JP2018098407A - Winding, manufacturing apparatus thereof and manufacturing method of winding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a winding and a manufacturing apparatus thereof capable of achieving a desired space factor, which is superior in manufacturing efficiency and quality, and manufacturing method of winding.SOLUTION: A manufacturing apparatus of winding in an embodiment has control means that controls first bending means to carry out a series of bending processing in order based on the feed amount of a single wire by a feeder, including: processing the wire into a shape to form a first winding part for winding while overlapping with the outer periphery; and processing the wire into a shape to form a second winding part for winding the wire overlapping with the inner periphery; and a second bending means to carry out a series of bending processing on a part, which is equivalent to a part between the first winding part and a second winding part, into a shape to displace to a lamination direction.SELECTED DRAWING: Figure 1

Description

  Embodiments described herein relate generally to a winding, a manufacturing apparatus thereof, and a manufacturing method of the winding.

  Conventionally, various winding methods have been proposed for a winding formed by winding a wire having an insulating coating on a conductor. For example, the basic coil is formed by combining two layers of one layer, each of which is wound on the inner circumference side of an oval shape and overwound on the outer circumference side, and connecting the respective winding start ends. There is one in which a plurality of windings are formed to form a long cylindrical winding as a whole (see, for example, Patent Document 1).

  However, in such a winding, winding bulge occurs due to the spring back due to the lap winding of the wire, and the space factor is reduced. In addition, for the two layers, many man-hours are required for soldering work and insulation processing work for connecting and covering the respective end portions, and further, winding resistance at the connecting portion of the end portions is increased. There is a problem of poor quality.

JP 2004-72824 A JP 2014-93847 A

  Accordingly, an object of the present invention is to provide a winding, a manufacturing apparatus therefor, and a winding manufacturing method that can obtain a desired space factor and are excellent in manufacturing efficiency and quality.

  The winding manufacturing apparatus according to the present embodiment is a winding manufacturing apparatus in which a wire having an insulating coating applied to a conductor is wound, the feeding unit feeding the wire as a supply source of the wire, and the feeding A feeder provided between the means and a holding portion capable of placing or holding the wire being wound as the winding, and a feeder for feeding the wire drawn by the feeding means to the holding portion side, and the feeder For the one wire to be sent, the first winding part wound around the outer periphery of the wire from the inner peripheral side to the outer peripheral side, and the inner periphery of the wire from the outer peripheral side to the inner peripheral side In order to form a plurality of stages of the windings alternately stacked in the axial direction with the second winding part wound in an overlapping manner, before the winding in the holding part, the first winding part and the The second winding part is bent into a shape that is wound on the outer circumference or inner circumference of the wire. Based on the bending means, the second bending means for bending into the shape shifted in the laminating direction, and the feed amount of the one wire by the feeder, the wire for forming the first winding portion The first processing is performed so as to sequentially perform bending to a shape that is wound on the outer periphery and bending to a shape to be wound on the inner periphery of the wire for forming the second winding portion. The bending means is controlled, and the second bending means is controlled so as to bend into a shape shifted in the stacking direction at a corresponding portion between the first winding portion and the second winding portion. Control means for controlling the first bending means and the second bending means by the control means, so that the outer circumference or the inner circumference of the wire according to the winding amount of the wire in the holding portion is controlled. Bending scissors with a shape that winds around the circumference and the way to stack And characterized in that a previously granted constitutes a residual bend of the shape shifting to.

Conceptual diagram for explaining the overall configuration of the winding manufacturing apparatus Block diagram showing electrical configuration The top view which shows a 1st bending apparatus typically Side view schematically showing the second bending apparatus The perspective view for demonstrating the wire wound on a mounting table A direction arrow view of FIG. Perspective view of a winding that forms a substantially rectangular tube Typical sectional drawing which follows the VIII-VIII line of FIG. FIG. 3 equivalent view showing another form of the first bending apparatus Schematic view of the outer peripheral winding forming a quadrangle as seen from the center axis direction It is the schematic diagram which looked at the outer periphery shape coil | winding which makes an octagon from the center axis direction, (a) And (b) is a figure showing the coil | winding structure which made the space factor of an oblique angle part mutually differ (A) And (b) is a figure showing the winding structure provided with the duct for cooling of various forms.

Hereinafter, an embodiment applied to a winding of a transformer as a stationary induction device will be described with reference to the drawings.
As shown in FIG. 7, the winding 100 of the transformer to be manufactured is formed by winding a rectangular wire 3 having a conductor coated with an insulating coating, and has a shape of a square cylinder having rounded corners R1 to R4 as a whole. Make. The winding 100 is formed by alternately laminating a plurality of stages of first winding portions 1 and second winding portions 2 described later in the axial direction of the center O (see FIG. 1) of the rectangular tube. The rectangular wire 3 is formed so that no gap is generated between the respective layers.

  The rectangular wire 3 is, for example, a rectangular enameled wire having a rectangular cross-sectional shape in which a rectangular conductor wire is enamel-coated. In this embodiment, as shown in FIGS. 3 to 5, the plate thickness of the flat wire 3 is represented by a symbol “t”, and the plate width of the flat wire 3 is represented by a symbol “w”. Note that the wire 3 is not limited to a flat enameled wire, and the outer periphery of the conductor wire may be covered with an insulating tape, or other cross-sectional shape, that is, a conductor wire having a polygonal shape, an oval shape, an elliptical shape, or the like may be used. .

  In the manufacturing apparatus for the winding 100 shown in FIG. 1, reference numeral 11 denotes a drum around which the flat wire 3 is wound, reference numeral 12 denotes a supply device as a supply source for feeding the wire 3, and reference numeral 13 denotes a winding rod of the wire 3. Reference numeral 14 denotes a feeder that intermittently feeds the wire 3, and reference numerals 15 and 16 denote bending devices that make a pair as a first bending means and a second bending means for the wire 3.

  That is, the drum 11 has a single rectangular wire 3 wound around the shaft portion 11a in advance. Although not shown in detail, the supply device 12 rotatably supports the drum 11 and feeds out the rectangular wire 3 by rotating in the direction opposite to the winding direction of the rectangular wire 3 wound around the drum 11. It is configured as. Moreover, the supply apparatus 12 is provided with a guide mechanism (not shown) for feeding out the rectangular wire 3 from a predetermined position, for example. This guide mechanism supplies the drum 11 without shifting from a predetermined position by guiding the drum 11 in the axial direction of the shaft portion 11a, that is, in the vertical direction in the plane of FIG. 1, or by guiding the flat wire 3 itself.

  The leveler 13 includes a plurality of work rolls 13a, 13b, and 13c that are provided on the side in the feeding direction from the supply device 12 and arranged in a staggered manner with the flat wire 3 interposed therebetween as shown in FIG. The curl in the drawn flat wire 3 is corrected by passing between the work roll groups 13a to 13c.

  The feeder 14 performs an intermittent feed operation that repeats feeding and stopping, in addition to a continuous feed operation in which the flat wire 3 from which the curl has been removed by the leveler 13 is continuously fed toward the bending devices 15 and 16. Specifically, the feeder 14 includes, for example, a pair of rolls (only one roll 14a is shown in FIG. 1) for sandwiching the flat wire 3 and a motor 14b (see FIG. 2) for driving the pair of rolls 14a. . The motor 14b is composed of, for example, a servomotor, and an encoder 14c (see FIG. 2) for detecting the rotation amount is attached and feedback-controlled. The feed amount of the rectangular wire 3 by the feeder 14 is calculated by the control device 30 described later based on the detection signal of the encoder 14c and the like. Further, the roll 14a of the feeder 14 is positioned at the front side in the conveying direction with respect to the bending devices 15 and 16, that is, in the vicinity of the entry side of the bending devices 15 and 16, so that no bending error is generated between the bending devices 15 and 16. Closely arranged. Although the detailed description and illustration are omitted, the feeder 14 is made of a material or surface shape having a large frictional resistance between the roll 14a and the flat wire 3 as a material of the surface of the roll 14a, and a predetermined pressurizing force. By setting (holding force), the conveyance accuracy is improved.

  The first bending device 15 and the second bending device 16 are disposed between the feeder 14 and the mounting table 17 so as to be close to each other, and before the winding on the mounting table 17 with respect to the rectangular wire 3. Bending is performed. Here, FIG. 3 schematically shows a plan view of the first bending device 15, and FIG. 4 schematically shows a side view of the second bending device 16.

  The 1st bending apparatus 15 of FIG. 3 is provided with the three rolls 151-153 as a pressing member arrange | positioned facing the horizontal direction, for example. Each of the rolls 151, 152, and 153 is rotatable about the vertical shafts 15 a, 15 b, and 15 c, respectively, and moves forward and backward in the direction of the arrow in the figure to hold the flat wire 3, thereby plasticizing the flat wire 3. Gives bending bends to deform. More specifically, the rectangular wire 3 is pressed in the plate thickness direction by causing the presser roll 151 on the front side in the transport direction and the presser roll 153 on the rear side to move forward and backward relative to the central roll 152. Thereby, the bending process at an angle of 90 degrees with respect to the flat wire 3 is performed, and a rounded corner is formed. Further, the control device 30 to be described later changes the position when pressing the flat wire 3 of each of the rolls 151 to 153 in conjunction with the feed amount, so that a curved wrinkle having a predetermined curvature radius is formed on the flat wire 3. The

  The 1st bending apparatus 15 is changed not only according to the said rolls 151-153 but according to the coil | winding shape etc. to manufacture. For example, when the winding 101 of FIG. 10 is manufactured, the first bending device 15 bends the bending die 152 ′ of FIG. 9 and the rectangular wire 3 along the bending die 152 ′ so as to be plastically deformed to a predetermined angle α. A presser mechanism 151 ′ is used. For example, a 90-degree bent fold is formed on the flat wire 3 by the relative advance and retreat operation between the bending die 152 ′ and the pressing mechanism 151 ′. In addition, as will be described in detail later, when manufacturing the windings 102 to 105 of FIGS. 11 and 12, a bending die having a bending angle α and a pressing mechanism (both not shown) are used to form a 135-degree bending fold. It is done.

  In this way, in the first bending device 15, the curved crease or the bent crease is formed in the direction in which the rectangular wire 3 circulates, so that the shape is wound around the outer periphery of the wire 3 from the inner peripheral side to the outer peripheral side. And bending into a shape that is wound around the inner periphery of the wire 3 from the outer peripheral side to the inner peripheral side. In the present embodiment, the portion of the rectangular wire 3 that is wound around and wound from the inner peripheral side to the outer peripheral side is referred to as a first winding portion 1 and is wound from the outer peripheral side to the inner peripheral side. This part is referred to as a second winding part 2.

  The 2nd bending apparatus 16 of FIG. 4 is equipped with the two rolls 161 and 162 as a press member pressed in the direction orthogonal to the press direction of the said rolls 151-153. Each of the rolls 161 and 162 can roll around the horizontal axes 16a and 16b, respectively, and moves forward and backward in the directions of the up and down arrows in FIG. Specifically, one roll 161 and the other roll 162 perform a vertical movement operation at a position shifted in the transport direction, press the flat wire 3 in the plate width direction, and a step corresponding to the plate width w. (Refer to FIG. 6) Bend to the shape to attach. As a result, as shown in FIG. 5, the winding portions 1, 3 b are respectively connected to the end portions 3 a, 3 b on the outer peripheral side and the inner peripheral side between the first winding portion 1 and the second winding portion 2. A stepped shape or a crank-shaped bending rod shifted in the stacking direction is applied.

  Here, the second bending device 16 applies bending wrinkles so that a gap in the stacking direction does not occur between the winding portions 1 and 2 at the outer peripheral side end portion 3a and the inner peripheral side end portion 3b ( As shown in FIGS. 6 and 8, the end portions 3 a and 3 b of the end portion 3 a and 3 b are folded back to the inner peripheral side or the outer peripheral side with high accuracy as a folded portion. On the other hand, the 1st bending apparatus 15 can also form the above-mentioned curved wrinkle or bending wrinkle so that the gap | interval of a plate | board thickness direction does not arise between the flat wire 3. Therefore, in the mounting table 17, automatic winding is performed so that the supplied rectangular wire 3 is dropped as it is.

  The mounting table 17 is a holding unit capable of mounting or holding the rectangular wire 3 being wound as a winding. As shown in FIGS. 1 and 5, the mounting table 17 has, for example, a horizontal flat surface and a shaft portion 17 a at the center O thereof. The shaft portion 17a of the mounting table 17 is rotationally driven by a motor 17b (see FIG. 2) as driving means.

  On the flat surface of the mounting table 17, round bar-shaped receiving portions 18 a to 18 c that receive the corner portions of the winding portions 1 and 2 on the inner peripheral side are provided so as to protrude upward. For convenience of explanation, the three receiving portions 18a to 18c are shown in FIG. 5, but can be constituted by four receiving portions that receive the respective corner portions of the winding portions 1 and 2, and each of the receiving portions 18a to 18c protrudes upward. The length is set according to the height of the winding parts 1 and 2 to be laminated. In the mounting table 17, in addition to the receiving portions 18a to 18c for the winding 100 shown in FIG. 5, receiving portions (illustrated) corresponding to the shapes and sizes of the various windings 101 and 102 to 105 shown in FIGS. Abbreviation) is used.

  The mounting table 17 is provided with a presser roll 19 that presses the winding portions 1 and 2 from above. The presser roll 19 is rotatable about the horizontal shaft 19a, and can be moved up and down according to the height of the winding portions 1 and 2 wound at the position where the flat wire 3 is dropped. Yes. Thus, the mounting table 17 rotates the winding portions 1 and 2 being wound by the presser roll 19 while rotating around the shaft portion 17a together with the flat wire 3 together with the receiving portions 18a to 18c as the motor 17b is driven. The wire 3 is wound while pressing the layers so that they are aligned from the upper end side.

  Here, FIGS. 10 to 12 show the various windings 101 and 102 to 105 as the first winding part 1 as the uppermost layer as schematic views as seen from the axial direction. Among these, the winding 101 in FIG. 10 is bent by the bending mold 152 ′ having a bending angle α and a holding mechanism 151 ′ in the first bending device 15 to form a 90 ° bending rod, and the outer peripheral shape of the rectangular wire 3 and The inner peripheral shape is a quadrangular square cylinder.

  The windings 102 to 105 shown in FIGS. 11 and 12 are bent in the first bending device 15 by a bending die having a bending angle α and a holding mechanism (both not shown) that form a bending fold having an obtuse angle of 135 degrees, for example. The outer peripheral shape and the inner peripheral shape of the flat wire 3 are both octagonal octagonal cylinders. In this case, portions of the windings 102 to 105 that are inclined at 135 degrees at the corners of the four sides S1 to S4 are beveled portions.

  Specifically, the winding 102 in FIG. 11A has a slight thickness in the plate thickness direction between the rectangular wires 3 at the oblique portions C1 to C4, as is clear from comparison with the other windings 103 to 105. By performing a bending process that provides play in which gaps are generated, the space factor at the beveled portions C1 to C4 of the flat wire 3 is made lower than the space factor of the four side portions S1 to S4. As a result, the winding 102 is not easily caught at the bent portion when the flat wire 3 is dropped onto the mounting table 17 and enables smooth winding. On the other hand, the main wire S1 to S4 allows the flat wire 3 to be wound. It is configured to increase the space factor as much as possible by close contact with each other. In FIG. 11A, the gap between the rectangular wires 3 in the oblique portions C1 to C4 of the winding 102 is exaggerated.

  For the convenience of explanation, the winding 103 in FIG. 11B represents a small gap between the flat wire 3 in the beveled portions C1 ′ to C4 ′, and the remaining configuration is the same as that of the winding 102. In addition, the beveled portions C1 ′ to C4 ′ of the windings 104 and 105 in FIGS. 12A and 12B also represent small gaps between the flat wire 3 but the beveled portions C1 to C4 of the winding 102. You may make it perform the bending process made into the same space factor.

  The winding 104 in FIG. 12A includes a cooling duct 21 including a duct piece 21a made of an insulating material and a mount 21b as an attachment member. A plurality of duct pieces 21a are fixedly arranged side by side at a predetermined interval with respect to the mount 21b, and are integrated. In the middle of winding the rectangular wire 3 on the mounting table 17 side, the duct 21 is placed at a duct insertion position I set in advance for each winding 104 by fixing means such as an adhesive or an adhesive on the mount 21b. Fixed. As illustrated in FIG. 12A, in the case of the winding 104, an arrangement space for the duct 21 is formed with a substantially intermediate position in the plate thickness direction in the main side portions S <b> 1 to S <b> 4 as the duct insertion position I. The

  The space for the duct 21 is formed so that the flat wire 3 and the duct 21 are in close contact with each other according to the shape and size of the duct 21, so that the heat radiation effect of the flat wire 3 is enhanced. Further, portions C1 ′ to C4 ′ in which the duct 21 is not provided at the duct insertion position I in the rotating rectangular wire 3 are bent by the first bending device 15 so that no gap is generated. For this reason, even if an arrangement space for the duct 21 is provided, the space (particularly the corner portion) can be prevented from becoming a weak point, and a short-circuit mechanical force, that is, a short-circuit current flows as a whole of the winding 104. It is excellent in mechanical force that acts sometimes.

  A duct 22 of the winding 105 shown in FIG. 12B is a corrugated duct formed in a corrugated shape, for example. In the case of the winding 105, an installation space for the duct 22 is formed at the insertion position I of the duct 22 over the entire circumference of the rotating rectangular wire 3. Since the arrangement space for the duct 22 is also formed according to the shape and size of the duct 22, as described above, the heat dissipation effect is high and the mechanical characteristics are excellent.

  Although illustration is omitted, a space for arranging a cooling duct may be provided between the first winding portion 1 and the second winding portion 2 for each of the windings 100 to 105 described above. In other words, the second bending device 16 provides a stepped-shaped bending rod that allows for the thickness of the duct between the winding portions 1 and 2 as a duct insertion position, so that the arranged duct and the rectangular wire 3 are in close contact with each other. Space can be formed. As described above, the windings 100 to 105 may be provided with a duct extending in the horizontal direction between the winding portions 1 and 2 and / or a duct extending in the axial direction as the vertical direction, as necessary. Moreover, you may change suitably the shape and arrangement | positioning form of a duct.

  FIG. 2 is a block diagram illustrating a configuration of a control system according to the manufacturing of the windings 100 to 105. The control device 30 is configured mainly with a microcomputer, and is a control means having an internal storage unit 31 including a CPU, ROM, and RAM. The control device 30 is connected to an operation input unit 32 for inputting various operation signals from the encoder 14c and a key switch (none of which is shown) of the operation panel. The control device 30 is connected to various detection sensors 33 including a detection sensor that is provided in the vicinity of the mounting table 17 so as to detect the winding state of the flat wire 3. For example, as the detection sensor 33, wire rod detection means for detecting the outer peripheral side end portion 3a and the inner peripheral side end portion 3b of the flat wire 3 on the mounting table 17, and the thickness t and the width w of the flat wire 3 are measured. You may make it provide the dimension detection means to detect. Further, the control device 30 is connected with drive circuits 34, 35, 36, and 37 for driving the motor 14b for the feeder 14, the actuators for the bending devices 15 and 16, and the motor 17b for the placement table 17, respectively. .

  The storage unit 31 stores winding information related to the windings 100 to 105, duct information related to the ducts 21 and 22, and the like in advance. The winding information includes the dimensions of each side in the windings 100 to 105, the thickness t and the width w of the wire 3, the number of windings 1 and 2 and the number of layers, the bending angle, the radius of curvature, and the like. Contains information and is defined for each type of winding. The duct information includes positional information of the arrangement space in each of the windings 100 to 105 in addition to the dimensions of the ducts 21 and 22, and is defined in association with the winding information. These winding information and duct information may be set based on the operation of the operation input unit 32 by the operator as described in the following explanation of the operation, or the thickness t and the width w of the plate from the detection sensor 33. May be obtained. Then, the control device 30 controls the motors 14b and 17b, the actuators of the bending devices 15 and 16 and the like based on the above information, and automatically executes the winding operation of the flat wire 3 on the mounting table 17. It is like that.

Next, the operation of the above configuration will be described.
The drum 11 is set in the supply device 12 in advance, the winding end side of the flat wire 3 is fed out from the drum 11, and sent to the mounting table 17 side through the leveler 13, the feeder 14, and the bending devices 15 and 16. Shall be set as follows. In addition, the winding end end portion on the drum 11 is an end portion at which the winding is started on the mounting table 17. For convenience of explanation, this winding start end portion is represented by a position of “3s” in FIG.

  The operator operates the operation input unit 32 to select the type of the windings 100 to 105 to be manufactured, or sets winding information and duct information. When the start switch of the operation input unit 32 is operated, the rectangular wire 3 is fed out from the drum 11 and an intermittent feeding operation by the feeder 14 is performed. In this case, the flat wire 3 fed out from the drum 11 is passed between the upper and lower work roll groups 13a to 13c by the leveler 13, so that the internal distortion is removed and the curl is corrected and becomes flat. Further, in this case, the control device 30 calculates the feed amount of the flat wire 3 based on the detection signal of the encoder 14c for the motor 14b for the feeder 14, and based on the winding information, the angle of each winding part 1 and 2 is calculated. And the stepped-shaped bending rods corresponding to the end portions 3a and 3b on the outer peripheral side and the inner peripheral side thereof are intermittently driven.

The feed amount in this feed process will be described in detail assuming a specific example. When manufacturing the winding 100, the dimension M1 of the short side parts S1 and S3 among the four side parts S1 to S4 shown in FIG. 7 corresponds to the receiving parts 18a and 18b, and the dimension M2 of the long side parts S2 and S4. Is previously defined as winding information corresponding to the receiving portions 18b and 18c. Therefore, the control unit 30 based on the winding information M1, the driving feed amount L ₁ from the winding start end portion 3s has the motor 14b for feeder 14 so that the length corresponding to the receiving portion 18a, 18b Output a signal. Thereafter, the control device 30 causes the rolls 151 to 153 of the first bending device 15 to advance and retreat in the direction of the arrow in FIG. 3 with the motor 14b stopped (first bending step). As a result, the rectangular wire 3 is formed with a 90-degree bent portion having a roundness at a position P1 that is spaced apart from the winding start end portion 3s by M1. Of course, the bent portion can be formed while the motor 14b is driven as a continuous feed by the feeder 14 in accordance with the radius of curvature.

Further, the control device 30 drives the motor 14b to move the rolls 151 to 153 forward and backward so that the _second feed amount L2 has the same M2 as the long side dimension corresponding to the receiving portions 18b and 18c. As a result, a 90 ° bent portion is formed in the flat wire 3 at a position P2 that is spaced apart from the bent portion P1 by M2. Thus, the mount table 17, the winding start of the rectangular wire 3, the feeding amount _L 1 by the feeder _14, L 2, _{L 3} is a pitch M1 of rectangular wire 3 with respect to receiving 18a~18c meet at the inner peripheral side, The bending portions P1, P2, and P3 that are plastically deformed are formed by driving the motor 14b and bending the motor 14b.

For example, the motor 17b for the mounting table 17 is driven to be synchronized (tuned) with the motor 14b for the feeder 14. For this reason, in the mounting table 17, the flat wire 3 is wound so that the bent portion of the wire 3 is aligned with the receiving portions 18 a to 18 c as it is dropped by the presser roll 19. The control device 30, the feed amount L ₄ after bent portion P3 is formed, based on the winding information, folding at a position obtained by adding the amount of plate thickness of the rectangular wire 3 (L 4 ₌ M2 + thickness t) The motor 14b is driven so that the curved portion is formed.

Thereafter, the control device 30 feeds the flat wire 3 by the feeders L ₅ , L ₆ ,..., L so as to have a shape overlapping the outer periphery of the flat wire 3 on the mounting table 17. _{N 1} , L _{N + 1} ,... (See FIG. 1) are set, and the forward / backward movement of the rolls 151 to 153 in the first bending device 15 is controlled according to the setting. That is, the control unit 30, based on the above-mentioned dimensions M1, M2 and rectangular wire 3 winding information sheet thickness or the like, already feeding amount L _{5 ~} operations in anticipation of plate thickness of the flat wire 3 wound At the same time, the radius of curvature corresponding to the winding amount is calculated or corrected. Then, by bending by the feed quantity L _{5 ~} order soon 1 bending apparatus 15 according to is carried out, the rectangular wire 3 is bent section in accordance with the winding amount on the mount table 17, the mounting It is given before winding on the table 17. As a result, the first winding part 1 wound in a multiple manner on the mounting table 17 is formed of the rectangular wire 3 from the inner peripheral side to the outer peripheral side at the four side parts S1 to S4 and the corner parts R1 to R4. The gap can be eliminated, the dimensional accuracy is high, and the short-circuit mechanical force is excellent.

  Further, when the feed amount of the rectangular wire 3 by the feeder 14 reaches a position corresponding to the outer peripheral side end 3a of the first winding portion 1, the control device 30 moves the rolls 161 and 162 of the second bending device 16 to the position shown in FIG. The plate is moved back and forth in the plate width direction (second bending step). Accordingly, as shown in FIG. 6, the flat wire 3 is formed with bending folds (folded portions) shifted upward in the stacking direction by the plate width w at the outer peripheral side end portion 3 a of the first winding portion 1. The

Next, the control device 30 determines the inner portion of the wire 3 from the outer peripheral end 3a to the inner peripheral end 3b of the second winding 2 stacked on the first winding 1 on the mounting table 17. The advancing and retracting operations of the rolls 161 and 162 are controlled so as to overlap the circumference. In this case, with respect to the second winding part 2, the feed amounts (..., L _{N + 1} , L _{N in the} reverse order of the feed amounts of the first winding part 1 (..., L _N , L _{N + 1} ,...). ,...) Is set, and the radius of curvature corresponding to the amount of winding is set, so that the dimensional accuracy can be increased in the same manner as the first winding portion 1. As a result, in the mounting table 17, the second winding portion 2 concentrically overlapping the first winding portion 1 can be wound.

  Further, when the feed amount of the flat wire 3 by the feeder 14 reaches a position corresponding to the inner peripheral side end portion 3b of the second winding portion 2, the control device 30 advances and retracts the rolls 161 and 162 of the second bending device 16. Make it work. As a result, a bending rod (folded portion) that is shifted to the upper side in the stacking direction is formed on the inner peripheral side end portion 3b of the second winding portion 2 in the flat wire 3 (see FIG. 5). .

  In this manner, the bending process for the first winding part 1 and the bending process for the second winding part 2 are repeatedly performed on one flat wire 3 with the bending process of the folded part interposed therebetween. A winding 100 in which a plurality of winding portions 1 and 2 are connected in the axial direction on the mounting table 17 can be manufactured.

  In the above example, in the mounting table 17, the first winding part 1, the second winding part 2, the first winding part 1,... Of course, the part 1 and the second winding part 2 may be laminated in this order. Here, FIG. 8 is a schematic cross-sectional view along the line VIII-VIII in FIG. 7, and reference numerals “1, 2, 3,...” In FIG. This represents the winding order. That is, the lowermost block in FIG. 8 corresponds to the second winding portion 2 that is wound first on the mounting table 17. As shown by the arrows in FIG. 8, the flat wire 3 has a winding direction from the outer peripheral side (right side in the same figure) to the inner peripheral side (left side in the same figure) and from the inner peripheral side to the outer peripheral side. A predetermined number of turns are wound while being reversed for each layer through 3a and 3b.

  When manufacturing the windings 102 and 103 shown in FIGS. 11A and 11B, a 135-degree bending fold is formed in the first bending device 15 as described above. Among them, the feeder 102 is provided with a winding so that the space factor at the oblique portions C1 to C4 of the rectangular wire 3 is lower than the space factor of the main sides S1 to S4. 14, the feed amount of the rectangular wire 3 is set.

Further, the manufacturing method of the windings 104 and 105 having the cooling ducts 21 and 22 will be described by taking the winding 104 of FIG.
Based on the winding information and duct information, and the integrated value of the feed amount, the control device 30 attaches the attached portions Ia, Ib, Ic, Id at the duct insertion position I in the rectangular wire 3 (FIG. 12A). The feeder 14 is temporarily stopped before each of (see) is overwrapped. In this case, each duct 21 prepared in advance is manually attached and fixed to each of the attached portions Ia to Id (may be automated). At this time, the attached portions Ia to Id in the flat wire 3 are located closer to the mounting table 17 than the feeder 14 and the bending devices 15 and 16, and can be identified by using a 135 degree bent portion as an index. The duct 21 can be accurately attached.

  In this case, the feed amount of the rectangular wire 3 is set by the control device 30 so that the space for the duct 21 is formed in the four sides S1 to S4. Thereby, since the said bending part is formed so that the flat wire 3 and the duct 21 may closely_contact | adhere according to the shape dimension of the duct 21, the heat dissipation effect of the flat wire 3 is improved. As a result, as shown in FIG. 12A, the winding 104 wound in multiple directions can bring the flat wire 3 into close contact in the plate thickness direction except for the arrangement space for the duct 21. And high short circuit mechanical force.

  Furthermore, even the winding 104 having the duct 21 is obtained from the winding information including the plate thickness of the rectangular wire 3 and the duct information, and the amount of winding on the mounting table 17 (the integrated value of the feeding amount). Since the bending process is performed after the feed amount of the feeder 14 is calculated by the control device 30 based on the number of windings), the winding 104 can be dimensioned with high accuracy, and at the mounting table 17 Interference between the duct 21 and the flat wire 3 during winding of the wire can be suppressed, and the flat wire 3 can be wound smoothly. Note that the dimension of the duct 21 in the direction perpendicular to the paper surface of FIG. 12 is set to the same dimension as the plate width w of the flat wire 3, and the duct 21 does not interfere with the winding of the flat wire 3.

  As described above, the apparatus for manufacturing the windings 100 to 105 of the present embodiment is based on the feed amount of one flat wire 3 by the feeder 14, and the outer periphery of the wire 3 for forming the first winding portion 1. The first bending is performed so as to sequentially perform the bending process into a shape that is wound over and wound on the inner periphery of the wire 3 for forming the second winding portion 2. The second bending means is configured to control the device 15 and perform bending to a shape shifted in the direction of stacking at the corresponding folded portions 3a and 3b between the first winding portion 1 and the second winding portion 2. 16, and the first bending device 15 and the second bending means 16 are controlled by the control device 30, so that the amount corresponding to the winding amount of the flat wire 3 on the mounting table 17 is controlled. Bending ridges with a shape that wraps around the outer periphery or inner periphery of the wire 3 and the folded portion a, was previously granted constitutes a residual bend of the shape shifting in the direction of stacking in 3b.

  According to this structure, the bending rod having a winding shape corresponding to the winding amount of the flat wire 3 on the mounting table 17 with respect to the flat wire 3 and a shape shifted in the direction of stacking at the folded portions 3a and 3b. The bending rod can be provided before winding on the mounting table 17. For this reason, about the windings 100-105 after winding, while being able to eliminate reliably the swelling by a springback, a dimensional accuracy can be improved and the expected space factor can be obtained. The windings 100 to 105 can be formed of a single rectangular wire 3 and do not require soldering work or insulation processing work between the winding parts, and have excellent manufacturing efficiency and quality. It can be.

  The first bending device 15 is a bending rod in which the inner peripheral shape or outer peripheral shape of the wire 3 forms a polygonal shape with respect to the flat wire 3, and the wire is wound around the outer periphery or inner periphery of the wire 3. Bending folds corresponding to the corners are formed. According to this, even if it is the windings 101-105 which make a polygon, a corner | angular part can be reliably bent beforehand to a plastic region by the 1st bending apparatus 15. FIG. Therefore, the gap between the wire rods 3 at the corners can be surely eliminated, and high-precision dimensions can be obtained.

  The first bending device 15 forms a bending rod for bending the flat wire 3 at 135 degrees. As described above, the inner or outer peripheral shape of the flat wire 3 is changed into four side portions S1 to S4 and the beveled portions C1 to C4 and C1 ′ to C4 at the four corners by bending creases of 135 degrees or substantially 135 degrees. The windings 102 to 105 that form an octagon with 'can be formed.

  Among these, with respect to the winding 102, the first bending device 15 has a slight play in which the space factor at the beveled portions C1 to C4 of the flat wire 3 is lower than the space factor of the four side portions S1 to S4. A folding fold is formed to give Thereby, when the flat wire 3 is dropped onto the mounting table 17, it is difficult to be caught at the bent portion and enables smooth winding, while the flat wires 3 are brought into close contact with each other at the main sides S <b> 1 to S <b> 4. Thus, the space factor can be increased as much as possible.

  As described above, since the control device 30 calculates or corrects the radius of curvature according to the thickness of the flat wire 3 or the like, the control device 30 provides a curved wrinkle in which the inner peripheral shape or the outer peripheral shape of the wire 3 forms an annular shape. By controlling the first bending device 15 as described above, it is possible to manufacture a winding (not shown) that has a cylindrical shape as a whole.

  Thus, the first bending device 15 is a curved rod having a polygonal or annular shape in which the inner peripheral shape or the outer peripheral shape of the wire 3 is rounded at the corners with respect to the flat wire 3. A curved ridge corresponding to the curvature of the wire 3 wound around the outer periphery or the inner periphery of the wire 3 is formed. According to this, it is possible to give the flat wire 3 a curled crease according to the amount of winding on the mounting table 17 before winding on the mounting table 17, and the corners are rounded. With respect to the rectangular cylindrical winding 100 and the cylindrical winding, it is possible to reliably eliminate the swollenness due to the springback and to improve the dimensional accuracy.

  The feeder 14 and the bending apparatuses 15 and 16 are arranged close to each other in the manufacturing apparatus. According to this, the shaping | molding error resulting from the bending | flexion etc. of the flat wire 3 between the feeder 14 and the bending apparatuses 15 and 16 can be eliminated as much as possible, and a dimensional accuracy can be improved further.

  A leveler 13 is provided between the feeding means and the feeder 14 and corrects curling of the flat wire 3 fed from the feeding means. According to this, the internal strain is removed by the leveler 13, the curl can be corrected and flattened, and the highly accurate windings 100 to 105 can be stably formed.

  The wire rod 3 described above is not limited to the flat wire rod 3, and the holding portion that can hold the wire rod 3 being wound is not limited to the mounting table 17. Although not specifically shown, for example, instead of the mounting table 17, a rod-like horizontal shaft portion that supports the wire 3 that circulates during winding from the inner diameter side can be used as the holding portion. In this case, the horizontal shaft portion may be constituted by a plurality of horizontal shaft portions (receiving portions) in which the vertical receiving portions 18a to 18c are turned sideways, or may be constituted by a single horizontal shaft portion (receiving portion). May be. Further, the horizontal shaft portion in this case may be driven to rotate together with the wire rod 3 being wound, or the horizontal shaft portion is fixed to a machine frame (not shown) and the wire rod 3 being rotated is rotated. May be allowed.

  In this way, the holding unit is a table on which the wound wire rod 3 dropped along the outer periphery or inner periphery of the wire rod 3 is placed according to the feed amount of the single wire rod 3 by the feeder 14. A mounting table 17 that rotates in the winding direction together with the wire rod 3 being wound, or a receiving portion that holds the wire wire 3 being wound so as to be able to rotate in the winding direction. According to this, coupled with the configuration in which the wire rod 3 is preliminarily provided with the bending rod, the winding wire rod 3 can be held with a simple configuration such as the mounting table 17 and the receiving unit, and the entire manufacturing apparatus Can be simplified.

  As mentioned above, although some embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention.

  For example, the present invention can be applied not only to the above-described transformer windings 100 to 105 but also to other static induction devices (for example, reactors) and windings of general electric devices including rotating electrical machines. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

  In the drawings, 100 to 105 are windings, 1 is a first winding part, 2 is a second winding part, 3 is a wire, 12 is feeding means, 14 is a feeder, 15 is first bending means, and 16 is second. Bending means, 17 is a mounting table (holding part), 18a to 18c are receiving parts, and 30 is a control means.

Claims (9)

An apparatus for manufacturing a winding formed by winding a wire having an insulating coating on a conductor,
A feeding means for feeding out the wire as a supply source of the wire;
A feeder that is provided between the feeding unit and a holding unit capable of mounting or holding the wire being wound as the winding; and a feeder that feeds the wire fed by the feeding unit to the holding unit side;
For the one wire rod fed by the feeder, a first winding portion wound around the outer circumference of the wire rod from the inner circumference side to the outer circumference side, and the wire rod from the outer circumference side to the inner circumference side. In order to form a plurality of stages of windings alternately stacked in the axial direction with the second winding part wound on the inner circumference, the first winding is wound before the winding in the holding part. A first bending means for bending the part and the second winding part into a shape to be wound on the outer periphery or the inner periphery of the wire, and a second bending means for bending to a shape shifted in the laminating direction;
Based on the feed amount of the one wire by the feeder, bending to a shape that is wound around the outer periphery of the wire to form the first winding, and the second winding The first bending means and the second winding part are controlled so as to sequentially perform bending processing into a shape that is wound on the inner circumference of the wire to be formed. Control means for controlling the second bending means so as to bend into a shape shifted in the laminating direction at a corresponding portion during
And the control means controls the first bending means and the second bending means so as to overlap the outer circumference or inner circumference of the wire according to the winding amount of the wire at the holding portion. An apparatus for manufacturing a winding, characterized in that a bending rod having a shape to be rotated and a bending rod having a shape shifted in the stacking direction are provided in advance.   The first bending means is a folding rod in which the inner peripheral shape or outer peripheral shape of the wire forms a polygon with respect to the wire, and the first bending means overlaps the outer periphery or inner periphery of the wire. The winding manufacturing apparatus according to claim 1, wherein the winding folding apparatus is configured to form a corresponding folding fold.   3. The winding manufacturing apparatus according to claim 2, wherein the first bending means forms a folding rod for bending the wire rod at approximately 135 degrees. When the inner peripheral shape or the outer peripheral shape of the wire forms an octagon with four sides, and the beveled portion inclined by bending approximately 135 degrees or an obtuse angle of the wire at the four corners,
The first bending means is characterized in that a folding rod is formed which has a slight play that lowers the space factor at the beveled portion of the wire as compared with the space factor at the four sides. The winding manufacturing apparatus according to any one of claims 1 to 3.   The first bending means is a curved rod having a polygonal shape or an annular shape in which the inner peripheral shape or the outer peripheral shape of the wire is rounded at the corners with respect to the wire, and the outer periphery or the inner periphery of the wire The winding manufacturing apparatus according to claim 1, wherein the winding is formed so as to form a curved ridge corresponding to the curvature of the wire wound in a stacked manner.   The winding manufacturing apparatus according to any one of claims 1 to 5, wherein the feeder, the first bending means, and the second bending means are arranged close to each other in the manufacturing apparatus. .   The holding portion is a wire rod being wound as a table on which a wire rod being wound is dropped along the outer circumference or inner circumference of the wire rod according to the feeding amount of the one wire rod by the feeder. And a receiving section that holds the mounting table that rotates in the winding direction, or the winding table that can be rotated in the winding direction. The manufacturing apparatus of winding as described. A method of manufacturing a winding formed by winding a wire having an insulating coating on a conductor,
A step of feeding out the wire from a feeding means as a supply source of the wire;
Sending the wire fed from the feeding means by the feeder to the side of the holding unit that can place or hold the wire being wound as the winding; and
For the one wire rod fed by the feeder, a first winding portion wound around the outer circumference of the wire rod from the inner circumference side to the outer circumference side, and the wire rod from the outer circumference side to the inner circumference side. In order to form a plurality of stages of windings alternately stacked in the axial direction with the second winding part wound on the inner circumference, the first winding is wound before the winding in the holding part. A first bending step of bending the wire portion and the second winding portion into a shape to be wound around the outer periphery or the inner periphery of the wire, and a second bending step of bending the shape to be shifted in the laminating direction; With
In the first bending step, based on the feeding amount of the one wire by the feeder, bending to a shape that is wound around the outer periphery of the wire to form the first winding portion; Bending to a shape to be wound on the inner circumference of the wire to form the second winding portion is performed,
In the second bending step, the shape is shifted in the stacking direction at a corresponding portion between the first winding portion and the second winding portion based on the feed amount of the one wire rod by the feeder. Bending is performed,
A shape that is wound on the outer periphery or the inner periphery of the wire according to the winding amount of the wire in the holding portion by bending in the first bending step and bending in the second bending step. And a bending rod having a shape shifted in the laminating direction is applied in advance. A winding formed by winding a wire with an insulating coating on a conductor,
One of the wires is bent by bending means before being wound as the winding,
A first winding portion wound on the outer periphery of the wire from the inner peripheral side to the outer peripheral side, a second winding portion wound on the inner periphery of the wire from the outer peripheral side to the inner peripheral side, and Are bent in a shape that is wound on the outer periphery or the inner periphery of the wire according to the winding amount of the wire so as to form a plurality of stages of the windings laminated alternately in the axial direction, and the laminated A winding having a configuration in which a bending rod having a shape shifted in a direction to be formed is formed before the winding.

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