JP2016063661A - Winding method and winding device for coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a bending method and a bending device by which, in a processing for bending a wire or the like with a roll while continuously conveying the wire, influences exerted by a molded coil strand upon bending of a coil strand being processed is reduced and even a coil with a thin strand and many times of winding can be wound with high precision.SOLUTION: In a winding method, an air-core coil is molded by winding a coil strand with a desired curvature radius by a push-in operation of pressing the coil strand in a direction across a direction of conveyance using a push-in roll while continuously conveying the coil strand. Correspondingly to a processing progress of the coil strand, at least one end of a support shaft is moved so as to follow a coil center, a support is rotated and the wound molded coil strand is supported, moved and rotated.SELECTED DRAWING: Figure 1

Description

  The present invention provides an air-core coil capable of winding a workpiece with high accuracy in a processing machine configured to bend a metal plate or a wire while continuously conveying a conveyance roll and a processing roll in a pinch shape or a pyramid shape. This invention relates to a winding method and a winding apparatus.

As an electric motor as a power source, a motor in which a coil is formed by winding a conductive wire in a slot formed in a rotor or a stator is used. In recent years, a slotless motor using an alpha winding coil as disclosed in the cited document 2 is also used.
On the other hand, motors for electric vehicles and hybrid vehicles are required to be smaller and have higher output. For this reason, the space factor of coils used in the motor is improved. As a method for manufacturing such a motor with a high space factor, a method of arranging a previously formed air-core coil on a stator has been proposed.
Patent Document 1 and Patent Document 2 are conventional techniques related to a manufacturing method and a manufacturing apparatus for an air-core coil.

Patent Document 1 discloses a technique regarding a coil, a manufacturing method and manufacturing apparatus, a tooth, a core, and a rotating electrical machine.
Specifically, the base shaft portion includes a base shaft portion that abuts the coil strand that is continuously fed, and a swinging portion that is disposed on the opposite side of the base shaft portion and sandwiches the coil strand and swings in an arc shape. A manufacturing apparatus is disclosed that continuously adjusts the curvature of the coil wire by sandwiching the coil wire between the swing portion and the swing portion and swinging the swing portion.

Patent Document 2 discloses a technique regarding a coil, a slotless motor, and a manufacturing method of the coil.
Specifically, using a bending device provided with a fixing tool for fixing the conducting wire and a pressing tool for pressing the conducting wire in a perpendicular direction, the conducting wire as a material protrudes a predetermined length and the root is fixed with the fixing tool. In this state, after pressing the protruding portion of the conducting wire with the pressing tool in a right angle direction on the plane to bend the conducting wire at a right angle, the operation of projecting the conducting wire by a predetermined length from the fixture and bending it at a right angle is sequentially repeated. Thus, a method for manufacturing a coil is disclosed, in which a rectangular spiral body is formed.

JP 2004-336984 A JP 2009-71939 A

However, Patent Document 1 has the problems described below.
In Patent Document 1, the curvature of the coil wire can be continuously adjusted by continuously feeding the wire (coil wire) and swinging the swinging portion. On the other hand, it is affected by the weight and inertial force of the already formed processed wire. For this reason, the applicant has confirmed that, depending on the physical properties and cross-sectional shape of the coil wire, as the number of turns of the designed coil increases and the processing proceeds, the wire cannot be processed with high accuracy.

  In Patent Document 2, a wire (copper wire) is projected for a predetermined length, the pressing tool is pressed in a state where the wire is fixed by a fixing tool, and the wire is bent along a guide 22 having a round outer peripheral surface. For this reason, compared with Patent Document 1, although the influence of the already formed processed portion is small, the curvature imparted to the wire cannot be changed unless the guide 22 is changed.

  Therefore, in order to solve such problems, the present invention reduces the influence of the molded body that is formed by bending with a roll while continuously conveying the coil wire on the bending of the coil wire being processed. An object of the present invention is to provide a winding method and a winding device for an air-core coil that can be wound with high accuracy even with an air-core coil that is a thin coil wire and has a large number of turns.

In order to achieve the above object, the bending method according to the present invention has the following characteristics.
(1) A molded body is formed by deforming the coil wire so as to circulate in a spiral shape with a desired curvature by a pressing operation in which the coil wire is transferred using a pressing roll in a direction crossing the conveying direction. In the winding method of the air-core coil in which the formed body is compressed in the axial direction to closely contact the coil wire,
A winding method of an air-core coil that supports the molded body that is drawn out while being rotated and molded so as to be led out in a predetermined direction.

(2) The winding method of the air-core coil according to (1), wherein the molded body is supported by a support shaft provided inside the molded body.

(3) The winding method of the air-core coil according to (2), wherein the support shaft is rotated and / or moved in accordance with the movement of the molded body.

  (4) A conveying unit that conveys the coil wire along a predetermined conveying path, a deforming unit that presses the pressing roll against the coil wire to be conveyed and deforms it into a desired curvature, and a spiral shape. A support unit that supports the molded body drawn out in a predetermined direction, and a control for forming the coil wire so as to circulate spirally by controlling the feeding operation of the coil wire and the pressing operation of the push roll. And an air core coil winding device.

(5) The winding device for an air-core coil according to (4), wherein the support portion includes a support shaft disposed inside the molded body.

(6) The winding device for the air-core coil according to (4) or (5), wherein the support shaft is formed with an open end in a developing direction in which the molded body is drawn out.

  (7) The air core coil winding device according to (5) or (6), wherein the support shaft is set along an axis of a fulcrum roll serving as an action point of the pushing operation.

(8) The winding device for an air-core coil according to (7), wherein the support shaft is integrated with the fulcrum roll.

(9) The support portion includes a rotating means for rotating the support shaft and / or a moving means for moving the support shaft. The air core coil according to any one of (5) to (8) Winding device.

  (10) The air core coil winding device according to (7), wherein the support shaft is made of a wire.

  (11) The winding device for an air-core coil according to (10), wherein the wire is provided so as to pass through a hollow shaft of the fulcrum roll.

The winding method and winding apparatus of the present invention having such characteristics can provide the following operational effects.
By supporting the molded body that is bent and formed by a roll while being continuously conveyed and fed out by a support part so as to lead it in a predetermined direction, it is possible to bend the coil wire during processing. Thus, even an air-core coil having a thin coil wire and a large number of turns can be wound with high accuracy.

It is a perspective view which shows the process part 1 which concerns on this invention. FIG. 6 is a perspective view in which a guide 5 is provided in the deformable portion 4. It is a perspective view of a coil and a developed coil. It is a front view of Example 1 of the coil to process. It is a figure showing the change of the coil center position when the coil of FIG. 4 is processed into a spiral. It is the perspective view and XY top view of 1st Embodiment which concern on this invention. It is the perspective view and YZ top view of 2nd Embodiment which concern on this invention. It is the perspective view of 3rd Embodiment (modification of 1st Embodiment) which concerns on this invention, sectional drawing of a fulcrum roll, and YZ top view. It is the perspective view of 3rd Embodiment (modification of 2nd Embodiment) which concerns on this invention, sectional drawing of a fulcrum roll, and YZ top view. It is a perspective view of the modification of 3rd Embodiment (modification of 1st Embodiment) which concerns on this invention, sectional drawing of a fulcrum roll, and YZ top view. It is a front view of Example 2 of the coil to process. It is a perspective view of 4th Embodiment which concerns on this invention, XY top view, and sectional drawing of a fulcrum roll. It is the figure which extracted the change of the coil center position already with progress of a process. It is a perspective view of the mechanism which moves the support shaft of 5th Embodiment concerning this invention. It is a schematic diagram of the coil strand and each roll in process. It is a block diagram of the winding device concerning the present invention.

  Hereinafter, embodiments according to the present invention will be described in detail. The embodiments described below are preferable specific examples for carrying out the present invention, and thus various technical limitations are made. However, the present invention is particularly limited in the following description. Unless otherwise specified, the present invention is not limited to these forms.

(First embodiment)
An air-core coil winding apparatus according to a first embodiment of the present invention will be described with reference to FIGS. The winding device according to the present embodiment includes a conveying unit that conveys a coil wire along a predetermined conveying path, a deforming unit that presses a pressing roll against the coiled wire that is conveyed, and deforms the coil wire into a desired curvature, and a spiral The coil body wire is spirally wound by controlling the support portion for supporting the formed body that is molded into a shape and being drawn out in a predetermined direction, and the feeding operation of the coil wire and the pressing operation of the push roll. The control part which shape | molds is provided.
As shown in FIG. 1, the transport unit 3 includes a drive roll 12 a and a driven roll 12 b disposed to face the drive roll 12 a, and the coil wire 2 is sandwiched between the drive roll 12 a and the drive roll 12 b. By rotating and driving the drive roll 12a, the coil wire 2 is fed out from a supply unit (not shown) and conveyed to the deformation unit 4 while being shaped so as to be linear in the longitudinal direction.

The deformation unit 4 includes a pressing roll 13, a fulcrum roll 14, and a pressing roll 15. The fulcrum roll 14 is arranged on one side of the conveyance path of the coil wire 2, and the push roll 15 is arranged on the other side of the conveyance path of the coil element wire 2 so as to move in a direction crossing the conveyance path. It has become. Then, the coil wire 2 is deformed into a desired curvature by a pressing operation of pressing the coil wire 2 with the pressing roll 15. When the coil element wire 2 is deformed, the coil element wire 2 can be deformed with high accuracy by holding the coil element wire 2 so as not to be bent by the pressing roll 13.
As shown in FIG. 1, the control unit controls the conveyance amount of the coil wire 2 by controlling the drive roll 12 a of the conveyance unit 3 and also controls the pushing operation of the pushing roll 15 of the deformation unit 4. Thus, a molded body can be obtained which is formed so as to wrap around the coil wire 2 in a spiral shape. The molded body 50 shown in FIG. 3 is formed in a spiral shape by alternately forming straight portions and curved portions by repeatedly performing a pushing operation at a predetermined timing while conveying the coil wire 2 at a predetermined conveyance speed. ing. And as shown in FIG. 3, an air-core coil can be manufactured by compressing the molded object 50 in a spiral direction and sticking a coil strand.

In order to prevent interference between the molded body 50 and the coil wire 2 positioned on the upstream side of the conveyance path from the fulcrum roll 14 and interference with each roll, it is desirable to appropriately install the guide 5 as shown in FIG. The coil wire 2 that has passed through the fulcrum roll 14 is conveyed while being guided by the guide 5, and the formed body 50 is formed in a spiral shape.
When the forced displacement amount in the Z direction of the molded body 50 by the guide 5 is large, the Z direction of the molded body 50 increases, and therefore the position of the end portion on the guide 5 side of the pressing roll 13 and the fulcrum roll 14 is determined in the Z direction. It is desirable to have

FIG. 3 shows an example of an air-core coil. The air-core coil is a coil that can be closely arranged by compressing the coil wire 2 in the spiral axis direction by alternately forming a linear portion and a curved portion having a different curvature in a spiral shape. In order to facilitate the description of the outer shape of the molded body and the movement of the central axis when the coil is molded, a case where only one round of the coil shown in FIG. 4 is molded will be described.
FIG. 5 shows the outer shape and the central axis of the molded body when the coil shown in FIG. 4 is formed in the order of the short side portion 30a → curved portion 30b → long side portion 30c → curved portion 30d. To move. 5A shows the short side 30a, FIG. 5B shows the curved portion 30b, FIG. 5C shows the long side 30c, and FIG. 5D shows the outline of the curved portion 30d. And the central axis respectively. The solid line indicates the machining start point, the broken line indicates the machining end point, and the two-dot chain line indicates the locus along which the central axis moves. From the appearance of the molded body and the movement of the central axis, it can be seen that the molded body moves about the axis of the fulcrum roller 14, which is the point of action when bending the coil wire. Further, in such movement of the formed body, as shown in FIG. 5 (e), a non-interference area 23 where the coil wire does not pass during bending is present along the axial direction of the fulcrum roll 14. In this example, the non-interference region 23 has a substantially rectangular shape having the same width as the outer diameter of the fulcrum roll 14 and the same length as the short side portion 33a. The non-interference area in the case of forming an air core coil having a circular air core shape is a circular shape having the diameter of the air core circular shape.

As shown in FIG. 6, the support portion 20 is composed of a rod-like support shaft 21 disposed in a non-interference area along the axial center direction of the fulcrum roll 14. The support shaft 21 is installed in the non-interference area at the start of machining, and supports the molded body 50 that is deformed and drawn out in the deformable portion 4 so as to circulate around the coil wire 2 in a spiral shape. By providing and supporting the support shaft 21 inside the molded body 50, it is possible to minimize the contact of the support shaft 21 with the surface of the coil wire 2 being damaged.

As shown in FIG. 6, the deformed portion 4 is deformed by being supported by the support portion 20 so as to be led out in the axial direction of the fulcrum roll 14 in a deformable portion 4 so as to be spirally circulated. The going coil wire 2 is fed out along the support shaft 21 in a stable state, and the influence of the weight of the formed body 50 on the coil wire 2 being processed can be reduced, and the coil wire can be made with high accuracy. 2 can be processed.
An air core coil having a high space factor can be obtained by cutting the molded body 50 thus molded with high accuracy in a predetermined length in the axial direction and compressing the molded body 50 in the axial direction so that the coil strands are brought into close contact with each other.

(Second Embodiment)
An air-core coil winding device according to a second embodiment of the present invention will be described with reference to FIG. The winding device according to the second embodiment controls the rotation of the support body according to the forming of the support section including the support body fixed to the support shaft and rotating around the support shaft, and the coil element wire. Except for having a control part, it has the same composition as a 1st embodiment.

As shown in FIG. 7, a support body 22 that is fixed to the support shaft 21 and rotates around the support shaft 21 is used as the support portion 20. The support shaft 21 is connected to a support shaft rotation motor 27 that can control the amount of rotation, which is a rotation means, and is set to rotate about the central axis. The support 22 rotates around the support shaft 21 in synchronization with the rotation of the support shaft 21 by screwing or the like. As shown in FIG. 16, the control unit 30 controls the support unit 20 in addition to the bending unit 1.
The control unit 30 controls the support shaft rotation motor 27 so that the timing and amount of rotation of the support 22 correspond to the processing of the coil wire 2. For example, as shown in FIG. 5, by rotating the support body 22 in accordance with the operation timing of the molded body 50 that is molded and fed out while rotating, the molded body 50 can be drawn out smoothly and processed. The influence which it has on the bending process of the inside coil wire 2 can be reduced.
The XY cross-sectional shape of the support body 22 is substantially rectangular and smaller than the innermost peripheral shape of the molded body 50 to be molded, and the long side of the XY cross-sectional shape of the support body 22 is the innermost peripheral surface of the molded body 50 to be molded. It is set longer than the short side. Therefore, the molded body 50 can be rotated by rotating the support body 22.

The end of the support 22 on the fulcrum roll 14 side is tapered, and the position thereof is set at a position where the number of turns of the molded body 50 is two or more away from the fulcrum roll 14. As a result, even if the support body 22 restrains the movement of the molded body 50 to move as shown in FIG. 7, the portion of the molded body 50 between the taper portion or the tip of the taper and the fulcrum roll 14 is buffered in a spring shape. Since it plays the role of a material, the coil wire 2 being processed can be bent with high accuracy.

(Third embodiment)
An air-core coil winding device according to a third embodiment of the present invention will be described with reference to FIGS. The configuration of the third embodiment is the same as that of the first embodiment except that the support shaft 21 of the support portion 20 is integrated with the shaft of the fulcrum roll 14 so that the axes are aligned.

As shown in FIGS. 8 and 9, the fulcrum roll 14 is configured by disposing a bearing 17 on the fulcrum roll shaft 16 and disposing a fulcrum roll cylindrical body 18 serving as a contact surface with the coil wire 2 on the bearing 17. Is done. A support shaft 21 is formed by extending the fulcrum roll shaft 16.
A separate shaft fastened to the fulcrum roll shaft 16 by a coupling or the like may be used as the support shaft 21, or a separate shaft may be installed separately from the fulcrum roll shaft 16.

As shown in FIG. 9, in the case where the support body 22 is used, the power of the support shaft rotating motor that rotates the support body 22 is transmitted from the fulcrum roll shaft 16 side, thereby supporting the unfolded direction in which the molded body 50 is fed out. The end of the body 22 can be an open end. As a result, the molded body 50 can be taken out from the open end and continuously conveyed to the next process such as an assembly process, so that the production efficiency can be increased.

A modification of the third embodiment is shown in FIG. FIG. 10A is a perspective view of a modification.
As shown in FIG. 10 (b), a hollow pipe is used for the fulcrum roll shaft 16 ', and a wire passed through it is passed through and supported by a hanging tool 24 provided in the direction of progress of the molded body 50. It may be used as the shaft 21. If the wire is installed so as not to contact the fulcrum roll shaft 16 ', the weight of the molded body 50 does not affect the fulcrum roll 14, and therefore the coil wire 2 can be bent with high accuracy.
Since the molded body 50 rotates according to the processing of the coil wire 2, the molded body 50 can extend in the Z direction beyond the hanger 24 as shown in FIG.

(Fourth embodiment)
An air-core coil winding device according to a fourth embodiment of the present invention will be described with reference to FIGS. 11 and 12. In the fourth embodiment, when the support shaft 21 is configured so as to be integrated with the fulcrum roll 14, the configuration other than that in which the radius of the support shaft 21 and the fulcrum roll 14 is limited according to the thickness of the coil wire 2. Is the same as in the third embodiment.

As shown in FIG. 11, when the molded body 50 is processed from the inside to the outside in the order of 31a → 31b →... 31h → 31i, when the coil element wire 31i comes on the fulcrum roll 14, the molded body 50 has been molded. 31 a becomes a part of the molded body 50 and rides on the support shaft 21.
By making the difference between the radius of the support shaft 21 and the radius of the fulcrum roll 14 equal to or greater than the thickness of the coil wire 2, the molded body 50 smoothly moves to the support shaft 21 as shown in FIG. It becomes possible to get on and the portion immediately after molding of the molded body 50 to be molded is held in a stable state, and the coil wire 2 can be bent with high accuracy.

(Fifth embodiment)
An air-core coil winding device according to a fifth embodiment of the present invention will be described with reference to FIGS. 13 and 14. In the present embodiment, the support shaft 21 of the second embodiment has two degrees of freedom so that the support shaft 21 follows the center locus of the molded body 50 in addition to the rotation of the support body 22. Other configurations are the same as those in the second embodiment.

FIG. 13 is a diagram in which the two-dot chain line that is the locus of the center of the coil shown in FIGS. 5A to 5D is continuously drawn. The support shaft 21 follows the locus of the two-dot chain line. To move.
As a mechanism for causing the support shaft 21 to follow, for example, as shown in FIG. 14A, the support shaft 21 is disposed on a base (not shown), and a rotation angle by a support shaft rotating motor 27 serving as a rotating means. The rotation of θ _1, the X-axis movement by the X-direction actuator 25 as a moving means, and the Y-axis movement by the Y-direction actuator 26 as a moving means are possible. Alternatively, as shown in FIG. 14 (b), the support shaft 21 is controlled by controlling the azimuth angle θ ₂ by the azimuth angle drive motor 28 as the rotation means and the elevation angle θ ₃ by the elevation angle drive motor 29 as the rotation means. It may be rotated to follow only the tip side.
By rotating and / or moving the support shaft 21 to follow the movement of the center of the molded body 50, inadvertent swinging of the molded body 50 moving along the support shaft 21 during processing is suppressed, and the coil is moved. The influence on the curvature of the strand 2 can be reduced.

The trajectory shown in FIG. 13 is drawn based on the center of the shape after the coil is formed. Therefore, in actual processing, as shown in FIG. 15, the contact location or contact between the coil wire 2 and the fulcrum roll 14 since the angle is different, the position of the rotation angle theta ₁ and the support shaft 21 or the rotation angle theta ₁ azimuth angle theta ₂ and elevation depression angle theta _3, it is desirable to appropriately adjust the actual machining.

As described above, the support shaft 21 is moved or the support body 22 is rotated so as to be supported by the support shaft 21 in accordance with the movement timing of the molded body 50 that is deformed and fed out of the coil wire 2. However, the influence of the molded body 50 moving while being exerted on the bending operation of the coil wire 2 being processed can be reduced.

Depending on the deviation between the machining curvature and the design curvature, for example, when the machining curvature of the coil wire 2 is lower than the design curvature, the operation of changing the rotation angle θ ₁ of the support shaft 21 precedes the timing of the bending operation. If the machining curvature is higher than the design curvature, the support shaft rotates as a means for finely adjusting the curvature of the coil wire 2 such as delaying the start of the operation of changing the rotation angle θ ₁ from the timing of the bending operation. A motor 27 can also be used.

  DESCRIPTION OF SYMBOLS 1 ... Processing part, 2 ... Coil strand, 3 ... Conveyance part, 4 ... Deformation part, 5 ... Guide, 12 ... Drive roll and driven roll, 13 ... Presser Roll, 14 ... fulcrum roll, 15 ... push roll, 16 ... fulcrum roll shaft, 17 ... bearing, 18 ... fulcrum roll cylindrical body, 20 ... support part, 21 ... Support shaft, 22 ... support, 23 ... non-interference area, 24 ... hanging tool, 25 ... X direction actuator, 26 ... Y direction actuator, 27 ... support shaft rotation motor, 28 ... Azimuth angle drive motor, 29 ... Elevation angle drive motor, 30 ... Control unit, 50 ... Molded body, 100 ... Winding device

Claims (11)

While the coil wire is being conveyed, the coil element is deformed so as to circulate in a spiral shape with a desired curvature by a pressing operation that uses a pressing roll in a direction crossing the conveying direction, and a molded body is formed. In the winding method of the air core coil in which the body is compressed in the axial direction and the coil wire is brought into close contact,
A winding method of an air-core coil that supports the molded body that is drawn out while being rotated and molded so as to be led out in a predetermined direction.   The winding method of the air-core coil according to claim 1, wherein the molded body is supported by a support shaft provided inside the molded body.   The air core coil winding method according to claim 2, wherein the support shaft is rotated and / or moved in accordance with the movement of the molded body. A conveying part that conveys the coil wire along a predetermined conveying path, a deforming part that presses the pressing roll against the coil element wire that is conveyed and deforms it into a desired curvature, and is spirally formed and fed out. A support unit that supports the molded body so as to be led out in a predetermined direction, and a control unit that controls the conveying operation of the coil wire and the pressing operation of the pushing roll to form the coil wire so as to circulate spirally. A winding device for air-core coils.   The air core coil winding apparatus according to claim 4, wherein the support portion includes a support shaft disposed in the molded body.   The winding device for an air-core coil according to claim 4 or 5, wherein the support shaft has an open end in a developing direction in which the molded body is drawn out.   The winding device for an air-core coil according to claim 5 or 6, wherein the support shaft is set along an axis of a fulcrum roll serving as an action point of the pushing operation.   The air core coil winding device according to claim 7, wherein the support shaft is integrated with the fulcrum roll.   The winding device for an air-core coil according to any one of claims 5 to 8, wherein the support portion includes a rotating means for rotating the support shaft and / or a moving means for moving the support shaft.   The winding device for an air-core coil according to claim 7, wherein the support shaft is made of a wire. The winding device for an air-core coil according to claim 10, wherein the wire is provided so as to pass through a hollow shaft of the fulcrum roll.