JP2015050364A - Coil manufacturing device and coil manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve an aligning property of a wire by preventing the wire moving from a lower layer to an upper layer and just starting to be wound from moving to outside in an axial direction of a winding core.SOLUTION: A coil manufacturing device 20 comprises: a winding core 22 around which a wire 11 is wound by rotation; a wire feeding machine 50 for feeding the wire 11 via a wire guide 51 at a constant tension; a moving mechanism 52 for moving the wire guide 51 through which the wire 11 is fed at least in a rotation axis direction of the winding core 22; and a wire movement banning mechanism 70 for banning movement of one part of the wire 11 wound around the winding core 22. The wire movement banning mechanism 70 comprises: a displacement prevention member 71; movement means 72 that can move between a contact position for moving the displacement prevention member 71 in a longitudinal direction into contact with the wire 11 wound around the winding core 22, and an isolation position isolated from the wire 11; and rotation means 73 for rotating the displacement prevention member 71 at the contact position around a rotation shaft of the winding core 22 as a center together with the movement means 72.

Description

  The present invention relates to a coil manufacturing apparatus in which a plurality of winding layers made of a plurality of rows of wire rods are stacked on a winding core, and a manufacturing method thereof. More specifically, the present invention relates to a coil manufacturing apparatus and a manufacturing method thereof that are particularly excellent in the alignment of wound wires.

  2. Description of the Related Art Conventionally, as a coil applied to a magnetic actuator such as a motor or a solenoid, a coil in which a plurality of winding layers made of a plurality of rows of wire materials are stacked is known. This coil forms one winding layer composed of a plurality of rows of wire by sequentially winding the wire from one side to the other side in the axial direction of the core, and the wire is formed on the outer periphery of the one winding layer. Are wound in order from the other side in the axial direction of the winding core toward the other side to form another winding layer made of a plurality of lines of wire, and these are sequentially repeated.

  Here, in order to save power such as a motor by reducing the size of the coil and improving the magnetic force, the conductor space factor of the coil (the cross-sectional area of the space in which the coil winding layer is formed is It is desired to increase the ratio of the cross-sectional area occupied by the conductor portion. In order to increase the conductor space factor, it is necessary to improve the alignment of the wires, that is, to wind the wires so that the wires are aligned without any gaps.

  In this aligned winding, the winding width of each winding layer is defined by a flange, and each time the wire is wound, the guide for feeding the wire is an amount equal to the wire diameter of the wire in the axial direction of the core. Only moving is done. In this way, by defining the winding width in each winding layer with the flange, the wire material at the beginning of each winding of the second and subsequent winding layers moved from the lower layer to the upper layer is moved outward in the axial direction of the winding core. Therefore, the alignment of the wires constituting each winding layer is ensured, whereby the wires are wound so that the wires are in close contact with the winding core.

  On the other hand, in the coil to be obtained, the winding width of the winding layer on the outer peripheral side may be narrowed. In the winding layer with the reduced winding width, since there is no flange that defines the winding width, the wire material at the beginning of the winding that has moved from the lower layer to the upper layer moves to the outside in the axial direction of the winding core. It becomes difficult to make the winding width within a specified dimension, and a gap is generated between the wire members constituting the winding layer, causing a problem that the alignment of the wire members is not ensured.

  In order to eliminate this point, it has been proposed that when the winding layer is changed along with the winding of the wire, a defining member that defines the folding position of the wire moving from the lower layer to the upper layer is provided separately from the flange (for example, a patent Reference 1). In this way, by defining the folding position of the wire moving from the lower layer to the upper layer with the defining member, the wire material at the beginning of each winding of the winding layer moved from the lower layer to the upper layer in order to narrow the winding width is on the outer side in the axial direction of the winding core. It is supposed that the alignment of the wire constituting each winding layer is secured by preventing the movement.

JP 2003-332164 A

  Here, when forming the upper winding layer with a reduced winding width, the wire drawn from the lower winding layer and the wire constituting the first row of the upper winding layer are predetermined. It will intersect at an angle. However, in the winding device and the winding method in Patent Document 1, for example, if the cross section of the core is a square, the wire in one piece is only defined by the defining member, and is wound around the core. A predetermined tension is applied to the wire. For this reason, when the wire wound by rotating the winding core passes through the regulating member, and the regulation is released by the regulating member, the wire at the beginning of the winding moved to the upper layer by the tension applied to the wire. May expand and move outward in the axial direction of the core. As a result, there still remains a problem to be solved that the alignment of the wires constituting the winding layer cannot be secured.

  An object of the present invention is to provide a coil manufacturing apparatus and a coil manufacturing method that can prevent the wire at the beginning of winding, which has moved from the lower layer to the upper layer, from moving outward in the axial direction of the core and improve the alignment of the wire. It is to provide.

  The coil manufacturing apparatus of the present invention includes at least a winding core on which a wire is wound by rotation, a wire feeding machine that feeds the wire with a constant tension via the wire guide, and a wire guide from which the wire is fed. A moving mechanism that moves in the axial direction and a wire movement prohibiting mechanism that prohibits movement of a part of the wire wound around the core.

  The characteristic configuration is that the wire rod movement prohibiting mechanism has a slip prevention member, a contact position where the slip prevention member is moved in the longitudinal direction to contact the wire wound around the winding core, and a separation position separated from the wire. And a moving means for rotating the contact position deviation preventing member around the rotation axis of the winding core together with the moving means.

  In this case, it is preferable that the moving means is a fluid pressure cylinder that moves the displacement preventing member by the pressure of the fluid, or the structure can be simplified by simply using a retractable spring. Moreover, it is preferable that the wire is a coated conductor having a heat-fusible coating, and further includes hot air generating means for blowing hot air onto the wound wire to bond the wires together.

  In the method of the present invention, a wire guide for feeding a wire is moved from one side in the axial direction of the core toward the other side, and the core is rotated to turn around the core from one side in the axial direction to the other side. Forming one winding layer composed of a plurality of rows of wire rods that are sequentially wound, and rotating the winding core while moving the wire rod guide for feeding out the wire from the other axial direction of the winding core to one side. To form the other winding layer composed of a plurality of rows of wire rods wound sequentially from the other side in the axial direction toward the one side on the outer periphery of one winding layer, and by repeating these sequentially, a plurality of layers are formed on the winding core. This is a method of manufacturing a coil in which the winding layers are stacked.

  The characteristic point is that in the formation of any one or two or more winding layers after the second layer among the plurality of laminated winding layers, a slip prevention member is added to the wire material that has shifted from the lower layer to the upper layer. A position where the wire rod is brought into contact with the transition side, the wire rod guide is moved to the side where the displacement prevention member abuts, the wire rod is bent from the wire rod guide, and then the wire rod between the displacement prevention member and the wire rod guide extends in the circumferential direction of the winding core. The wire guide is returned to the position until the slip prevention member is in contact with the wire, and is rotated about the rotation axis of the core together with the winding core. After that, the slip prevention member is separated from the wire, and then the winding layer is formed. There is a place to continue.

  In this coil manufacturing method, it is preferable that the range of rotation about the rotation axis of the core together with the core is in a state where the misalignment prevention member is in contact with the wire, and the deviation prevention member is separated from the wire. When the second row wire adjacent to the first row wire of the winding layer formed after winding is wound, the slip prevention member may be brought into contact with the first row wire again. preferable. When the wire is a coated conductor having a heat-fusible coating, it is preferable to blow hot air on the wound wire to bond the wires together.

  In the coil manufacturing apparatus and the coil manufacturing method of the present invention, when a winding layer whose winding width is not defined by the flange is formed, the wire rod that constitutes the first row at the beginning of the winding is prevented from slipping. By winding the wire in advance in a state in which the member is brought into contact and the displacement of the wire is prevented, the wire material at the beginning of the winding can be adapted to the outer surface of the lower winding layer. In particular, by winding the wire around the outer periphery of the lower winding layer in excess of 90 degrees, the wire material at the beginning of the winding can be surely adapted to the outer surface of the lower winding layer.

  Here, when the winding width is narrowed, the wire drawn from the lower winding layer and the wire constituting the first row of the winding layer intersect at a predetermined angle. However, it is possible to prevent the wire rod from expanding at the intersecting portion by bringing the wire rod drawn out from the lower winding layer into contact with the displacement preventing member and bending it in advance. As a result, it is possible to effectively prevent the wire material at the beginning of winding wound around the outer periphery of the lower winding layer from being displaced thereafter. Therefore, it is possible to prevent the winding wire from the lower layer to the upper layer from moving outward in the axial direction of the core.

  Further, when winding the second row wire adjacent to the first row wire of the winding layer after separating the displacement prevention member from the wire, the deviation prevention member is wound on the first row wire. If the shift prevention member is rotated about the rotation axis of the core together with the core in the state where the shift prevention member is again in contact with the wire, the first row of wire It can be prevented that the wire is pushed by the wire in the second row and moves outward in the axial direction of the core.

  Then, when the wire is a coated conductor having a heat-fusible coating, the first row and the second row are adhered to each other by blowing hot air on the wound wire, and then the third row Even if the eye wire is wound, these deviations can be reliably prevented. Therefore, the wire material at the beginning of winding that has moved from the lower layer to the upper layer is reliably prevented from moving outward in the axial direction of the core. As a result, the alignment of the wires can be improved.

It is a top view which shows the manufacturing apparatus of the coil of embodiment of this invention. It is the sectional view on the AA line of FIG. 1 containing the wire movement prohibition mechanism. FIG. 2 is an enlarged view of a wire feeder and a moving mechanism as viewed from a direction B in FIG. 1. It is the CC sectional view taken on the line of FIG. 1 which shows the winding apparatus in the manufacturing apparatus. It is a figure which shows the state which pulled out diagonally from the winding end of the lower winding layer, and made the slip prevention member contact the outer side. FIG. 6 is a view corresponding to FIG. 5 illustrating a state in which the wire rod is bent around the shift prevention member by moving the wire rod guide. It is a figure corresponding to Drawing 5 which shows the state where the wire rod guide was moved in the reverse direction and the wire rod was returned to the position extended in the peripheral direction of a core. FIG. 5 is a cross-sectional view taken along the line DD of FIG. 4 showing a state in which a slip prevention member is brought into contact with the wire drawn obliquely. FIG. 9 is a view corresponding to FIG. 8 illustrating a state in which the shift prevention member is rotated around the rotation axis of the core together with the core while the deviation preventing member is in contact with the wire. It is a figure corresponding to Drawing 5 showing the state where the wire of the 2nd row adjacent to the wire of the 1st row is wound. FIG. 6 is a cross-sectional view taken along the line DD of FIG. 4 illustrating a state in which a slip prevention member is in contact with the second row of wires. FIG. 12 is a view corresponding to FIG. 11, showing a state in which the deviation preventing member is further rotated around the rotation axis of the winding core in a state where the deviation preventing member is in contact with the wire. It is a figure which shows the state which pulled out diagonally in the reverse direction from the winding end of the winding layer, and made the slip prevention member contact the outer side. It is a figure corresponding to FIG. 13 which shows the state which moved the wire guide and bent again the wire rod centering on the slip prevention member. It is a figure corresponding to FIG. 13 which shows the state which returned the wire to the position extended in the circumferential direction of a winding core. FIG. 6 is a cross-sectional view taken along the line DD of FIG. 4 showing a state in which a slip prevention member is in contact with the drawn wire. FIG. 17 is a view corresponding to FIG. 16 illustrating a state in which the shift prevention member is rotated around the rotation axis of the core together with the core in a state in which the shift prevention member is in contact with the wire. It is a figure corresponding to FIG. 13 which shows the state which winds the wire of the 2nd row adjacent to the wire of the 1st row. FIG. 6 is a cross-sectional view taken along the line DD of FIG. 4 illustrating a state in which a slip prevention member is in contact with the second row of wires. FIG. 20 is a view corresponding to FIG. 19, showing a state in which the deviation preventing member is further rotated about the rotation axis of the core in a state where the deviation preventing member is in contact with the wire. FIG. 6 is a view corresponding to FIG. 5 showing a coil in which the winding widths of two layers on the outer peripheral side are sequentially reduced. It is a figure corresponding to FIG. 2 which shows the moving means using the spring which can be expanded-contracted.

  Next, the best mode for carrying out the present invention will be described with reference to the drawings.

  FIG. 21 shows a coil 10 obtained by the present invention. This coil 10 is a coil 10 in which a winding layer composed of a spirally wound winding is laminated over a plurality of layers in the radial direction of the winding, and several layers on the outer peripheral side (this embodiment) Then, the outer circumferential two layers 13 and 14) are such that their winding widths W1 and W2 are gradually narrowed toward the outer circumferential side. FIG. 21 shows a state where the coil 10 sandwiched between first and second flanges 23 and 24 described later is viewed from the outer peripheral side. In the coil 10, the wires 11 adjacent to each other in the winding direction are in contact with each other, thereby increasing the space factor of the wire in the coil 10. The wire 11 in this embodiment exemplifies a case where a self-bonding wire (so-called cement wire) having a circular cross section and having an insulating coating fused by hot air or a solvent is used.

  A coil manufacturing apparatus 20 of the present invention is shown in FIG. Here, three axes X, Y, and Z orthogonal to each other are set, the X axis extends in a substantially horizontal front-rear direction, the Y axis extends in a substantially horizontal lateral direction, and the Z axis extends in a substantially vertical direction. The structure of will be described.

  The coil manufacturing apparatus 20 of the present invention includes a winding device 21 provided on a gantry 19. The winding device 21 includes a winding core 22 that actually winds the wire 11 by rotating, and disk-shaped first and second flanges 23 and 24 provided coaxially on both sides of the winding core 22. . The winding core 22 is formed of a cylindrical member having a circular cross section. The winding core 22 has a length equal to the thickness direction of the coil 10 to be obtained. Since the winding core 22 winds up the wire 11 to form the coil 10, the outer diameter of the winding core 22 is to be obtained. It is formed equal to the inner diameter of the coil 10 (FIG. 21). The outer diameters of the first and second flanges 23 and 24 are formed substantially the same as the outer diameter of the outermost winding layer having the same winding width of the coil 10 wound around the winding core 22. Although not shown, the cylindrical winding core 22 is divided into a plurality of portions in the circumferential direction and attached to the first flange 23 so as to be slightly movable.

  As shown in FIG. 1 and FIG. 4, the coil manufacturing apparatus 20 includes a first rotating body 28 having a winding core 22 provided at the tip thereof and a second rotating body 28 provided coaxially so as to face the first rotating body 28. A rotating body 29 is provided. The winding core 22 is provided coaxially at the tip of the first rotating body 28 via the first flange 23. A first support wall 32 is erected on the gantry 19, and the first rotating body 28 extends in the Y-axis direction and is rotatably provided on the first support wall 32. A servo motor 33 that rotates the first rotating body 28 is attached to the first support wall 32. Pulleys 34a and 34b are provided on the first rotating body 28 and the rotary shaft 33a of the servo motor 33, respectively, and a belt 34c is installed on these pulleys 34a and 34b. As a result, when the servo motor 33 is driven to rotate the rotating shaft 33a, the rotation is transmitted to the first rotating body 28 via the belt 34c, thereby rotating the first rotating body 28 together with the winding core 22. Configured.

  The first rotating body 28 is provided with a locking pin 28a to which the end of the wire 11 is locked. The first flange 23 in the vicinity of the locking pin 28a has a tip locked to the locking pin 28a. A slit 23 a (FIG. 2) for guiding the wire 11 thus formed to the periphery of the core 22 is formed. And this core 22 is comprised so that it may wind around the core 22 by rotating the wire 11 which reached the outer periphery of the core 22 via the slit 23a.

  The second flange 24 is configured to be detachable from the core 22, an insertion portion 24 b that can be inserted into the core 22, and the core together with the first flange 23 in a state where the insertion portion 24 b is inserted into the core 22. And a disc-shaped flange main body 24a sandwiching 22. The insertion portion 24 b of the second flange 24 has an outer diameter equal to the inner diameter of the core 22, and the coil 10 is intended to obtain the outer diameter of the core 22 by inserting the insertion portion 24 b into the core 22. When the insertion portion 24 b is detached from the core 22, the outer diameter of the core 22 is also reduced, and the coil 10 made of the wire 11 wound around the outer periphery of the core 22 is removed from the core 22. It is configured to be removable.

  As shown in FIGS. 1 and 4, on the gantry 19, the second and third support walls 36 and 37 are parallel to the first support wall 32 at a predetermined distance from the first support wall 32 in the Y-axis direction. The second rotating body 29 is installed on the second and third support walls 36 and 37 so as to extend coaxially with the first rotating body 28 in the Y-axis direction and move in the longitudinal direction. A servo motor 38 that rotates the second rotating body 29 is attached to the third support wall 37. Pulleys 39a and 39b are provided on the rotating shaft 38a of the second rotating body 29 and the servo motor 38, respectively, and a belt 39c is installed on these pulleys 39a and 39b. The pulley 39 b provided on the second rotating body 29 is movable in the longitudinal direction of the second rotating body 29 and is provided on the third support wall 37. As a result, when the servo motor 38 is driven and the rotating shaft 38a rotates, the rotation is transmitted to the second rotating body 29 via the belt 39c, whereby the second rotating body 29 is configured to be rotatable.

  A second flange 24 is coaxially provided at an end of the second rotary body 29 facing the first rotary body 28, and an insertion portion 24 b is provided so as to face the winding core 22 provided on the first rotary body 28. It is done. The second and third support walls 36 and 37 are provided with a variable interval mechanism 41 that moves the second rotating body 29 together with the second flange 24 in the axial direction with respect to the first rotating body 28. Then, with this variable spacing mechanism 41, the second rotary body 29 is moved in the axial direction together with the second flange 24 with respect to the first rotary body 28, and the insertion portion 24 b of the second flange 24 is inserted into the core 22. By making the inner diameter of the coil to obtain the outer diameter of the winding core 22 and rotating both the first rotating body 28 and the second rotating body 29 in this state, the flange main body 24a and the first flange The wire 11 is wound around the winding core 22 located between 23.

  The distance varying mechanism 41 in this embodiment includes a ball screw 42 installed on the second and third support walls 36 and 37 so as to be parallel to the second rotating body 29, and a servo motor 43 for rotating the ball screw 42. , And a movable base 44 that is engaged with the ball screw 42 and moves in the Y-axis direction. The second rotating body 29 is attached to the movable table 44 so as not to move in the axial direction and to be rotatable. Accordingly, when the servo motor 43 is driven to rotate the ball screw 42 and the movable table 44 moves in the Y-axis direction, the second rotating body 29 also moves in the Y-axis direction together with the movable table 44. When the second rotating body 29 moves in the Y-axis direction, which is its axial direction, the first rotating body 28 does not move, so the second rotating body 29 is moved together with the second flange 24 with respect to the first rotating body 28. It is configured to move in the axial direction.

  As shown in FIGS. 1 and 3, on the gantry 19, at least a core is provided with a wire rod feeder 50 for feeding the wire 11 with a constant tension via the wire rod guide, and a wire guide for feeding the wire 11. A moving mechanism 52 for moving in the direction of the rotation axis 22 is provided. The wire guide in this embodiment is a nozzle 51 through which the wire 11 is inserted, and the moving mechanism 52 is configured to be able to move the nozzle 51 in three axial directions. The nozzle 51 is fixed to the support plate 54, and the nozzle moving mechanism 52 is configured to be able to move the support plate 54 with respect to the gantry 19 in three axial directions.

  Specifically, the nozzle moving mechanism 52 in this embodiment is configured by a combination of X-axis, Y-axis, and Z-axis direction extendable actuators 56 to 58. In this embodiment, a support plate 54 provided with a nozzle 51 is attached to a housing 56d of an X-axis direction extendable actuator 56 so as to be movable in the X-axis direction, and the support plate 54 is attached together with the X-axis direction extendable actuator 56 in the Z-axis direction. The follower 56c of the X-axis direction expansion / contraction actuator 56 is attached to the follower 57c of the Z-axis direction expansion / contraction actuator 57. The support plate 54 can be moved in the Y-axis direction together with the X-axis and Y-axis expansion / contraction actuators 56, 57, and the housing 57 d of the Z-axis expansion / contraction actuator 57 serves as a follower 58 c of the Y-axis expansion / contraction actuator 58. Mounted. The housing 58 d of the Y-axis direction extendable actuator 58 extends in the Y-axis direction and is fixed to the gantry 19. The servo motors 56a to 58a in the telescopic actuators 56 to 58 are connected to control outputs of a controller (not shown) that controls them.

  As shown in FIG. 3, the support plate 54 has a cutter device 59 (patent application number; Japanese Patent Application No. 2010-87668) for cutting the wire 11 that has passed through the nozzle 51 by air pressure in addition to the nozzle 51, and the wire 11. A gripping device 60 is provided that grips the wire 11 by the gripping piece 60 a and prohibits the movement of the wire 11 passing through the nozzle 51. The cutter device 59 is attached to the support plate 54 via an air cylinder 59a that is driven by a command from a controller (not shown). With this air cylinder 59 a, the cutter device 59 is configured to be movable between a cutting position where the cutter teeth 59 b cut the wire 11 and a standby position where it is separated from the wire 11. As a result, the cutter device 59 and the gripping device 60 move with the nozzle 51 and can be controlled by a controller (not shown).

  On the other hand, the wire rod feeder 50 includes a drum 62 around which the wire rod 11 is wound, and a tension device 53 that applies tension to the wire rod 11 unwound from the drum 62. The tension device 53 can apply tension to the fed wire 11 and pull back the wire 11. The tension device 53 in this embodiment includes a casing 61 provided on the gantry 19, and a drum 62 and a tension bar 63 provided on a side surface of the casing 61 in the Y-axis direction. A wire rod 11 is wound around a drum 62, and a feed control motor 64 for rotating the drum 62 to feed the wire rod 11 is provided inside the casing 61. The wire rod 11 fed from the drum 62 is a wire rod at the tip of the tension bar 63. Guided to guide 63a. The wire 11 guided to the wire guide 63a is wired so as to penetrate the nozzle 51 from the wire guide 63a.

  The tension bar 63 is rotatable in the X-axis direction with the rotation shaft 63b at the base end as a fulcrum. The rotation angle of the rotation shaft 63b is detected by a potentiometer 65 serving as a rotation angle detection means housed in the casing 61 and attached to the rotation shaft 63b. The detection output of the potentiometer 65 is input to a controller (not shown), and the control output from the controller is connected to the feeding control motor 64.

  Further, one end of a spring 66, which is an elastic member serving as a biasing means for applying a biasing force in the rotation direction of the tension bar 63, is attached to a predetermined position between the rotation shaft 63b of the tension bar 63 and the wire guide 63a. It is attached via a bracket 63c. The tension bar 63 is given an elastic force according to the rotation angle by a spring 66 which is an elastic member. The other end of the spring 66 is fixed to the moving member 67. The moving member 67 is screwed into a male screw 68a of a tension adjusting screw 68, and is configured to be movable and adjustable according to the rotation of the male screw 68a. In this way, the fixing position of the other end of the spring 66 can be displaced, and the tension of the wire 11 applied by the tension bar 63 can be adjusted.

  A controller (not shown) is configured to control the feed control motor 64 so that the rotation angle detected by the potentiometer 65 serving as a rotation angle detection means becomes a predetermined angle. Therefore, in this tension device 53, tension is applied to the wire 11 via the tension bar 63 by the spring 66, and the drum 62 rotates so that the tension bar 63 becomes a predetermined angle, and a predetermined amount of the wire 11 is fed out. Is done. Therefore, the tension of the wire 11 is maintained at a predetermined value.

  As shown in FIGS. 1 and 2, the coil manufacturing apparatus 20 of the present invention includes a wire movement prohibiting mechanism 70 that contacts the wire 11 wound around the winding core 22 and prohibits its movement. The wire movement prohibiting mechanism 70 includes an elongated displacement prevention member 71, a moving means 72 that moves the displacement prevention member 71 in the longitudinal direction, and the displacement prevention member 71 together with the movement means 72 around the rotation axis of the winding core 22. And rotating means 73 for rotating. In addition, although the case where the slack prevention member 71 in this embodiment uses an elongate rod-shaped thing is demonstrated, this slip prevention member 71 may be a plate-shaped thing, or uses the thing of another shape. You can also It is desirable to use a material having a shape and material that can smoothly contact the wire 11 without damaging the wire 11.

  The moving means is movable between a contact position where the displacement preventing member 71 is moved to contact the wire 11 wound around the core 22 and a separated position which is separated from the wire 11. In the embodiment, a fluid pressure cylinder 72 that moves the displacement preventing member 71 by the pressure of the fluid is used. The fluid pressure cylinder 72 includes a cylinder main body 72b attached to the turntable 77, and a slider 72a capable of reciprocating in the longitudinal direction along the cylinder main body 72b by fluid pressure supplied to and discharged from the cylinder main body 72b. .

  And the slip prevention member 71 is attached to the slider 72a. The slip prevention member 71 in this embodiment is a long pin having a circular cross section, and is provided so as to extend from the end edge of the slider 72a in the moving direction.

  The rotating means 73 includes a servo motor 75 that rotates the fluid pressure cylinder 72 around the Y axis together with the turntable 77, and a movable plate moving mechanism 78 that can move the servo motor 75 in three axial directions. The servo motor 75 is capable of both normal rotation and reverse rotation of the rotation shaft 75a, and is attached to the movable plate 74 so that the rotation shaft 75a is parallel to the Y axis. A rotary base 77 is attached to the rotary shaft of the servo motor 75, and a cylinder 72 attached to the rotary base 77 is rotatably attached to the rotary shaft 75a in the XZ plane.

  In this embodiment, the movable plate moving mechanism 78 for moving the movable plate 74 to which the servo motor 75 is attached in the three-axis direction with respect to the gantry 19 includes the X-axis, Y-axis, and Z-axis direction extendable actuators 79 to 81. It is comprised by the combination of. Since the movable table moving mechanism 78 has the same structure as the nozzle moving mechanism 52 described above, repeated description is omitted.

  The rotating means 73 having such a servo motor 75 and the movable plate moving mechanism 78 moves the movable plate 74 in an arc shape around the rotation axis of the winding core 22. When the servo motor 75 rotates the fluid pressure cylinder 72 as the moving means, the displacement preventing member 71 moved to the contact position by the fluid pressure cylinder 72 is rotated about the rotation axis of the core 22. Composed.

  A hot air generator 91 that heats and fuses the wire 11 wound around the core 22 that is the winding device 21 is provided on the mount 19 below the core 22. The hot air generator 91 is mounted on the gantry 19 so that the hot air outlet 91a faces the core 22, and in response to a command from a controller (not shown), hot air is blown from the outlet 91a toward the core 22. Configured.

  Next, the coil manufacturing method of the present invention using the above apparatus will be described.

  In the coil manufacturing method of the present invention, a wire guide 51 for feeding the wire 11 is moved from one side in the axial direction of the core 22 toward the other side, and the core 22 is rotated to rotate the shaft around the core 22. One winding layer composed of a plurality of rows of wire rods 11 sequentially wound from one side in the direction toward the other side is formed, and the wire rod guide 51 for feeding out the wire rod 11 is moved from the other side in the axial direction of the core 22 to one side. The other winding layer composed of a plurality of rows of wire rods 11 is sequentially wound around the outer periphery of one winding layer from the other side in the axial direction toward the one side by rotating the winding core 22 while moving toward This is a method of manufacturing the coil 10 in which a plurality of winding layers are laminated on the winding core 22 by forming and sequentially repeating these.

  In the detailed procedure, first, as shown in FIG. 1, the second rotating body 29 is moved together with the second flange 24 in the axial direction with respect to the first rotating body 28 by the interval variable mechanism 41, The core 22 is sandwiched between the first and second flanges 23 and 24. At the same time, the insertion portion 24b of the second flange 24 is inserted into the winding core 22 to keep the inner diameter of the coil 10 to obtain the outer diameter of the winding core 22 (FIG. 4). Thereafter, the cutter device 59 is maintained at the standby position, the wire 11 is gripped by the gripping piece 60 a of the gripping device 60, and the nozzle 51 is moved by the nozzle moving mechanism 52 with the wire 11 protruding from the nozzle 51. Then, the end edge of the wire 11 is locked to a locking pin 28 a provided on the first rotating body 28. Thereafter, the nozzle 51 is moved again, and the wire 11 extending from the locking pin 28 a is inserted into the slit 23 a formed in the first flange 23. The core 22 is rotated from this state, and the wire 11 reaching the outer periphery of the core 22 through the slit 23 a is wound around the core 22.

  The winding core 22 is rotated by rotating the servo motors 33 and 38 synchronously and rotating the first and second rotating bodies 28 and 29 together with the winding core 22. In this manner, the wire 11 fed from the wire feeder 50 through the nozzle 51 is wound around the core 22 sandwiched between the first and second flanges 23 and 24. When winding of the wire 11 is started from the first flange 23 side, the nozzle moving mechanism 52 is located on the first flange 23 side at the beginning of winding every time the winding core 22 rotates once and the wire 11 is wound once. The nozzle 51 is moved in the axial direction of the winding core 22 by an amount equal to the wire diameter of the wire 11. As a result, the wires 11 are wound so that they are in close contact with each other in the longitudinal direction of the core 22, and a plurality of rows of wires are sequentially wound around the core 22 from one side to the other side in the axial direction. One winding layer consisting of 11 is formed. And the hot air generator 91 (FIG. 2 and FIG. 4) which is a hot air generation means heats the wire 11 wound around the winding core 22 which is the coil | winding apparatus 21, and fuses the wire 11 which adheres mutually.

  After the nozzle 51 reaches the second flange 24 side and the first winding layer is formed, the wire 11 is further wound as a second layer winding on the first layer winding. . In this second layer of winding, the nozzle moving mechanism 52 (FIG. 3) causes the nozzle 51 to move to the first layer each time the winding core 22 rotates once and the wire 11 is wound once. In the direction opposite to the moving direction at the time of winding, that is, the nozzle 51 which is a wire guide for feeding the wire 11 is directed from the other side in the axial direction of the core 22 to one side, and is equal to the wire diameter of the wire 11 Move by the amount. Then, the wire 11 is wound around the core 22 a predetermined number of times in the second layer winding, and a plurality of rows are sequentially wound around the outer periphery of the one winding layer from the other side in the axial direction toward the one side. Another winding layer made of the wire 11 is formed. The winding of the second layer is performed over the entire width of the winding core 22 sandwiched between the first and second flanges 23, 24, that is, the entire winding width of the winding of the first layer.

  By sequentially repeating the formation of such winding layers, a plurality of winding layers are sequentially formed around the core 22 sandwiched between the first and second flanges 23 and 24. Here, the outer diameters of the first and second flanges 23, 24 are the total length of the winding core 22 between the first and second flanges 23, 24, that is, the outer circumference of the outermost winding layer having the same winding width. The winding layer is formed to have the same outer diameter as that of the outermost periphery of the winding layer reaching the outer periphery of the first and second flanges 23 and 24. In this case, since the winding width W3 (FIG. 21) in each winding layer is defined by the first and second flanges 23 and 24, the wire material at the beginning of each winding of the second and subsequent winding layers moved from the lower layer to the upper layer. 11 is prevented from moving outward in the axial direction of the core 22. As a result, the alignment of the wire 11 constituting each winding layer is ensured.

  In the formation of the respective winding layers, a certain tension is applied to the wire 11 fed from the wire feeder 50. As shown in FIG. 3, this tension is applied by a tension device 53 in the wire rod feeder 50, and the tension device 53 applies tension to the wire 11 through a tension bar 63 by a spring 66. Therefore, in the formation of each winding layer, the tension of the wire 11 is maintained at a predetermined value, thereby preventing a difference in the degree of adhesion between the layers of the wire 11 in each winding layer.

  As shown in FIG. 5, after the winding layer 12 reaching the outer peripheries of the first and second flanges 23 and 24 is formed, a plurality of winding layers 13 and 14 (see FIG. 21) is further formed. A characteristic point of the present invention is that, in the formation of the winding layers 13 and 14 whose winding widths are successively narrowed, the wire rod 11 that has shifted from the lower layer to the upper layer is brought into contact with the shift preventing member 71 from the shifted side, and the wire rod guide 51 Is moved to the side on which the slip prevention member 71 contacts to bend the wire 11 from the slip prevention member 71, and then the wire 11 between the slip prevention member 71 and the wire guide 51 extends to a position extending in the circumferential direction of the core 22. After the wire rod guide 51 is returned and the slip prevention member 71 is in contact with the wire rod 11, the wire core 22 is rotated around the rotation axis of the core 22 together with the core 22, and then the slip prevention member 71 is separated from the wire rod 11. The formation of the winding layers 13 and 14 is continued.

  The specific procedure will be described. The winding 22 is stopped in a state where the winding layer 12 reaching the outer circumferences of the first and second flanges 23 and 24 is formed. Then, the nozzle 51 is moved by the nozzle moving mechanism 52, and the wire 11 extending from the winding end side flange 24 side of the winding layer 12 reaching the outer periphery of the first and second flanges 23, 24 is moved to the other flange 23 side. Pull out diagonally. In this embodiment, as shown in FIG. 5, it is assumed that the wire 11 is pulled out from the second flange 24 side, and the slip prevention member 71 is brought into contact with the wire 11 pulled out obliquely from the second flange 24 side. .

  The rod-shaped member 71 is positioned by the movable plate moving mechanism 78, and the rod-shaped member 71 is rotated together with the fluid pressure cylinder 72 by the servo motor 75 so that the longitudinal direction of the rod-shaped member 71 coincides with the radial direction of the core 22. Let 8, the slider 72a of the fluid pressure cylinder 72 is moved by the air pressure that is the fluid, and thereby the tip of the rod-like member 71 that moves in the axial direction is moved to the first and second flanges. The outer circumferences of the winding layers 12 reaching the outer circumferences of 23 and 24 are brought into contact with each other.

  As shown in FIG. 5, the position where the tip of the slip prevention member 71 is brought into contact with the outer periphery of the lower winding layer 12 is the width dimension of the winding layer 13 formed on the lower winding layer 12. This is a position that defines W2 (FIG. 21) and is on the second flange 24 side of the wire 11 drawn obliquely. Then, after the wire 11 is brought into contact with the slip prevention member 71, as shown in FIG. 6, the nozzle 51 is moved to the side on which the slip prevention member 71 is brought into contact by the nozzle moving mechanism 52. The wire 11 fed from a certain nozzle 51 is bent around the shift prevention member 71. The degree of this bending is performed until the angle at which the wire 11 drawn obliquely turns in the circumferential direction is exceeded.

  Thereafter, as shown in FIGS. 7 and 8, the wire guide 51 is returned to a position where the wire 11 between the slip prevention member 71 and the wire guide 51 extends in the circumferential direction of the winding core 22, and as shown in FIG. The slip prevention member 71 is rotated around the rotation axis of the core 22 together with the core 22 in a state of contacting the wire 11. As shown in FIGS. 8 and 9, the range in which the deviation preventing member 71 is rotated around the rotation axis of the core 22 together with the core 22 in a state where the slip prevention member 71 is in contact with the wire 11 is a range exceeding 90 degrees.

  The winding core 22 is rotated by synchronously driving the servo motors 33 and 38 (FIG. 1). When the winding core 22 starts to rotate, the nozzle moving mechanism 52 causes the nozzle 51 to move the winding core 22. The movement is started again in the axial direction from the second flange 24 side toward the first flange 23 side. The degree of this movement is that the nozzle 51 is moved by an amount equal to the wire diameter of the wire 11 every time the core 22 rotates once and the wire 11 is wound once.

  On the other hand, the shift prevention member 71 is rotated by the rotation means 73, and the movable plate moving mechanism 78 moves the movable plate 74 in an arc shape around the rotation axis of the core 22, and the servo motor 75 moves. By rotating the fluid pressure cylinder 72 as means, as shown in FIG. 9, the displacement preventing member 71 moved to the contact position by the fluid pressure cylinder 72 is rotated about the rotation axis of the core 22. It will be. At this time, even if the rotation center of the shift prevention member 71 is shifted from the rotation center of the winding core 22 due to an error, the shift prevention member 71 is moved in the axial direction by the fluid pressure to contact the outer periphery of the winding layer 12. The fluid pressure cylinder 72 is allowed to move slightly due to the error of the deviation preventing member 71 and absorbs the error. For this reason, it can be effectively avoided that the slip prevention member 71 is separated from the outer periphery of the winding layer 12 due to an error and the contact with the wire 11 is eliminated.

  As shown in FIG. 9, with the deviation preventing member 71 in contact with the wire 11, the winding core 22 and the rotation axis of the winding core 22 are rotated around the winding core 22 to constitute the first row at the beginning of the winding. After the wire 11 to be turned is wound around the outer periphery of the lower winding layer 12 over 90 degrees, the fluid pressure cylinder 72 separates the slip prevention member 71 from the wire 11 as indicated by a one-dot chain line arrow, Thereafter, the core 22 is rotated, and each time the core 22 rotates once and the wire 11 is wound once, the nozzle 51 is moved in the axial direction of the core 22 by an amount equal to the wire diameter of the wire 11. Thus, the formation of the winding layer 13 (FIG. 21) in which the winding width W2 (FIG. 21) is narrowed is continued.

  Thus, when forming the winding layer 13 with a reduced winding width, the slip prevention member 71 is brought into contact with the wire 11 constituting the first row at the beginning of the winding, and the wire 11 The winding wire 12 at the beginning of the winding can be made to conform to the outer surface of the lower winding layer 12 by being wound around the outer periphery of the lower winding layer 12 over 90 degrees in a state where the deviation is prevented.

  In particular, when the winding width is narrowed, the wire 11 drawn from the lower winding layer 12 and the wire 11 constituting the first row of the winding layer 13 intersect at a predetermined angle. However, in the present invention, since the wire 11 drawn out from the lower winding layer 12 is brought into contact with the displacement preventing member 71 and bent in advance, the wire 11 does not swell at the intersecting portion. It is possible to effectively prevent the wire 11 at the beginning of the winding wound around the outer periphery of the lower winding layer 12 from exceeding 90 degrees from shifting thereafter.

  Further, in this embodiment, as shown in FIG. 10, the second row wire adjacent to the first row wire 11 of the winding layer formed after the deviation preventing member 71 is separated from the wire 11. When winding 11, the slip prevention member 71 is brought into contact again with the wire 11 in the first row as shown by the solid line arrow. Then, from the state shown in FIG. 11 where the deviation preventing member 71 is brought into contact with the wire 11 again, as shown in FIG. 12, the deviation preventing member 71 together with the core 22 is centered on the rotation axis of the core 22. Turn to. The range is similarly a range exceeding 90 degrees. Thereby, it can prevent that the wire 11 of the 1st row is pushed by the wire 11 of the 2nd row, and moves to the axial direction outer side of the core 22. Since the wire 11 is a coated conductor having a heat-fusible coating, hot air is blown to the wound wire 11 by a hot air generator 91 as hot air generating means, and the wires 11 in the first and second rows. By adhering to each other, even if the subsequent third row wire 11 is wound, these deviations can be reliably prevented. Therefore, the wire 11 at the beginning of winding that has moved from the lower layer 12 to the upper layer 13 is prevented from moving outward in the axial direction of the core 22, and the alignment of the wires 11 can be improved reliably.

  In this embodiment, a case will be described in which the outer layer-side two layers 13 and 14 (FIG. 21) obtain a coil 10 whose winding widths W1 and W2 (FIG. 21) are gradually reduced toward the outer periphery. For this reason, the winding layer 14 in which the winding width is further narrowed is formed on the winding layer 13 in which the winding width is reduced by the procedure described above. This procedure is a similar procedure, and as shown in FIGS. 13 and 16, the wire 11 at the end of the winding layer 13 whose winding width is narrowed is slanted toward the center of the winding layer 13 in the width direction. Pull out. And the slip prevention member 71 is made to contact | abut from the side which transferred to the wire 11 which transferred to the upper layer 14 from the lower layer 13 by pulling diagonally.

  After that, as shown in FIG. 14, the nozzle 51, which is a wire guide, is moved to the side where the slip prevention member 71 comes into contact, and the wire 11 is bent from the wire guide 51, and then the slip prevention member 71 as shown in FIG. The wire rod 51 is returned to a position where the wire rod 11 between the wire rod 51 and the wire rod guide 51 extends in the circumferential direction of the core 22. Then, from the state shown in FIG. 16, as indicated by the solid line arrow in FIG. 17, the shift prevention member 71 is rotated around the rotation axis of the core 22 together with the core 22 in a state of being in contact with the wire 11. When the rotation exceeds 90 degrees, the wire 11 is wound around the outer periphery of the lower winding layer 13, and the winding wire 14 at the beginning of the winding layer 14 in the winding layer 14 whose winding width is further reduced is wound on the lower winding. It is surely adapted to the outer surface of the wire layer 13.

  Thereafter, the formation of the winding layer 14 is continued after the deviation preventing member 71 is separated from the wire 11, but after the deviation preventing member 71 is separated from the wire 11, the wire 11 in the first row of the winding layer 14 is used. When winding the wire 11 in the second row adjacent to the wire, as shown in FIG. 18 and FIG. 19, the slip prevention member 71 is again brought into contact with the wire 11 in the first row, and the slip prevention member In a state where 71 is brought into contact with the wire 11 again, as shown in FIG. 20, the deviation preventing member 71 is rotated around the rotation axis of the core 22 together with the core 22 (FIG. 1). This prevents the first row of wire rods 11 from being pushed by the second row of wire rods 11 and moving outward in the axial direction of the core 22.

  After that, the formation of the winding layer 14 (FIG. 21) with a further reduced winding width W1 is continued, and when the winding layer 14 with a predetermined winding width W1 is obtained, the rotation of the winding core 22 is stopped. The formation of the winding layer 14 is terminated. In this way, as shown in FIG. 21, several coils on the outer peripheral side (in this embodiment, two layers 13 and 14 on the outer peripheral side) have a coil 10 whose winding width is gradually reduced toward the outer peripheral side. Get.

  In addition, after the coil 10 of a desired shape is obtained, as shown in FIG. 1, the wire 11 is gripped by the gripping piece 60 a of the gripping device 60 and the wire 11 is fed from the wire feeder 50. After the prevention, the cutter device 59 (FIG. 3) is moved to the cutting position by the air cylinder 59a, and the wire 11 extending from the first coil 12 to the wire rod feeder 50 is cut.

  Thereafter, the second rotating body 29 is moved in the axial direction with respect to the first rotating body 28 by the interval variable mechanism 41, the second flange 24 is separated from the core 22, and the insertion portion 24 b in the second flange 24 is moved. Separate from the core 22. Thereby, the outer diameter of the core 22 is reduced, and the coil 10 made of the wire 11 wound around the outer periphery of the core 22 is detached from the core 22. Thereby, the desired coil 10 detached from the winding core 22 can be obtained.

  In the above-described embodiment, the winding layers 13 and 14 in the two outer peripheral layers have been described using the coil 10 whose winding width is gradually reduced toward the outer peripheral side. As long as the coil does not have such a flange, the number of winding layers is not limited to two but may be any number.

  In the above-described embodiment, the servo motor 75 that rotates the fluid pressure cylinder 72 around the Y axis together with the turntable 77 and the movable plate moving mechanism 78 that can move the servo motor 75 in three axis directions are provided. Although the rotation means 73 has been described, the rotation means 73 is of another type as long as the displacement prevention member 71 can be rotated around the rotation axis of the core 22 together with the fluid pressure cylinder 72 as the movement means. There may be.

  Moreover, although the case where the moving means is the fluid pressure cylinder 72 has been described in the above-described embodiment, the moving means can be simplified in structure using an extendable spring. Specifically, as shown in FIG. 22, the moving means includes an elongated housing 92 attached to the turntable 77, and a base end of the slip prevention member 71 provided inside the housing 92 so as to be movable in the longitudinal direction. The connected moving member 93 and a coil spring 94 provided inside the housing 92 and biasing the moving member 93 so as to project the displacement preventing member 71 from the end of the housing 93 are provided. May be.

  When such a moving means is used, the displacement prevention member 71 is moved to the contact position using the movable plate moving mechanism 78 movable in the three-axis directions, and the displacement prevention member moved to the contact position. The rotating means 73 is rotated about the rotation axis of the core 22 by 71. At this time, even if the rotation center of the shift prevention member 71 is shifted from the rotation center of the core 22 due to an error, the shift prevention member 71 is immersed in the housing 92 against the biasing force of the coil spring 94. The slight movement caused by the error of the deviation preventing member 71 is allowed and the error is absorbed. For this reason, even if it is a moving means as shown in FIG. 22, it is effectively avoided that the slip prevention member 71 is separated from the outer periphery of the winding layer 12 due to an error and the contact with the wire 11 is eliminated. Can do.

  In the above-described embodiment, the nozzle moving mechanism 52 and the movable plate moving mechanism 78 configured by a combination of the X-axis, Y-axis, and Z-axis direction extendable actuators have been described. However, these moving mechanisms have this structure. The present invention is not limited to this, and other types may be used as long as the nozzle 51 and the movable plate 74 can move in the three-axis directions with respect to the gantry 19.

  In the above-described embodiment, the wire 11 having a circular cross section has been described. However, the wire 11 may be a so-called square line having a square cross section.

  Further, in the above-described embodiment, the nozzle 51 is used as the wire guide. However, the wire guide may be other as long as the wire 11 can be fed to a predetermined position. For example, a pulley around which the wire 11 is wound may be used.

DESCRIPTION OF SYMBOLS 11 Wire rod 20 Coil manufacturing apparatus 22 Core 50 Wire rod feeder 51 Nozzle (wire rod guide)
52 moving mechanism 70 wire rod movement prohibiting mechanism 71 slip prevention member 72 fluid pressure cylinder (moving means)
73 Rotating means 91 Hot air generator (hot air generating means)
92 Housing 93 Moving member 94 Coil spring

Claims (8)

A winding core (22) around which the wire (11) is wound by rotation, a wire rod feeder (50) for feeding out the wire (11) with a constant tension via a wire guide (51), and the wire (11) Is a moving mechanism (52) for moving the wire guide (51) at least in the rotation axis direction of the core (22), and a part of the wire (11) wound around the core (22). A winding device provided with a wire movement prohibiting mechanism (70) that prohibits movement of
The wire rod movement prohibiting mechanism (70) includes a slip prevention member (71), and a contact position for bringing the slip prevention member (71) into contact with the wire (11) wound around the core (22). A moving means (72) that moves between a separating position separated from the wire (11), and a rotation preventing member (71) at a contact position together with the moving means (72) of the winding core (22). An apparatus for manufacturing a coil, comprising: a rotating means (73) for rotating about an axis.   The coil manufacturing apparatus according to claim 1, wherein the moving means is a fluid pressure cylinder (72) for moving the displacement preventing member (71) by the pressure of the fluid.   The moving means includes a housing (92), a moving member (93) that is movably provided inside the housing (92) and to which a base end of the slip prevention member (71) is connected, and the housing (92) The coil according to claim 1, further comprising a coil spring (94) provided inside for biasing the moving member (93) so that a tip of the slip prevention member (71) protrudes from the housing (92). manufacturing device.   The wire rod (11) is a coated conductor having a heat-fusible coating, further comprising hot air generating means (91) for blowing hot air onto the wound wire rod (11) to bond the wire rod (11) to each other The coil manufacturing apparatus according to any one of claims 1 to 3. By rotating the core (22) while moving the wire guide (51) for feeding out the wire (11) from one side in the axial direction of the core (22) to the other side of the core (22) One winding layer consisting of a plurality of rows of wire rods (11) wound sequentially from one side to the other side in the axial direction is formed around the wire, and the wire rod guide (51) for feeding out the wire rod (11) is wound on the winding. By winding the core (22) while moving it from the other side in the axial direction of the core (22) to the one side, the winding is sequentially wound around the outer periphery of the one winding layer from the other side in the axial direction to the one side. A method of manufacturing a coil in which a plurality of winding layers are laminated on the core (22) by forming another winding layer composed of a plurality of wires (11) rotated and sequentially repeating these. There,
In the formation of any one or two or more winding layers after the second layer among the plurality of stacked winding layers, the wire rod (11) shifted from the lower layer to the upper layer is prevented from slipping (71 ) From the transition side,
The wire rod (11) is bent from the shift prevention member (71) by moving the wire guide (51) to the side where the shift prevention member (71) abuts,
Thereafter, the wire rod (11) between the slip prevention member (71) and the wire rod guide (51) returns the wire rod guide (51) to a position extending in the circumferential direction of the core (22),
With the slip prevention member (71) in contact with the wire (11), the core (22) and the core (22) are rotated around the rotation axis,
Thereafter, the winding preventing layer (71) is separated from the wire (11) and then the formation of the winding layer is continued.   The range in which the slip prevention member (71) is rotated about the rotation axis of the core (22) together with the core (22) in a state of being in contact with the wire (11) exceeds 90 degrees. The manufacturing method of the coil of description.   When winding the wire (11) in the second row adjacent to the wire (11) in the first row of the winding layer formed after separating the slip prevention member (71) from the wire (11) The method for manufacturing a coil according to claim 5 or 6, wherein the slip prevention member (71) is brought into contact with the wire rod (11) in the first row again.   The wire (11) is a coated conductor having a heat-fusible coating, and hot air is blown onto the wire (11) to be wound to bond the wires (11) to each other. The manufacturing method of the coil as described in any one of.

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