JP2022180856A - Transformer and manufacturing method of the transformer - Google Patents

Abstract

To provide a transformer and a manufacturing method of the transformer, capable of easily stacking coils.SOLUTION: A manufacturing method of a transformer comprises the steps of: rotating, around a shaft center, an annular frame body on which a guide column stands from an end part of an axial length direction of the frame body in the outer periphery of the frame body so as to form a first coil in, e.g., an outer periphery of the frame body; after formation of the first coil, drawing a conductive wire extending from a winding end part of the first coil out of the frame body, causing the conductive wire to contact with one part of a peripheral surface in a peripheral direction of the guide column while rotating the frame body; winding the conductive wire drawn out of the frame around a certain member provided externally on the frame body while continuously rotating the frame body; after the winding around the member, drawing the conductive wire into the frame body, causing the conductive wire to contact with the other part of the peripheral surface in the peripheral direction of the guide column while rotating the frame body; and after the drawing of the conductive wire, rotating the frame body so as to form a second coil around an outer periphery of the first coil.SELECTED DRAWING: Figure 8

Description

The present disclosure relates to a method of manufacturing a transformer and a transformer.

Conventionally, transformers are used for the purpose of voltage transformation or current transformation.
A transformer may comprise an annular frame and a coil formed around the periphery of the frame. This coil is formed by winding a conductive wire around a frame. Conductive wires are drawn out from the winding start portion and the winding end portion of the coil. A transformer of this type is disclosed, for example, in US Pat.

JP 2020-188213 A

A plurality of coils may be laminated on the frame. First, the leading end portion of the conductor wire wound around the reel for supplying the conductor wire is temporarily fixed to a first jig outside the frame. By rotating the frame, the lead wire having the fixed starting end portion is wound around the outer circumference of the frame. As a result, a first coil is formed on the outer periphery of the frame.
After forming the first coil, the rotation of the frame is stopped, and the conductor wire extending from the winding end portion of the first coil is cut off from the conductor wire wound around the reel. The cut conductors are temporarily fixed to a second jig outside the frame.

Next, the leading end portion of the conductor wound around the reel is temporarily fixed to a third jig outside the frame. By rotating the frame again, a second coil is formed around the outer periphery of the first coil.
In this way, between the winding end of the first coil and the winding start of the second coil, the rotation of the frame is stopped to cut off the conductor wire, and the conductor wire is temporarily fixed to each of the two jigs. work needs to be done. Such a coil stacking procedure is complicated.

An object of the present disclosure is to provide a method of manufacturing a transformer and a transformer that can easily stack coils.

A method of manufacturing a transformer according to the present disclosure is a method of manufacturing a transformer that includes an annular frame and a plurality of coils that are laminated on the outer periphery of the frame by winding conductive wires in the circumferential direction. The coil formed on the outer circumference or the frame is rotated around the axis center by rotating the frame, in which guide columns are erected from the ends of the frame on the outer circumference in the axial direction. A first coil is formed on the outer circumference, and after the formation of the first coil, the frame is rotated and the conducting wire is moved in the axial direction toward the outside of the frame, thereby obtaining the first coil. The conductor wire extending from the winding end portion of the coil is pulled out of the frame while being in contact with a part of the circumferential surface of the guide column in the circumferential direction, and the frame continues to rotate. The conductor drawn out to the outside is wound around a member outside the frame, and after being wound around the member, the conductor is moved in the axial direction toward the frame while rotating the frame. By doing so, the conductor wire is drawn into the frame while being brought into contact with the other portion of the peripheral surface of the guide column in the circumferential direction, and after the conductor wire is drawn in, the frame is rotated, whereby the first coil is rotated. It is characterized by forming a second coil on the outer circumference.

According to the present disclosure, after forming the first coil, the conductor wire extending from the winding end portion of the first coil is pulled out of the frame. The lead wire is wound around a member outside the frame. The conductor wound around the member is pulled into the frame. A second coil is formed by the conductor drawn into the frame. The frame continues to rotate from the start of formation of the first coil to the end of formation of the second coil.
That is, between the end of winding of the first coil and the start of winding of the second coil, there is no need to stop the rotation of the frame or disconnect the conductor. In addition, the temporary fixation of the conductor only needs to be performed once.
As a result, coils can be easily stacked.

The lead-out of the conductor wire is guided to a part of the peripheral surface of the guide column in the circumferential direction, and the lead-in of the lead wire is guided to the other part of the peripheral surface of the guide column in the circumferential direction. Therefore, the lead-out and lead-in of the conductor wire can be performed smoothly. Also, if it is known where the contact is on the peripheral surface of the guide column, the conductor pulled out from the frame (that is, the conductor extending from the winding end portion of the first coil) and the conductor drawn into the frame (that is, the second coil) conductor extending from the winding start portion of the coil) can be easily distinguished.

Since the lead wire is pulled out and pulled in while the frame rotates, the lead wire must be brought into contact with the guide post rotating in the frame rotating direction. (upstream side in the winding direction around the frame).

In the method of manufacturing a transformer according to the present disclosure, the frame is rotated together with a support that supports the frame, and while the rotation of the frame and the support is continued, the transformer pulled out to the outside of the frame is rotated. A conductive wire is wound around the support.

In the present disclosure, a support that supports the frame and rotates together with the frame is used as a member around which the conductive wire pulled out to the outside of the frame is wound. Therefore, since it is not necessary to separately use a member for winding the conductor wire, the configuration of the apparatus for manufacturing the transformer can be simplified.

In the method for manufacturing a transformer according to the present disclosure, the frame in which the plurality of guide columns are arranged in parallel in the circumferential direction of the frame is rotated, and after the second coil is formed, the frame is By moving the conductor in the axial direction toward the outside of the frame while rotating, the conductor extending from the winding end portion of the second coil extends from the winding start portion of the second coil. The conductive wire is pulled out of the frame while being brought into contact with a part of the peripheral surface of another guide post in the circumferential direction different from the guide post with which the conductive wire is in contact, and the frame is continued to rotate while the frame is being rotated. The conductor pulled out to the outside of the body is wound around the member, and after being wound around the member, the conductor is moved in the axial direction toward the frame while rotating the frame. A conductor wire is drawn into the frame while being brought into contact with the other portion of the peripheral surface of the other guide column in the circumferential direction, and after the conductor wire is drawn in, the frame is rotated to extend the outer circumference of the second coil. 3 coils are formed.

According to the present disclosure, after the second coil is formed, the conductive wire extending from the winding end portion of the second coil is drawn out of the frame. The lead wire is wound around a member outside the frame. At this time, the member around which the conducting wire is wound is the member around which the conducting wire pulled out from the winding end portion of the first coil is wound. That is, since it is not necessary to use a different member for each winding of the conductor wire, the configuration of the apparatus for manufacturing the transformer can be simplified.

The conductor wound around the member is pulled into the frame. A third coil is formed by the conductor drawn into the frame. The frame continues to rotate from the start of formation of the second coil to the end of formation of the third coil.
That is, between the end of winding of the second coil and the start of winding of the third coil, there is no need to stop the rotation of the frame or disconnect the conductor. In addition, the temporary fixation of the conductor only needs to be performed once.
As a result, coils can be easily stacked.

The lead-out of the conductor wire is guided to a part of the peripheral surface of the guide column in the circumferential direction, and the lead-in of the lead wire is guided to the other part of the peripheral surface of the guide column in the circumferential direction. Therefore, the lead-out and lead-in of the conductor wire can be performed smoothly. Further, if it is known where the contact is on the peripheral surface of the guide column, the conductor pulled out from the frame (that is, the conductor extending from the winding end portion of the second coil) and the conductor drawn into the frame (that is, the third conductor extending from the winding start portion of the coil) can be easily distinguished.

A guide column with which conductors extending from the winding end portion of the first coil and the winding start portion of the second coil are in contact, and a conductor extending from the winding end portion of the second coil and the winding start portion of the third coil. They differ from each other with the contacting guide posts. Therefore, if it is known which guide column the conductor is in contact with, it is possible to easily distinguish from which part of which coil the conductor extends.

[Appendix]
In the method for manufacturing a transformer according to the present disclosure, a groove extending over the entire circumference is provided on the outer periphery, and a window portion having a shape that is notched from the top to the bottom is provided in the side wall of the groove, rotating the frame, in which the three or more guide columns are arranged in parallel in the circumferential direction of the frame at the bottom of the window, and pulling the conductor wire out of or into the groove through the window; When drawing the lead wire into the groove while making the first turn of the lead wire contact the inner surface of the side wall and contacting the most downstream guide column in the winding direction of the lead wire, The conductive wire is drawn through a position closer to the guide post adjacent to the guide post than the guide post, and the plurality of coils are stacked on the bottom surface of the groove.

In the present disclosure, multiple coils are laminated on the bottom surface of the groove provided on the outer periphery of the frame. A side wall of the groove is provided with a notch-like window, through which the conductor wire is pulled out of the groove or drawn into the groove.

For aligned winding of the wire, it is desirable for the wire to contact the inner surface of the sidewall of the groove for the first turn. However, due to the momentum of the wire being pulled in, the wire being pulled into the groove is likely to bend in the direction of the wire being pulled in. If the curved conductor contacts the inner surface of the side wall of the groove, the curved portion of the conductor may interfere with the second winding of the conductor and interfere with the aligned winding.
However, if the position where the conductor is drawn into the groove is appropriately separated upstream in the winding direction of the conductor from the position where the conductor contacts the inner surface of the side wall of the groove, the conductor will not contact the inner surface of the side wall of the groove. , the bending of the conducting wire is eliminated by the external force applied to the conducting wire in the circumferential direction of the frame.

The conducting wire to be guided by the most downstream guide column and drawn into the groove is drawn into the groove through a position closer to the guide column adjacent to this guide column than the most downstream guide column. That is, the position where the conductor wire is drawn into the groove is separated upstream in the winding direction of the conductor wire from the position where the conductor wire contacts the inner surface of the side wall of the groove. Therefore, before the conductor contacts the inner surface of the side wall of the groove, the bending of the conductor is eliminated by the external force applied to the conductor in the circumferential direction of the frame.

A transformer according to the present disclosure includes a ring-shaped frame and a plurality of coils laminated on the outer periphery of the frame by winding conductive wires in the circumferential direction, wherein the frame on the outer periphery A guide column rises from an end in the axial direction, and the conductor wire is pulled out from the winding start portion and the winding end portion of each coil, and the conductor wire pulled out from the winding end portion of one coil is A portion of the peripheral surface of the guide column in the circumferential direction is in contact from the upstream side in the winding direction of the conductor wire around the frame, and the portion in contact with the portion is positioned relative to the winding end portion. , and the conductor wire drawn out from the winding start portion of another coil laminated on the outer periphery of the one coil It is characterized in that a portion of the conductive wire that is in contact with the other portion is inclined at an obtuse angle with respect to the winding start portion.

According to the present disclosure, the transformer is manufactured by the manufacturing method of the transformer according to the present disclosure.
A portion of the conducting wire drawn out from the winding end portion of the one coil, which is guided by the peripheral surface of the guide column, is inclined at an obtuse angle with respect to the winding end portion of the one coil. The portion of the conductor drawn out from the winding start portion of the other coil, which is guided on the peripheral surface of the guide column, is inclined at an obtuse angle with respect to the winding start portion of the other coil. Since the conductive wire is gently bent, the stress applied to the bent portion of the conductive wire can be reduced to prevent breakage.
Also, if it is known where the contact is on the peripheral surface of the guide column, it is possible to easily distinguish between the conductor wire extending from the winding end portion of one coil and the conductor wire extending from the winding start portion of the other coil.

In the transformer according to the present disclosure, the part of the guide column is one inclined surface that is inclined with respect to the circumferential direction of the frame from the upstream side in the winding direction of the conductor wire toward the lead-out side of the conductor wire. , the other portion of the guide column is another inclined surface inclined with respect to the circumferential direction of the frame from the upstream side in the winding direction of the conductor wire toward the side opposite to the lead-out side of the conductor wire. do.

In the present disclosure, a portion of the guide column in the circumferential direction is one inclined surface, and the other portion of the guide column in the circumferential direction is the other inclined surface.
A lead drawn out from the winding end portion of one coil is in contact with one inclined surface. By being guided by the one slanted surface when the lead wire is pulled out, the part of the lead wire in contact with the one slanted face can be stably inclined at an obtuse angle with respect to the winding end portion of the one coil.
Conductive wires drawn out from the winding start portions of other coils are in contact with other inclined surfaces. By being guided by the other inclined surface when the wire is pulled in, the portion of the wire in contact with the other inclined surface can be stably inclined at an obtuse angle with respect to the winding start portion of the other coil.

In the transformer according to the present disclosure, three or more of the coils are laminated on the outer circumference of the frame, and a plurality of the guide columns are arranged in parallel in the circumferential direction of the frame. From the winding start portion of the second coil laminated on the outer circumference of the conductor drawn out from the winding end portion of the first coil closest to the frame among the three coils in the The guide column that is in contact with the lead-out conductor wire, the conductor lead-out from the winding end portion of the second coil, and the third coil that is laminated on the outer circumference of the second coil. It is characterized in that the guide pillar with which the conductor drawn out from the winding start portion is in contact is different from each other.

In the present disclosure, a guide column with which conductive wires drawn from the winding end portion of the first coil and the winding start portion of the second coil are in contact, the winding end portion of the second coil and the third coil. They are different from the guide posts with which the conductors drawn out from the winding start portions of the coil come into contact. Therefore, if it is known which guide column it is in contact with, it is possible to easily distinguish from which part of which coil the lead wire is drawn.

[Appendix]
In the transformer according to the present disclosure, the outer periphery of the frame body is provided with a groove extending all around, and the side wall of the groove is provided with a window portion having a shape notched from the top to the bottom. At the bottom of the window, three or more guide pillars are arranged in parallel in the circumferential direction of the frame, and the guide pillar adjacent to the guide pillar from the most downstream guide pillar in the winding direction of the conductor wire. is longer than the circumferential length of the frame from the most upstream guide column in the winding direction of the conductor wire to the guide column adjacent to the guide column, and the plurality of The coil of (1) is laminated on the bottom surface of the groove, and the conducting wire is drawn out through the window.

In the present disclosure, multiple coils are laminated on the bottom surface of the groove provided on the outer periphery of the frame. A notch-shaped window is provided in the side wall of the groove, and the conducting wire is pulled out from the groove through the window.

At the bottom of the window, three or more guide columns are arranged in parallel in the circumferential direction of the frame body at uneven intervals. Specifically, the distance between the most downstream guide column in the conductor winding direction and the guide column adjacent to this guide column is equal to the distance between the most downstream guide column in the conductor winding direction and the guide column adjacent to this guide column wider than the interval between
Therefore, this frame allows the conductor wire to be guided by the most downstream guide post and drawn into the groove to be placed in the groove at a position as far upstream as possible in the winding direction of the conductor wire from the position where the conductor wire contacts the inner surface of the side wall of the groove. It is suitable for drawing into

According to the method of manufacturing a transformer and the transformer disclosed herein, coils can be easily stacked.

1 is an exploded perspective view of a transformer according to an embodiment; FIG. It is a perspective view of the upper side part of a frame. It is an expansion perspective view of a coil bobbin. It is an enlarged plan view of a coil bobbin. It is a schematic diagram which shows the principal part of a coil forming apparatus. It is a schematic diagram for demonstrating the formation procedure of a primary coil. It is a schematic diagram for demonstrating the formation procedure of a primary coil. It is a schematic diagram for demonstrating the formation procedure of a primary coil. It is a schematic diagram for demonstrating the formation procedure of a primary coil. It is a schematic diagram for demonstrating the formation procedure of a primary coil. It is a schematic diagram for demonstrating the formation procedure of a primary coil. It is a schematic diagram for demonstrating the formation procedure of a primary coil.

Embodiments of the present disclosure will be described below. In the following description, up/down, front/rear, and left/right indicated by arrows in the drawings are used.

FIG. 1 is an exploded perspective view of a transformer according to an embodiment.
In the figure, 1 is a transformer, and the transformer 1 has a coil bobbin 11, two secondary coils 12 and 13, a cover 14, and two wound cores (not shown).
A coil bobbin 11 includes a frame 2 and primary coils 3 , 4 , 5 and 6 .

The frame 2 has a rectangular annular shape. Four corners of the frame 2 are curved in an arc shape. The frame 2 is an insulator, for example, made of synthetic resin.
The left and right sides of the frame 2 are the two long sides of the frame 2 , and the top and bottom sides of the frame 2 are the two short sides of the frame 2 . The direction parallel to the long sides of the frame 2 corresponds to the up-down direction, and the direction parallel to the short sides of the frame 2 corresponds to the left-right direction. The axial direction of the frame 2 corresponds to the front-rear direction. Below, the peripheral direction of the frame 2 is called an outer peripheral direction.

FIG. 2 is a perspective view of the upper side of the frame 2. FIG.
As shown in FIGS. 1 and 2, a groove 21 is provided on the outer circumference of the frame 2 . The groove 21 extends over the entire circumference of the frame 2 .
A window 22 is provided in the front side wall 21 a (side wall) of the groove 21 on the upper side of the frame 2 . The window 22 has a rectangular shape obtained by cutting the front wall 21a from the top to the bottom.

Between the front side wall 21a and the rear side wall 21b of the groove 21, three insulating walls 23 are arranged side by side in the front-rear direction. Each insulating wall 23 extends outward in the radial direction of the frame 2 from the bottom surface of the groove 21 over the entire circumference of the frame 2 .
As shown in FIG. 1, the primary coils 3-6 are inside the groove 21 and are arranged in this order from front to back. Each of the primary coils 3 to 6 is formed by winding a conductive wire around the bottom surface of the groove 21 in the outer peripheral direction. Conductive wires forming each of the primary coils 3 to 6 are wound in an aligned manner.

The primary coil 3 is arranged between the front wall 21a of the groove 21 and the front insulating wall 23 (see FIG. 3, which will be described later). A front insulating wall 23 is interposed between the primary coils 3 and 4 . A central insulating wall 23 is interposed between the primary coils 4 and 5 . A final insulating wall 23 is interposed between the primary coils 5 and 6 . The primary coil 6 is arranged between the rear wall 21 b of the groove 21 and the last insulating wall 23 .

The secondary coil 12 has a rectangular annular shape and is accommodated inside the coil bobbin 11 in the radial direction. The secondary coil 13 has a rectangular annular shape. The coil bobbin 11 is accommodated inside the secondary coil 13 in the radial direction. Each of the secondary coils 12 and 13 is formed by bending a rectangular wire, for example.

The cover 14 has two cover members 141 . Each cover member 141 integrally has two semi-cylinders laterally adjacent to each other, and the axial length direction of each semi-cylinder extends vertically. Combining the two cover members 141 forms a cover 14 having two cylinders.
The cylinder on the left side of the cover 14 passes through the inside of the secondary coil 12 and covers the left sides of the coil bobbin 11 and the secondary coils 12 and 13 . Similarly, the cylinder on the right side of cover 14 covers the right sides of coil bobbin 11 and secondary coils 12 and 13, respectively.
A cylindrical wound core (not shown) is provided on each of the outer peripheral surfaces of the two cylinders of the cover 14 .

FIG. 3 is an enlarged perspective view of the coil bobbin 11. FIG. FIG. 4 is an enlarged plan view of the coil bobbin 11. FIG. 3 and 4 show the vicinity of the window portion 22 of the frame 2. FIG. FIG. 4 shows a block diagram of a plurality of connection terminals 15 of transformer 1 .

Here, the configuration of the primary coil 3 will be described in detail.
The primary coil 3 comprises four coils 31,32,33,34. The coils 31 to 34 are layered on the bottom surface of the groove 21 in this order.

A lead wire 31 a is drawn out of the groove 21 through the window portion 22 from the winding start portion of the coil 31 . A lead wire 31 b is drawn out of the groove 21 through the window portion 22 from the winding end portion of the coil 31 . Similarly, conductors 32a-34a are led out from the winding start portions of the coils 32-34. Lead wires 32b-34b are drawn out from winding ends of the coils 32-34.
The conductors 31a to 34a and conductors 31b to 34b are connected to different connection terminals 15 .

The conducting wires 31a to 34a and the conducting wires 31b to 34b are connected to a power supply circuit (not shown) through the connection terminal 15, or are connected to each other. For example, when the conductors 31a and 31b are connected to the power supply circuit, the primary coil 3 having the same number of turns as the coil 31 is connected to the power supply circuit. When the conductors 31a, 32b are connected to the power supply circuit and the conductors 31b, 32a are connected to each other, the primary coil 3 having the same number of turns as the sum of the turns of the coils 31, 32 is connected to the power supply circuit.

Thus, by appropriately connecting the connection terminals 15, the primary coil 3 with the desired number of turns can be connected to the power supply circuit. Therefore, the turns ratio between the primary coils 3 to 6 and the secondary coils 12 and 13 can be changed by changing the connection state of the connection terminals 15 (so-called tap switching). By switching the taps when the input voltage to the primary coils 3-4 fluctuates, the output voltage from the secondary coils 12 and 13 can be kept constant.

FIG. 5 is a schematic diagram showing a main part of the coil forming device. FIG. 5 shows the frame 2 in plan view.
Reference numeral 7 in the figure denotes a coil forming device, and the coil forming device 7 comprises a rotary shaft 71 , a rotating table 72 , two clamping pieces 73 , a reel 74 and a traverse 75 .
The rotating shaft 71 extends in the front-rear direction and is rotatably supported by bearings (not shown). The rotary shaft 71 rotates about its axis by being driven by a motor (not shown).

The turntable 72 is provided at one end of the rotating shaft 71 and rotates integrally with the rotating shaft 71 . The turntable 72 has a support shaft 721 (support). The support shaft 721 protrudes rearward from the rear surface of the turntable 72 .
Each of the clamping pieces 73 is a plate-like member extending vertically and horizontally. The two holding pieces 73 face each other in the front-rear direction and hold the frame 2 from the front and rear sides. The front holding piece 73 is directly supported by the support shaft 721 and rotates integrally with the turntable 72 . The rear holding piece 73 is connected to the front holding piece 73 through the inside of the frame 2 .

The frame 2 held between the two holding pieces 73 is arranged coaxially with the rotating shaft 71 and rotates as the rotating shaft 71 rotates.
Here, the upper surface, left surface, lower surface, and right surface of the frame 2 are called A surface, B surface, C surface, and D surface. When the rotating shaft 71 rotates clockwise when viewed from the front, the frame 2 rotates so that the A surface, the B surface, the C surface, the D surface, the A surface, .

A reel 74 supplies the wire 30 to be wound around the frame 2 . An operator pulls out the conductor 30 from the reel 74 and introduces it into the space between the front side wall 21 a of the groove 21 of the frame 2 and the front insulating wall 23 . Next, the operator brings the wire 30 into contact with the rear surface of the front wall 21 a and draws the wire 30 out of the groove 21 through the window 22 . Furthermore, the worker temporarily fixes the leading end portion of the lead wire 30 pulled out from the groove 21 to a jig (not shown) provided in the front clamping piece 73 . The coil forming device 7 is not limited to the configuration in which the wire 30 is temporarily fixed to the holding piece 73, and may be configured to be temporarily fixed to a jig provided on the turntable 72, for example. .

After fixing the wire 30 to the clamping piece 73 , the wire 30 is continuously pulled out from the reel 74 by receiving an external force from the clamping piece 73 and the frame 2 by rotating the frame 2 . The conducting wire 30 pulled out from the reel 74 is wound in the outer peripheral direction in order of the A surface, the B surface, the C surface, the D surface, the A surface, and so on.
Hereinafter, the upstream side/downstream side in the winding direction of the wire 30 around the frame 2 is simply referred to as the upstream side/downstream side. The upstream side/downstream side of the A side is the D side/B side.

The traverse 75 is a roller whose axial direction faces forward and backward, and is provided so as to be able to reciprocate in the forward and backward direction. An engaging groove 751 is provided on the peripheral surface of the traverse 75 , and the engaging groove 751 of the traverse 75 is engaged with the conductor 30 positioned between the reel 74 and the frame 2 . there is By reciprocating the traverse 75 in the front-rear direction with the engaging groove 751 facing the outer periphery of the frame 2 , the position at which the wire 30 winds around the frame 2 is adjusted in the front-rear direction.
The traverse 75 of this embodiment can move to a position where the engagement groove 751 is spaced forward from the frame 2 by an appropriate length.
The operation of the traverse 75 is controlled by a controller (not shown) included in the coil forming device 7 .

As shown in FIGS. 2 to 4, the frame 2 has three guide posts 24, 25 and 26. As shown in FIGS.
Each of the guide columns 24 to 26 rises outward in the radial direction of the frame 2 from the bottom of the window portion 22 . The guide columns 24 to 26 are arranged side by side in the outer peripheral direction. The left edge of the window 22, the guide posts 24 to 26, and the right edge of the window 22 are aligned in this order from the downstream side to the upstream side.
The distance between the left edge of the window 22 and the guide column 24 is the narrowest, and the distance between the guide columns 24 and 25 is the widest. The distance between the guide post 25 and the guide post 26 and the distance between the guide post 26 and the right edge of the window 22 are approximately the same.

The guide post 24 has a kite-shaped cross section. Of the two diagonal lines of the cross section of the guide column 24, the longer one runs along the outer peripheral direction and the shorter one runs perpendicular to the outer peripheral direction. Two long sides of the cross section of the guide column 24 are arranged on the upstream side.
Hereinafter, of the four side surfaces of the guide column 24, the upstream and front side surface is referred to as a side surface 24a, and the upstream and rear side surface is referred to as a side surface 24b.
The side surface 24a is an inclined surface that is inclined with respect to the outer peripheral direction from the upstream side toward the front side. The side surface 24b is an inclined surface that is inclined with respect to the outer peripheral direction from the upstream side toward the rear side.

The guide post 25 has a rhombic cross-sectional shape. Of the two diagonal lines of the cross section of the guide column 25, the longer one runs along the outer peripheral direction and the shorter one runs perpendicular to the outer peripheral direction. The guide post 25 has side surfaces 25 a and 25 b corresponding to the side surfaces 24 a and 24 b of the guide post 24 .
The configuration of the guide column 26 is similar to that of the guide column 25, and the guide column 26 has side surfaces 26a and 26b.

Here, the procedure for forming the primary coil 3 will be described.
6 to 12 are schematic diagrams for explaining the procedure for forming the primary coil 3. FIG. 6 to 12 show the vicinity of the window portion 22 of the frame 2 in plan view.

As described above, the operator guides the lead wire 30 pulled out from the reel 74 into the space between the front wall 21a of the groove 21 and the front insulating wall 23, brings it into contact with the rear surface of the front wall 21a, and through the groove 21 (see symbol A shown in FIGS. 5 and 6). At this time, the operator causes the lead wire 30 to pass between the left edge of the window portion 22 and the most downstream guide post 24 .
After temporarily fixing the leading end portion of the lead wire 30 pulled out from the groove 21 to the front clamping piece 73 , the operator operates the motor that drives the rotating shaft 71 . As a result, the frame 2 starts rotating.

By rotating the frame 2, first, the first winding of the conductor wire 30 is arranged at a position adjacent to the front wall 21a. When the frame 2 rotates once, the traverse 75 moves rearward by a length equal to the diameter of the wire 30 . As a result, the second turn of the conductor wire 30 is arranged at a position adjacent to the rear side of the first turn of the conductor wire 30 .
The traverse 75 moves rearward with each revolution of the frame 2 until the wire 30 is adjacent to the front face of the foremost insulating wall 23 . After the wire 30 has been wound one turn adjacent the front face of the foremost insulating wall 23, the traverse 75 moves forward with each revolution of the frame 2 until the wire 30 is adjacent the front side wall 21a. By reciprocating the traverse 75 in this manner, the conducting wire 30 is wound in an aligned manner.

As described above, the coil 31 is formed by winding the conducting wire 30 around the bottom surface of the groove 21 a predetermined number of times. A winding start portion and a winding end portion of the coil 31 extend along the outer peripheral direction adjacent to the rear surface of the front wall 21a.

After the coil 31 is formed, the traverse 75 moves forward to a position where the engagement groove 751 faces the support shaft 721, as shown in FIG. (See symbol B). At this time, the traverse 75 allows the conducting wire 30 to pass between the guide posts 24,25.
Since the frame 2 continues to rotate, the lead wire 30 pulled out through between the guide columns 24 and 25 is wound around the support shaft 721 while contacting the side surface 24a of the guide column 24 from the upstream side.

After the lead wire 30 is pulled out, when the frame 2 rotates once, the traverse 75 moves rearward to a position where the engagement groove 751 faces the portion of the frame 2 on the rear side of the front wall 21a, as shown in FIG. By moving to the side, the conductor 30 is pulled into the groove 21 through the window 22 (see symbol C). At this time, the traverse 75 is so arranged that the conducting wire 30 passes through a position closer to the guide column 25 than the guide column 24 between the guide columns 24 and 25 .
Since the frame 2 continues to rotate, the conductor 30 drawn through between the guide columns 24 and 25 contacts the side surface 24b of the guide column 24 from the upstream side as shown in FIG. wrap around the perimeter.

After the wire 30 is pulled in, the frame 2 rotates and the traverse 75 reciprocates to wind the wire 30 around the outer periphery of the coil 31 a predetermined number of times to form the coil 32 . As in the case of the coil 31, the winding start portion and the winding end portion of the coil 32 extend along the outer peripheral direction adjacent to the rear surface of the front wall 21a.

After the coil 32 is formed, as shown in FIG. 9, the traverse 75 moves forward to draw the wire 30 out of the groove 21 through the window 22 (see symbol D). At this time, the traverse 75 allows the conducting wire 30 to pass between the guide posts 25,26.
Since the frame 2 continues to rotate, the lead wire 30 pulled out through between the guide columns 25 and 26 is wound around the support shaft 721 while contacting the side surface 25a of the guide column 25 from the upstream side.

When the frame 2 rotates once after the wire 30 is pulled out, the traverse 75 moves rearward to draw the wire 30 into the groove 21 through the window 22 (see symbol E), as shown in FIG. At this time, the traverse 75 allows the conducting wire 30 to pass between the guide posts 25,26.
Since the frame 2 continues to rotate, the conducting wire 30 drawn through between the guide columns 25 and 26 winds around the outer periphery of the coil 32 while coming into contact with the side surface 25b of the guide column 25 from the upstream side.

Similarly, a coil 33 is formed by winding the conducting wire 30 around the outer periphery of the coil 32 a predetermined number of times.
After the coil 33 is formed, as shown in FIG. 11, the traverse 75 draws the conductor 30 out of the groove 21 through between the guide post 26 and the right edge of the window 22 (see symbol F). The traverse 75 winds the lead wire 30 around the support shaft 721 while contacting the side surface 26a of the guide column 26 from the upstream side.
After the lead wire 30 is pulled out, when the frame 2 rotates once, the traverse 75 draws the lead wire 30 into the groove 21 through between the guide post 26 and the right edge of the window 22 (see symbol G). The traverse 75 winds the lead wire 30 around the outer circumference of the coil 33 while contacting the side surface 26b of the guide column 26 from the upstream side.

Similarly, a coil 34 is formed by winding the conducting wire 30 around the outer periphery of the coil 33 a predetermined number of times. As a result, the coils 31 to 34 are laminated on the bottom surface of the groove 21 between the front wall 21a and the front insulating wall 23. As shown in FIG. That is, the primary coil 3 is formed.
After forming the coil 34, as shown in FIG. 12, the traverse 75 draws the conductor 30 out of the groove 21 through between the guide post 26 and the right edge of the window 22 (see symbol H). After the lead wire 30 is pulled out, the rotation of the frame 2 stops without the lead wire 30 being wound around the support shaft 721 .

After stopping the rotation of the frame 2 , the operator cuts off the lead wire 30 finally pulled out through between the guide post 26 and the right edge of the window 22 from the reel 74 .
The conducting wire 30 (see symbol H shown in FIG. 12) cut off at this time is the conducting wire 34b drawn out from the winding end portion of the coil 34 (see FIGS. 3 and 4). The operator temporarily fixes the conductor 34b to an appropriate location on the frame 2 using, for example, an adhesive tape (not shown) so that the conductor 34b contacts the right edge of the window 22 .
The conducting wire 30 (see symbol A shown in FIG. 12) fixed to the clamping piece 73 is the conducting wire 31a drawn out from the winding start portion of the coil 31 (see FIGS. 3 and 4).

The operator cuts the conducting wire 30 (see symbols B and C shown in FIG. 8) pulled out from between the guide posts 24 and 25 and wound around the support shaft 721 at an appropriate position. As a result, a conductor wire 31b drawn from the winding end portion of the coil 31 and a conductor wire 32a drawn from the winding start portion of the coil 32 are obtained (see FIGS. 3 and 4). The operator temporarily fixes the conductors 31b and 32a to appropriate locations on the frame 2 using, for example, an adhesive tape (not shown) so that the conductors 31b and 32a do not separate from the side surfaces 24a and 24b of the guide column 24. .

In addition, the operator cuts the conducting wire 30 (see symbols D and E shown in FIG. 10) drawn from between the guide posts 25 and 26 and wound around the support shaft 721 at an appropriate position. As a result, a conductor wire 32b drawn from the winding end portion of the coil 32 and a conductor wire 33a drawn from the winding start portion of the coil 33 are obtained (see FIGS. 3 and 4). The operator temporarily fixes the conductors 32b and 33a to the frame 2 in the same manner as the conductors 31b and 32a so that the conductors 32b and 33a do not separate from the side surfaces 25a and 25b of the guide column 25 .

Further, the operator pulls out from between the guide post 26 and the right edge of the window portion 22 and winds the lead wire 30 (see symbols F and G shown in FIG. 11) around the support shaft 721 to an appropriate position. to cut. As a result, a conductor wire 33b drawn from the winding end portion of the coil 33 and a conductor wire 34a drawn from the winding start portion of the coil 34 are obtained (see FIGS. 3 and 4). The operator temporarily fixes the conductors 33b, 34a to the frame 2 in the same manner as the conductors 31b, 32a so that the conductors 33b, 34a do not separate from the side surfaces 26a, 26b of the guide column 26 .

After the conductors 32a to 34a and the conductors 31b to 34b are fixed, the frame 2 rotates again and the primary coils 4 to 6 are formed on the frame 2 in sequence. After forming the primary coils 4 to 6 , the operator removes the frame 2 from the coil forming device 7 . As a result, the coil bobbin 11 is obtained.
The formation of the primary coils 4 to 6 may be performed after fixing the conductor 34b and before fixing the conductors 32a to 34a and the conductors 31b to 33b. Alternatively, the primary coil 3 may be formed after the primary coils 4-6 are formed.

When the transformer 1 is assembled, the operator connects the conductors 31a to 34a and the conductors 31b to 34b to different predetermined connection terminals 15, respectively.
A conductor wire 31 a of the coil 31 is in contact with the left edge of the window 22 , and a conductor wire 31 b of the coil 31 is in contact with the side surface 24 a of the guide column 24 . A conducting wire 32 a of the coil 32 is in contact with the side surface 24 b of the guide column 24 , and a conducting wire 32 b of the coil 32 is in contact with the side surface 25 a of the guide column 25 . Since the conductors 31a to 34a and the conductors 31b to 34b are in contact with different predetermined portions of the frame 2 in this manner, the operator can easily distinguish between the conductors 31a to 34a and the conductors 31b to 34b. be able to. Therefore, the conductors 31a to 34a and the conductors 31b to 34b can be connected to the correct connection terminals 15, respectively.

Even after connection with the connection terminal 15, the conductors 32a-34a and the conductors 31b-33b are in contact with different predetermined portions of the guide columns 24-26, respectively.
Conductive wire 31b drawn out from the winding end portion of coil 31 is inclined at an obtuse angle with respect to the winding end portion of coil 31 . A conducting wire 32 a drawn out from the winding start portion of the coil 32 is inclined at an obtuse angle with respect to the winding start portion of the coil 32 . Since the conducting wire 32a is gently bent, the stress applied to the bent portion of the conducting wire 32a can be reduced to prevent breakage.

Similarly, the conductor 32b drawn out from the winding end portion of the coil 32 is inclined at an obtuse angle with respect to the winding end portion of the coil 32. As shown in FIG. A conducting wire 33 a drawn out from the winding start portion of the coil 33 is inclined at an obtuse angle with respect to the winding start portion of the coil 33 . Conductive wire 33b drawn out from the winding end portion of coil 33 is inclined at an obtuse angle with respect to the winding end portion of coil 33 . A conducting wire 34 a drawn from the winding start portion of the coil 34 is inclined at an obtuse angle with respect to the winding start portion of the coil 34 .
Therefore, the stress applied to the bent portions of the conductors 33a, 34a and the conductors 32b, 33b can be reduced to prevent breakage.

According to the method of manufacturing the transformer 1 as described above, the frame 2 continues to rotate from the start of forming the coil 31 to the end of forming the coil 34 .
Therefore, it is not necessary to stop the rotation of the frame 2 between the winding end of the coil 31 and the winding start of the coil 32 . In addition, since the conductor 30 is temporarily fixed by winding the conductor 30 around the support shaft 721, the conductor 31b and 32a are provided by cutting the conductor 30, and the conductors 31b and 32a thus provided are individually and temporarily fixed. you don't have to.

Between the winding end of the coil 32 and the winding start of the coil 33, and between the winding end of the coil 33 and the winding start of the coil 34, there is no need to stop the rotation of the frame 2 and cut off the conductor 30. do not have. Also, the temporary fixation of the lead wire 30 may be performed once at a time.
As a result, the coils 31 to 34 can be easily stacked.

Sides 24a-26a of the guide posts 24-26 guide the drawing of the wire 30, and side surfaces 24b-26b of the guide posts 24-26 guide the drawing of the wire 30. As shown in FIG. Therefore, the lead-out and lead-in of the conducting wire 30 are performed smoothly.
The support shaft 721 is used as a member around which the lead wire 30 pulled out of the groove 21 is wound, and there is no need to separately provide different members for fixing the lead wires 32a to 34a and the lead wires 31b to 33b. Therefore, the configuration of the coil forming device 7 can be simplified.

By the way, due to the momentum of the lead wire 30 being pulled in, the lead wire 30 drawn into the groove 21 tends to be curved in such a way as to bulge rearward. However, if the position where the lead wire 30 is pulled into the groove 21 is appropriately separated from the left edge of the window 22 to the upstream side in the outer peripheral direction, the lead wire 30 will reach the inner surface of the front wall 21a before the lead wire 30 contacts the inner surface of the front wall 21a. On the other hand, the bending of the conducting wire 30 is eliminated by an external force applied in the outer peripheral direction.

As shown in FIG. 7 , the conducting wire 30 to be guided by the most downstream guide column 24 and drawn into the groove 21 is drawn into the groove 21 through a position closer to the guide column 25 than the guide column 24 . Moreover, the distance between the guide column 24 and the guide column 25 is wide. Therefore, the position where the conductor wire 30 is pulled into the groove 21 is sufficiently separated from the left edge of the window 22 to the upstream side in the outer peripheral direction. Therefore, the conductor 30 can contact the inner surface of the front wall 21a after the bending of the conductor 30 is eliminated.
As a result, there is no possibility that the bending of the conducting wire 30 will interfere with the aligned winding of the conducting wire 30 .

In the primary coil 3, the conductors extending from the lower/upper coils are in contact with the downstream/upper guide columns, but the present invention is not limited to this. For example, conductors extending from lower/upper layer coils may contact downstream/upstream guide posts.
Each of the guide columns 24 to 26 is a square column, but is not limited to this. For example, the guide post 24 may be a polygonal prism such as a triangular or pentagonal prism having sides 24a and 24b. The guide column 24 is not limited to a polygonal column, and may be, for example, an elliptical column, but preferably has side surfaces 24a and 24b. By bringing the conductors 31b and 32a into contact with the side surfaces 24a and 24b, the conductors 31b and 32a can be stably inclined with respect to the outer peripheral direction. The above also applies to the guide columns 25 and 26, respectively.

The embodiments disclosed this time should be considered as examples in all respects and not as restrictive. The scope of the present invention is intended to include all modifications within the scope of the claims and the meaning equivalent to the scope of the claims, rather than the meaning described above.

1 transformer; 11 coil bobbin; 12, 13 secondary coil; 14 cover; 141 cover member; 24,25,26 guide column; 24a, 24b, 25a, 25b, 26a, 26b side surface (surrounding surface); 3 primary coil; 33a, 33b, 34a, 34b conducting wire; 4, 5, 6 primary coil; 7 coil forming device; 71 rotating shaft; 74 reel; 75 traverse; 751 engagement groove

Claims (6)

an annular frame;
a plurality of coils laminated on the outer periphery of the frame by winding conductors in the circumferential direction, and
By rotating the frame, in which a guide column rises from the axial end of the frame on the outer periphery, around the axis, the coil formed on the outer periphery or on the outer periphery of the frame is rotated. forming a first coil;
After forming the first coil, the conductor wire extending from the winding end portion of the first coil is moved in the axial direction toward the outside of the frame while rotating the frame. is pulled out of the frame while contacting a part of the peripheral surface of the guide column in the circumferential direction,
While continuing to rotate the frame, the conductor pulled out to the outside of the frame is wound around a member outside the frame,
After being wound around the member, the lead wire is moved in the axial direction toward the frame while rotating the frame, thereby moving the lead wire to the other portion of the peripheral surface of the guide column in the circumferential direction. Draw into the frame while contacting,
A method of manufacturing a transformer, wherein the second coil is formed around the outer periphery of the first coil by rotating the frame after the lead wire is drawn. rotating the frame together with a support that supports the frame;
2. The method of manufacturing a transformer according to claim 1, wherein said lead drawn out of said frame is wound around said support while said frame and said support continue to rotate. rotating the frame in which a plurality of the guide columns are arranged in parallel in the circumferential direction of the frame;
After the second coil is formed, the conductor wire extending from the winding end portion of the second coil is moved in the axial direction toward the outside of the frame while rotating the frame. is pulled out of the frame while contacting a part of the peripheral surface of another guide column in the circumferential direction different from the guide column with which the conductive wire extending from the winding start portion of the second coil is in contact. ,
While continuing the rotation of the frame, the conductor pulled out to the outside of the frame is wound around the member;
After being wound around the member, the conductor is moved in the axial direction toward the frame while the frame is rotated, thereby moving the conductor in the circumferential direction of the peripheral surface of the other guide column. drawn into the frame while contacting the part,
3. The method of manufacturing a transformer according to claim 1, further comprising forming a third coil around the outer periphery of the second coil by rotating the frame after the lead wire is drawn. an annular frame;
A plurality of coils laminated on the outer periphery of the frame by winding conductors in a circumferential direction, and
A guide column rises from an axial end of the frame on the outer periphery,
The conducting wires are pulled out from the winding start portion and the winding end portion of each coil,
The conducting wire drawn out from the winding end portion of one coil is in contact with a portion of the peripheral surface of the guide column in the circumferential direction from the upstream side in the direction in which the conducting wire is wound around the frame. The part in contact with the part is inclined at an obtuse angle with respect to the winding end part,
The conductor wire drawn out from the winding start portion of another coil laminated on the outer periphery of the one coil is wound around the frame at another part in the circumferential direction of the peripheral surface of the guide column. A transformer, characterized in that the portion which is in contact from the upstream side of the direction and which is in contact with the other portion is inclined at an obtuse angle with respect to the winding start portion. The part of the guide column is one inclined surface inclined with respect to the circumferential direction of the frame from the upstream side in the winding direction of the conductor wire toward the lead-out side of the conductor wire,
The other part of the guide column is another inclined surface inclined with respect to the circumferential direction of the frame from the upstream side in the winding direction of the conductor wire toward the side opposite to the lead-out side of the conductor wire. 5. A transformer according to claim 4. Three or more of the coils are laminated on the outer periphery of the frame,
A plurality of the guide columns are arranged side by side in the circumferential direction of the frame,
Of the three mutually laminated coils, the conductor drawn out from the winding end portion of the first coil closest to the frame and the second coil laminated on the outer periphery of the first coil The guide column with which the conductor drawn from the winding start portion is in contact, the conductor drawn from the winding end portion of the second coil, and the second coil laminated on the outer periphery of the second coil. 6. The transformer according to claim 4, wherein said guide poles with which said conductors drawn out from winding start portions of said coils are in contact are different from each other.

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