JP2014239117A - Winding device and winding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To accurately position the leading end of a flat wire, extending from a core-less coil obtained by edge-wise winding the flat wire in a rectangular, with respect to a reference face inside the coil.SOLUTION: A flat wire 2 is fed by a feed unit 9, bent by a bending unit 11, and edge-wise wound in a rectangular, thereby forming a core-less coil 1. The flat wire 2 is further fed and the coil 1 is placed onto the slide table 19 of a positioning unit 12. A positioning lever 20 is inserted into the coil 1. The positioning lever 20 is moved into a feeding direction, the abutting reference face 24 of the positioning lever 20 is brought into contact with a reference face 1C inside the coil 1, and the coil 1 is moved to a predetermined position. In this state, the flat wire 2 is cut by a cutting unit 13. Thus, the position of the leading end of the flat wire 2 extending from the coil 1 can accurately be positioned with respect to the reference face 1C of the coil 1.

Description

  The present invention relates to a winding apparatus and a winding method for forming an air-core coil by winding a rectangular wire into a rectangle by edgewise winding.

  As a coil used for electric devices such as an electric motor and a generator, there is an air-core coil 1 as shown in FIGS. The coil 1 is an air-core coil that does not have a bobbin by winding a rectangular wire 2 having a rectangular cross-section as a wire rod in an edgewise manner with its short sides facing inward and outward, and having a long side 1A and a short side 1B. It is what. A stripped portion 2A from which the insulating layer on the surface is stripped is provided at the tip of both ends of the flat wire 2 extending along the long side 1A of the coil 1. As described above, by using the air-core coil 1 in which the rectangular wire 2 is wound edgewise in a rectangular shape, it is possible to increase the area ratio and the heat dissipation, and to increase the efficiency and size of the electric device.

  As a prior art for manufacturing this type of coil, for example, Patent Document 1 discloses a winding device that can wind a coil at high speed. In this winding device, a rectangular air-core coil is manufactured at a high speed by winding a rectangular wire in a rectangular shape by edgewise winding by alternately repeating a certain amount of feeding and bending of the rectangular wire.

  When the coil 1 shown in FIGS. 9 and 10 is incorporated into an electric device such as an electric motor or a generator, the core 3 (see FIG. 10) is inserted therein, and the peeling portion 2A at the end of the flat wire 2 is in phase. Are connected to the coil, lead wire, bus bar and the like by a connecting means such as soldering. At this time, the coil 1 is positioned by abutting against the end of the core 3 with the inner surface of one short side 1B as a reference surface 1C. Therefore, by increasing the accuracy of the length L from the reference surface 1C to the tip of the peeling portion 2A of the flat wire 2, the coil 1 can be connected accurately and smoothly.

  Therefore, conventionally, when the coil 1 is manufactured, after the winding is completed, the rectangular wire 2 is fed by a predetermined amount so that the length of the rectangular wire 2 extending from the coil 1 is L, and at a predetermined position. I try to cut it.

JP 2009-135222 A

  However, actually, the winding position of the flat wire 2 varies due to the tolerance of the bending position of the flat wire 2 at the time of winding, and the reference surface 1C does not become flat but has irregularities. Become. For this reason, the core 3 comes into contact with the flat wire 2 ′ that protrudes most (see FIG. 10) on the reference surface 1C. As a result, in the state in which the core 3 is inserted into the coil 1, the position of the distal end portion of the flat wire 2 extending from the coil 1 is varied, which causes a reduction in the accuracy of connection of the coil 1.

  The present invention has been made in view of the above points. In an air-core coil in which a flat wire is wound into a rectangle by edgewise winding, the position of the tip of the flat wire that extends from the coil is determined. It is an object of the present invention to provide a winding device and a winding method that can be accurately positioned with respect to an inner reference plane.

In order to solve the above-described problems, a winding device according to the present invention includes a feeding unit that sends a flat wire, a bending device that bends the flat wire and winds it into a rectangle by edgewise winding to form an air-core coil. Means, cutting means for cutting the flat wire to separate the coil, and positioning means for adjusting the length between the reference surface inside the coil and the cutting end of the flat wire extending from the coil. Winding device,
The positioning means includes a positioning lever that has an abutting reference surface that is inserted into the coil and contacts the reference surface, and is movable along the feeding direction of the rectangular wire.
Inserting the positioning lever into the wound coil, moving the positioning lever in the feeding direction, bringing the abutting reference surface into contact with the reference surface and moving the coil to a predetermined position; The rectangular wire is cut by the cutting means.
Further, the winding method according to the present invention is a winding method in which a flat wire is bent and an air-core coil is formed by winding it in a rectangle by edgewise winding,
Insert the positioning lever into the wound coil, move the positioning lever to bring the reference surface of the lever into contact with the reference surface inside the coil, and move the coil to a predetermined position And cutting the rectangular wire.

(Aspect of the Invention)
In the following, some aspects of the invention that can be claimed in the present invention (hereinafter sometimes referred to as “claimable invention”) will be exemplified and described. As with the claims, each aspect is divided into sections, each section is numbered, and is described in a form that cites the numbers of other sections as necessary. This is for the purpose of facilitating the understanding of the claimable invention, and is not intended to limit the combinations of the constituent elements constituting the claimable invention to those described in the following sections. In other words, the claimable invention should be construed in consideration of the description accompanying each section, the description of the embodiments, etc., and as long as the interpretation is followed, another aspect is added to the form of each section. In addition, an aspect in which constituent elements are deleted from the aspect of each item can be an aspect of the claimable invention. The following contents (1) to (6) correspond to claims 1 to 6.
(1) Feeding means for sending a flat wire, bending means for bending the flat wire and winding it into a rectangle by edgewise winding to form an air-core coil, and cutting for cutting the flat wire and separating the coil A winding device comprising: means; and positioning means for adjusting a length between a reference surface inside the coil and a cut end of a flat wire extending from the coil,
The positioning means includes a positioning lever that has an abutting reference surface that is inserted into the coil and contacts the reference surface, and is movable along the feeding direction of the rectangular wire.
Inserting the positioning lever into the wound coil, moving the positioning lever in the feeding direction, bringing the abutting reference surface into contact with the reference surface and moving the coil to a predetermined position; The winding device characterized in that the rectangular wire is cut by the cutting means.
(2) The winding device according to (1), wherein when the coil is moved by the positioning lever, a thrust in a feeding direction is applied to the rectangular wire by the feeding means.
(3) In (1) or (2), when the flat wire is cut by the cutting means, the flat wire is fixed and tension is applied to the flat wire by the positioning means. A winding device characterized by cutting the wire.
(4) In a winding method in which a flat wire is bent and wound into a rectangle by edgewise winding to form an air-core coil,
A positioning lever is inserted into the wound coil, the positioning lever is moved, and the reference surface of the positioning lever is brought into contact with the reference surface inside the coil to place the coil in a predetermined position. And winding the rectangular wire to cut the rectangular wire.
(5) The winding method according to (4), wherein when the coil is moved by the positioning lever, thrust in a feeding direction is applied to the rectangular wire.
(6) When cutting the flat wire in (4) or (5), fixing the flat wire and cutting the flat wire in a state where tension is applied to the flat wire by the positioning lever. Winding method characterized by.
According to (1) and (4), the abutting reference surface of the positioning lever is brought into contact with the reference surface of the wound coil, and the cutting position of the rectangular wire is determined based on the position of this abutting reference surface. By determining, the position of the tip portion of the flat wire extending from the coil can be accurately positioned with respect to the reference plane of the coil.
According to (2) and (5), when the coil is moved by the positioning lever, it is possible to reduce the resistance acting on the feeding of the rectangular wire, and to prevent the coil from being deformed.
According to (3) and (6), by applying tension to the flat wire at the time of cutting, the end of the cutting part escapes from the cutting means, so that the cutting part can be prevented from being deformed and cut smoothly. it can.

  According to the winding device and the winding method according to the present invention, in the air-core coil in which the flat wire is wound into a rectangle by edgewise winding, the position of the tip portion of the flat wire extending from the coil is positioned inside the coil. It is possible to accurately position relative to the reference plane.

It is a side view of the winding device concerning one embodiment of the present invention. It is explanatory drawing which shows schematic structure of the apparatus shown in FIG. It is a perspective view of the bending unit of the apparatus shown in FIG. It is a perspective view of the positioning unit of the apparatus shown in FIG. It is a side view of the positioning unit shown in FIG. It is a figure which shows the feed process which winds a flat wire into a rectangle by the bending unit of FIG. It is a figure which shows the positioning process by the positioning unit of FIG. It is a figure which shows the positioning process by the positioning unit of FIG. It is a perspective view of the coil of the air core which wound the flat wire in the rectangle by edgewise winding. It is a longitudinal cross-sectional view of the coil shown in FIG.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.
As shown in FIGS. 1 and 2, the winding device 4 according to this embodiment is used to manufacture an air-core coil 1 in which the rectangular wire shown in FIGS. 9 and 10 is wound into a rectangle by edgewise winding. Device. The winding device 4 includes a supply unit 6 that supplies a flat wire 2 that is a wire wound around a coil bobbin 5, a straightener 7 that removes the winding wrinkles of the flat wire 2 supplied from the supply unit 6, and a flat wire 2. A peeling unit 8 that peels off the insulating layer on the surface of the wire, forms a peeling portion 2A, a feeding unit 9 (feeding means) for feeding the flat wire 2 through each unit, a clamp unit 10 for fixing the flat wire, A bending unit 11 (bending means) for winding the wire 2 to form the coil 1, a positioning unit 12 (positioning means) for positioning the wound coil 1, and a cutting unit for cutting the rectangular wire 2 13 (cutting means).

  The supply unit 6 pulls out the flat wire 2 that is a wire wound around the bobbin 5 and continuously supplies the flat wire 2 through each unit by the feed unit 9. The flat wire 2 drawn from the supply unit 6 is sent so that the long side of the rectangular cross section is in the horizontal direction.

  The straightener 7 removes the curl by correcting the flat wire 2 drawn from the supply unit 6 by passing it between a plurality of rollers arranged at a predetermined angle so as to be straight. To do.

  The peeling unit 7 includes a vertical peeling portion 8A and a horizontal peeling portion 8B. The vertical peeling portion 8A peels the insulating layers on both side surfaces (short sides of the rectangular cross section) of the rectangular wire 2 to form the horizontal peeling. The insulating layer on both the upper and lower surfaces (long side of the rectangular cross section) of the flat wire 2 is peeled off by the portion 8B. The peeling unit 7 peels off the insulating layer by a predetermined length at a predetermined timing with respect to the flat wire 2 sent through the peeling unit 7 so that the peeling portion 2A is located at a position corresponding to both ends of the coil 1 to be wound. Can be formed.

  The feed unit 9 can clamp the flat wire 2 with the feed clamp 14 and apply thrust by the feed motor to feed in the feed direction and the return direction. Also, the feed unit 9 can detect the feed amount and control the feed amount. It is like that. Further, the thrust can be controlled by adjusting the output of the feed motor.

  The clamp unit 10 is configured to fix the flat wire 2 passing through each unit by clamping the flat wire 2 with a fixed clamp 10A and a movable clamp 10B.

  As shown in FIG. 3, the bending unit 11 includes a guide groove 15 that guides the flat wire 2 that is fed by the feed unit 9, and a bending shaft 16 that is disposed on the side of the flat wire 2 that is guided by the guide groove 15. The bending shaft 16 is inserted and a bending clamp 17 for supporting the lower surface of the flat wire 2 and a bending piece 18 provided around the bending shaft 16 for rotation are provided. The bending shaft 16 is in contact with the side surface of the rectangular wire 2 guided by the guide groove 15 (short side of the rectangular cross section) and extends in the vertical direction, and a large diameter formed at the upper end of the shaft portion 16. It has a flange-like presser clamp portion 16B and is provided so as to be movable in the vertical direction. The bending shaft 16 descends, a bending position where the upper and lower surfaces of the flat wire 2 are clamped and clamped between the presser clamp portion 16B and the bending clamp 17, and a feed position where the bending shaft 16 is raised to release the flat wire 2 (FIG. 2). And (see) can be selectively moved.

The process of winding the coil 1 by the bending unit 11 will be described mainly with reference to FIG.
With reference to FIG. 6A, the bending shaft 16 is raised to a feeding position, and the flat wire 2 is fed along the guide groove 15 to a predetermined position on the side of the bending shaft 16 by the feeding unit 9. With reference to FIG. 6B, the bending shaft 16 is lowered, the flat wire 2 is clamped as a bending position, the bending piece 17 is rotated, and the flat wire 2 is perpendicularly formed along the shaft portion 16A of the bending shaft 16. Bend it. At this time, by pressing the upper and lower surfaces of the flat wire 2 with the press clamp portion 16B and the bending clamp 17, bulging due to the bending of the flat wire 2 is prevented. Referring to FIG. 6C, the bending piece 17 is returned to the original position, the bending shaft 16 is raised to the feeding position, and the rectangular wire 2 is connected to the short side or the long side of the coil 1 by the feeding unit 9 (FIG. In C), a predetermined amount corresponding to the short side) is sent. Then, the bending shaft 16 is lowered to the bending position and the flat wire 2 is clamped. Referring to FIG. 6D, the bending piece 17 is rotated, and the flat wire 2 is bent at a right angle along the shaft portion 16A of the bending shaft 16. In this way, the rectangular wire 2 is edged into a rectangular shape by appropriately repeating feeding of a feed amount corresponding to the short side and long side of the rectangular shape of the coil 1 and bending at a right angle with respect to the rectangular wire 2. The air-core coil 1 is formed by wise winding.

  Here, the shape of the coil 1 can be set by appropriately adjusting the feed amount during the bending of the rectangular wire 2 by the bending piece 17, for example, a truncated pyramid or a multiple winding. Is possible.

  As shown in FIGS. 4 and 5, the positioning unit 12 includes a slide table 19 on which the coil 1 wound by the bending unit 11 is placed and guided so as to be movable along the feeding direction. A positioning lever 20 that can be inserted into the coil 1 placed on the slide table 19, a clamp plate 21 that is placed on the slide table 19 in front of the feeding direction of the coil 1, and a slide table 19. A presser plate 22 that presses the coil 1 from above is provided.

  The positioning lever 20 is movable in the vertical direction by the air cylinder 23 and has an abutting reference surface 24 that abuts on the reference surface 1 </ b> C inside the coil 1. The abutting reference surface 24 is formed in the same shape as the contact surface of the core 3 to which the coil 1 is attached to the reference surface 1C of the coil 1. The positioning lever 20 can be moved along the feeding direction of the flat wire 2 by a positioning motor 25, and the moving position can be controlled based on detection by a position sensor or the like.

  The clamp plate 21 can be moved forward and backward with respect to the positioning lever 20 by an air cylinder 26, and the coil 1 is sandwiched between the clamping plate 21 and the positioning lever 20. The presser plate 22 is elastically held so as to be movable in the vertical direction so as to face the upper surface of the coil 1 placed on the slide table 19. When the positioning lever 20 is lowered and inserted into the coil 1 on the slide table 19, the presser plate 22 elastically presses the coil 1 from the upper surface, and between the rectangular wires 2 of the wound coil 1. Hold the gap tightly. The clamp plate 21 and the presser plate 22 are supported so as to be movable along the feeding direction of the flat wire 2, and move together with the positioning lever 20 and the coil 1 when the coil 1 is clamped.

  The cutting unit 13 is fixedly disposed between the bending unit 11 and the positioning unit 12 and cuts (shears) the flat wire 2 by a pair of cutting blades 28 driven by an air cylinder 27.

The winding device 4 is provided with a control device (not shown) for controlling the operation of the supply unit 6, the peeling unit 8, the feeding unit 9, the clamping unit 10, the bending unit 11, the positioning unit 12 and the cutting unit 13. ing.
The control device controls the operation of each unit and executes the following steps.

  The feed unit 9 is operated, and the flat wire 2 drawn from the supply unit 6 is sent through each unit. The flat wire 2 is straightened by removing the curl from the straightener 7. The feed amount by the feed unit 10 is controlled, the rectangular wire 2 is fed and positioned with respect to each unit, and the clamp unit 10 is operated as appropriate to clamp and fix the rectangular wire 2.

  The peeling unit 8 is operated to peel off the insulating layer at positions corresponding to both ends of the coil 1 of the flat wire 2 to form a peeling portion 2A.

  The bending unit 11 is actuated and, as described above, the feeding and bending of the flat wire 2 shown in FIGS. 6A to 6D are repeated, and the flat wire 2 is wound into a rectangle by edgewise winding. Thus, the air-core coil 1 is formed.

  Next, the process of positioning the tip of the flat wire 2 extending from the coil 1 in the positioning unit 12 will be described mainly with reference to FIGS.

  With reference to FIG. 7A, the feeding unit 9 is operated to feed the coil 1 wound by the bending unit 11 onto the slide table 19 of the positioning unit 12. At this time, the feed clamp 14 of the feed unit 9 is in the clamped state, the movable clamp 10B of the clamp unit 10 is in the released state, and the bending shaft 16 of the bending unit 11 is capable of feeding the flat wire 2 as the feed position. The feeding position of the coil 1 on the slide table 19 is slightly ahead (about 6 mm in this embodiment) with respect to the cutting position (positioning point) of the flat wire 2 by the finally determined cutting unit 13. To.

  With reference to FIG. 7B, the air cylinder 23 is operated to lower the positioning lever 20, the presser plate 22 is brought into contact with the upper surface of the coil 1, and pressed to swell when the coil 1 is wound. Press down. At this time, the position in the feed direction of the flat wire 2 of the positioning lever 20 is appropriate between the reference surface 1C of the coil 1 and the abutting reference surface 24 of the positioning lever 20 (in this embodiment, about 2 mm). ) A position where the gap C is generated.

  Referring to FIG. 7C, the positioning motor 25 is operated to move the positioning lever 20 by an appropriate amount (about 4 mm in this embodiment) in the feed direction. As a result, the abutting reference surface 24 of the positioning lever 20 is brought into contact with the reference surface 1C of the coil 1, and the coil 1 is moved by an appropriate amount (about 2 mm in the present embodiment) in the feed direction, so that the final positioning is performed. Place it slightly before the point. At this time, the feed unit 9 is switched to thrust control, and a thrust in the feed direction that balances with the resistance force of the straightener 7 is applied to the rectangular wire 2, thereby preventing the coil 1 from being deformed and moving the coil 1 smoothly. can do.

  Referring to FIG. 8A, the positioning lever 20 is fixed, the clamp plate 21 is advanced by the air cylinder 26 and brought into contact with the outside of the short side 1B of the coil 1, and the clamp plate 21 and the coil 1 are The short side 1B of the coil 1 is clamped with the abutting reference surface 24 of the positioning lever 20 in contact with the reference surface 1C. At this time, the feed unit 9 stops the motor so that the flat wire 2A can be retracted, and prevents the flat wire 2A from being loosened when the positioning lever 21 is retracted by the pressing force of the clamp plate 21. .

  When the abutting reference surface 24 of the positioning lever 20 abuts on the reference surface 1C of the coil 1, the flat wire 2 'that protrudes most from the reference surface 1C (see FIG. 10) abuts on the abutting reference surface 24. Therefore, the positioning of the reference surface 1C of the coil 1 when the coil 1 is actually attached to the core 3 can be accurately performed by the position of the abutting reference surface 24 of the positioning lever 20.

  Referring to FIG. 8B, the positioning motor 25 is operated to move the positioning lever 20 in the feed direction, and the distance between the abutting reference surface 24 and the cutting blade 28 of the cutting unit 13 is the coil 1. The reference length 1C to the end of the flat wire 2 is set to a specified length L. At this time, the feed unit 9 is switched to thrust control again, and a thrust in the feed direction that balances with the resistance force of the straightener 7 is applied to the rectangular wire 2, thereby preventing the coil 1 from being deformed and smoothing the coil 1. Can be moved to.

  With reference to FIG. 8C, the movable clamp 10B of the clamp unit 10 is moved to the clamp position, and the bending shaft 16 of the bending unit 11 is moved to the bending position to fix the rectangular wire 2. At this time, the feed unit 9 stops the motor and releases the clamp of the feed clamp 14. Then, a thrust in the feeding direction is applied to the positioning lever 20 by the positioning motor 25 to apply an appropriate tension to the flat wire 2. In this state, the air cylinder 27 of the cutting unit 13 is operated and the flat wire 2 is cut by the cutting blade 28. At this time, since the distance between the abutting reference surface 24 and the cutting blade 28 of the cutting unit 13 is a predetermined length L from the reference surface 1C of the coil 1 to the tip of the flat wire 2, the flat wire 2 Is cut at the center of the peeling portion 2A. By applying tension to the flat wire 2 at the time of cutting, the end portion of the cutting portion escapes from the cutting blade 28, so that the cutting portion can be prevented from being deformed and cut smoothly.

Thereafter, the clamping by the positioning lever 20 and the clamp plate 21 is released, the positioning lever 20 and the presser plate 22 are raised, and the completed coil 1 is delivered.
In this way, it is possible to accurately position the tip of the flat wire 2 extending from the coil 1 with reference to the reference surface 1C that actually contacts the core 3.

  DESCRIPTION OF SYMBOLS 1 ... Coil, 1C ... Reference plane, 2 ... Flat wire, 4 ... Winding device, 9 ... Feed unit (feed means), 11 ... Bending unit (bending means), 12 ... Positioning unit (positioning means), 13 ... cutting unit (cutting means), 20 ... positioning lever, 24 ... abutting reference plane

Claims (6)

Feeding means for sending a flat wire; bending means for bending the flat wire and winding it into a rectangle by edgewise winding to form an air-core coil; and cutting means for cutting the flat wire to separate the coil; A winding device comprising positioning means for adjusting a length between a reference surface inside the coil and a cut end of a flat wire extending from the coil;
The positioning means includes a positioning lever that has an abutting reference surface that is inserted into the coil and contacts the reference surface, and is movable along the feeding direction of the rectangular wire.
Inserting the positioning lever into the wound coil, moving the positioning lever in the feeding direction, bringing the abutting reference surface into contact with the reference surface and moving the coil to a predetermined position; The winding device characterized in that the rectangular wire is cut by the cutting means.   The winding device according to claim 1, wherein when the coil is moved by the positioning lever, a thrust in a feeding direction is applied to the rectangular wire by the feeding means.   The rectangular wire is cut when the flat wire is fixed by the cutting means and the tension is applied to the flat wire by the positioning means. The winding device according to 2. In a winding method in which a flat wire is bent and wound into a rectangle with edgewise winding to form an air-core coil,
A positioning lever is inserted into the wound coil, the positioning lever is moved, and the reference surface of the positioning lever is brought into contact with the reference surface inside the coil to place the coil in a predetermined position. And winding the rectangular wire to cut the rectangular wire.   The winding method according to claim 4, wherein when the coil is moved by the positioning lever, a thrust in a feeding direction is applied to the rectangular wire.   The said flat wire is cut | disconnected in the state which fixed the said flat wire and gave the tension | tensile_strength to the said flat wire by the said positioning lever, when cutting the said flat wire. Winding method.

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