel gaps S ₄ and S ₅ that change in the width direction.
That is, the parallel gaps S ₃ and S ₃ appear so as to correspond to the portion to be the straight side 3a of the flat edgewise winding 3 later, and the curve of the flat edgewise winding 3 later. The tapered non-parallel gaps S ₄ and S ₅ appear so as to correspond to the portion to be the corner portion 3b.
The gap S ₃ is the same or slightly smaller value as the thickness of the synthetic flat wire 2. On the other hand, the non-parallel gaps S ₄ and S ₅ are such that the gap S ₄ corresponding to the synthetic rectangular wire portion to be on the inner peripheral side of the corner portion 3b is smaller than the thickness of the synthetic rectangular wire 2 and more than the parallel gap S ₃ . also a small value to a value larger than the outer peripheral side to the thickness of the synthetic flat wire 2 a gap S ₅ corresponding to synthesize flat wire portion to be corners 3b.

In order to cause the parallel gap S ₃ and the non-parallel gaps S ₄ and S ₅ to appear in the circumferential direction by the pair of rollers 41 and 42 as described above, the groove shape (hole shape) of the grooved roller 41 is circular. This can be achieved by changing in the circumferential direction.
By passing the wire thickness adjusting roller 40 composed of a pair of rollers 41 and 42 in which the parallel gap S ₃ and the non-parallel gaps S ₄ and S ₅ appear in the circumferential direction, the combined rectangular wire 2 is Later, in a portion that should become the corner portion 3b of the flat-angled edgewise winding, a tapered cross-sectional shape that changes in the width direction can be formed so as to be thin on the inner peripheral side of the corner portion 3b and thick on the outer peripheral side. Further, the other portion to be the side portion 3a of the flat edgewise winding 3 has a substantially rectangular cross-sectional shape that is constant in the width direction. Furthermore, the thickness of the synthetic rectangular wire portion to be the inner peripheral side of the corner portion 3b is thinner than the thickness of the synthetic rectangular wire portion to be the side portion 3a, and the thickness of the synthetic rectangular wire portion to be the outer peripheral side of the corner portion 3b is It becomes thicker than the thickness of the synthetic rectangular wire portion to be the side portion 3a.

In the above case, the gaps between the parallel gaps S ₃ and S ₃ and the non-parallel gaps S ₄ and S ₅ are formed on the pair of rollers 41 and 42 of the line thickness adjusting roller 40. However, it is also possible to use a line thickness adjusting roller 40 in which only the non-parallel gaps S ₄ and S ₅ are formed between the pair of rollers 41 and 42.
In this case, the pair of rollers 41, 42 retracts the upper roller 41 upward while the composite rectangular wire portion that will later become the side 3 a of the flat edgewise winding 3 passes. Then, only during the passing portion to the corner portion 3b, lowering the roller 41 above, thereby constituting a non-parallel gap S _4, S _5, as shown in FIG. 4 (C). By doing in this way, like the above case, only the part which becomes the corner part 3b of the flat edgewise winding 3 has a tapered cross-sectional shape with a thin inner peripheral side and a thick outer peripheral side, and the other part is substantially rectangular. The composite rectangular wire 2 having a cross-sectional shape can be obtained.

  Further, the wire thickness adjusting roller 40 is a roller die formed by a pair of horizontal (lateral) rollers and a pair of vertical (longitudinal) rollers, and a hole type regulated by each of these rollers is used. In this case, it is possible to adjust the gap between the pair of horizontal rollers to be parallel or non-parallel by adjusting the vertical movement of the rollers. Even in this case, only the portion that becomes the corner portion 3b of the flat edgewise winding 3 has a tapered cross section having a thin inner peripheral side and a thick outer peripheral side, and the other portion is a composite flat wire 2 having a substantially rectangular cross section. be able to.

  As shown in FIG. 4, the synthetic rectangular wire 2 that has undergone the synthetic rectangular wire thickness adjustment process is passed through a bending roller 30 in the roller bending process, thereby allowing the outer periphery of the corner portion 3b of the synthetic rectangular wire that has undergone the roller bending process. The decrease in the wall thickness on the outer peripheral side can be absorbed by making it thick in advance, and the increase in the wall thickness on the inner peripheral side of the corner portion 3b can be absorbed by making the wall thin in advance, resulting in a curve. The thickness of the rectangular corner portion 3b (indicated by reference numeral D in FIG. 4) can be made equal to the thickness of the linear side portion 3a (indicated by reference numeral C in FIG. 4).

In the second embodiment, the synthetic rectangular wire thickness adjusting step is performed after the synthetic rectangular wire processing step and before the roller bending step. However, the synthetic rectangular wire thickness adjusting process can be performed simultaneously with the synthetic rectangular wire machining process.
In this case, in the synthetic rectangular wire processing step, the shape of the die hole of the roller die 20 is a rectangular cross-sectional shape in which the thickness of the plurality of drawn wires is the same in the width direction, and the thickness of the plurality of drawn wires is the width direction. So that the portion to be the linear side portion 3a of the edgewise winding 3 has a substantially rectangular sectional shape with the same thickness in the width direction. For the portion to be the corner portion 3b of the edgewise winding 3, the composite rectangular wire 2 having a tapered cross-sectional shape whose thickness changes in the width direction is processed and formed. In this case, the minimum thickness portion of the tapered cross-sectional shape is thinner than the thickness of the substantially rectangular cross-sectional shape, and corresponds to the inner peripheral side of the corner portion 3b. The maximum thickness portion of the tapered cross-sectional shape is thicker than the thickness of the substantially rectangular cross-sectional shape, and corresponds to the outer peripheral side of the corner portion 3b.
In the above description, the change in the shape of the die hole of the roller die 20 is adjusted, for example, while the roller gap of the lateral roller 22 shown in FIG. 1 corresponds to the linear side portion 3a of the edgewise winding 3 (distance amount). ) Is adjusted so as to be a parallel gap, and a portion corresponding to the next curved corner portion 3b (distance) is adjusted to be a non-parallel gap in a tapered shape. is there.
In addition, when the shape of the die hole of the roller die 20 is a tapered non-parallel gap, and the composite rectangular wire portion having the tapered cross-sectional shape is processed and formed, the supply speed of the plurality of round wires to be supplied is set to the thin wall side. It is also possible to adjust the thickness of the resulting composite rectangular wire to change in the width direction by changing it slightly on the thick side, slightly lowering the supply rate on the thin side, and slightly increasing the supply rate on the thick side. Is possible.

  INDUSTRIAL APPLICABILITY The present invention can be used in the field of manufacturing electrical equipment such as motors, transformers, reactors, and other industrial equipment as a method for producing a flat edgewise winding.

It is a figure explaining the synthetic | combination flat wire processing process used for the manufacturing method of the flat edgewise winding which concerns on the 1st Embodiment of this invention. It is a figure explaining the process of the some wire | line used for the synthetic | combination rectangular wire process in 1st Embodiment, (A) is sectional drawing which shows the state in the middle of a process, (B) is the obtained synthetic | combination rectangular wire. FIG. It is a figure explaining the roller bending process used for 1st Embodiment, (A) is explanatory drawing of a process, (B), (C) is a figure explaining a roller space | gap, respectively. It is a figure explaining the synthetic | combination flat wire thickness adjustment process used for the manufacturing method of the flat edgewise winding which concerns on the 2nd Embodiment of this invention, (A) is explanatory drawing of a process, (B), (C) is It is a figure explaining a roller gap, respectively.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Insulation coated round wire 1a Insulation coated round wire 1b Insulation coated round wire 1c Insulation coated round wire 1d Insulation coated round wire 2 Composite flat wire 3 Flat rectangular edgewise winding 3a Side 3b Corner portion 10 Bobbin 10a Bobbin 10b Bobbin 10c Bobbin 10d Bobbin 20 Roller die 21 Vertical roller 22 Horizontal roller 30 Bending roller 31 Roller 32 Roller 40 Line thickness adjusting roller 41 Roller 42 Roller h Vertical gap w Horizontal gap S ₁ gap S ₂ gap S ₃ gap S ₄ gap S ₅ gap

Claims (4)

  A method of manufacturing a flat edgewise winding using a plurality of round wires, and supplying a plurality of round wires in parallel and passing through a drawing die such as a roller die, thereby having a small-diameter arc at four corners. Synthetic rectangular wire machining process for machining and forming a synthetic rectangular wire in which substantially rectangular lines are in close contact with each other, and a constant non-parallel gap is provided at every predetermined distance while supplying the obtained synthetic rectangular wire. A rectangular edgewise winding comprising a roller bending process for forming a composite rectangular wire into a straight side and a curved corner by bending through the adjusted roller. Production method.   Between the synthetic rectangular wire processing step and the roller bending step, a portion of the synthetic rectangular wire that is to be bent in the roller bending step to become a corner portion has its cross-sectional thickness changed in advance in the cross-sectional width direction. The method for producing a flat edgewise winding according to claim 1, further comprising a synthetic flat wire thickness adjusting step of processing into a tapered cross-sectional shape.   In the synthetic rectangular wire processing step, the shape of the die hole of a drawing die such as a roller die is changed to a rectangular cross-sectional shape in which the thickness of the drawn wire is the same in the width direction, and the thickness of the drawn wire is changed in the width direction. The width of the edgewise winding has a substantially rectangular cross-sectional shape with the same thickness in the widthwise direction, and the edgewise winding of the edgewise winding is adjusted. The method for manufacturing a rectangular edgewise winding according to claim 1, wherein a synthetic rectangular wire having a tapered cross-sectional shape whose thickness varies in the width direction is processed and formed at a portion to be a corner portion.   The method for producing a flat-angled edgewise winding according to any one of claims 1 to 3, wherein the round wire used is a conductive wire coated with insulation.

Images