JP2611419B2 - Multi-coil winding method with different wire diameter - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of winding a coil wire used for a switch coil of a starter, for example.

[Prior art]

Conventionally, a coil wire for winding used for a switch coil of a starter is, for example, as shown in FIG.
In FIG. 11, two kinds of round wires 4 and 5 having different wire diameters were sequentially wound on the same winding frame 11 in the order of the first and second wires from the one having a large cross-sectional area. However, it has been considered impossible to perform multiple-row winding in which the sectional area ratio of the wire diameter of the coil wire differs by 50% or more. The above reason will be described below using two types of coil wires. As shown in FIG. 6, the first coil wire 4 is wound around a bobbin.
After winding up to the fourth winding layer on 11, the second coil wire 5 becomes the winding form 11 in the final fourth winding layer of the first coil wire 4.
Can be started from the groove M formed on the right end face. Here, in FIG. 7, which is an enlarged view of a portion B in FIG. 6,
The wire diameter of the first coil wire 4 is d, and the wire diameter of the second coil wire 5 is 0.65 d. That is, 0.65 ² = 0.4225, and the cross-sectional area ratio of the wire diameter of the first coil wire 4 and the second coil wire 5 is 50% or more. Then, since the gap width G of 0.5 d already exists between the first coil wire 4 and the right end face of the winding frame 11 at the winding start position of the second coil wire 5, the second coil wire 5 5e, which is the first turn in the first turn layer, is wound around the groove M having the gap width G. Next, 5g, which is the second turn in the first winding layer of the second coil wire 5, is 4e, which is the fifth winding in the fourth winding layer of the first coil wire 4, and 4f, which is the sixth winding. And the winding is wound around the valley P generated. At this time, from the right end surface of the winding frame 11, the first
The distance F to the center of 5 g, which is the second turn in the winding layer, is 1.
Since it becomes 5d, the horizontal direction parallel to the winding direction of the second coil wire 5 generated by the first winding 5e and the second winding 5g in the first winding layer of the second coil wire 5 is obtained. The gap R in the direction is R = 1.5d−0.65d−0.65d / 2 = 0.525d. Actually, since the first winding 5e in the first winding layer of the second coil wire 5 is located closer to the winding center of the winding frame 11 than the second winding 5g, The gap is larger than the value of R. For this reason, it is assumed that the first winding 5f in the second winding layer of the second coil wire 5 falls into this gap. The fourth winding layer of the first coil wire 4 and the first winding layer of the second coil wire 5 on the left end surface of the winding frame 11 are the sixth winding layer.
The winding positional relationship is as shown in FIG. 8, which is an enlarged view of the portion C in FIG. Therefore, the first coil wire 5 in the first winding layer of the second coil wire 5 wound around the valley Q generated by the first and second turns of the fourth winding layer of the first coil wire 4 is formed. The gap E between the sixth turn 5c and the left end face of the winding frame 11 is E = d−0.65d / 2 = 0.675d. This gap E is the wire diameter of the second coil wire 5
Since it is larger than 0.65d, the second coil wire 5
The first winding in the winding layer falls into the groove N formed by the gap E. As described above, at the turns of the second coil wire 5 in the first winding layer, a gap approximately equal to or larger than the wire diameter of the second coil wire 5 is generated near both end surfaces of the winding frame 11. 6, the winding control of the second and subsequent coil wires 5 in the second and subsequent winding layers becomes impossible, and as shown in FIG. 6, the second coil wire 5 exhibits a turbulent winding state.

[Problems to be solved by the invention]

When the turbulent winding occurs as described above, the dimension of the outer diameter D of the winding frame 11 due to the winding of the first coil wire 4 and the second coil wire 5 increases and exceeds the allowable dimensional tolerance. Becomes In addition, the turbulent winding causes a change in the winding length and changes the coil resistance value, and consequently affects the product performance. Further, in order to wind the above-mentioned round wire materials having different wire diameters, it is necessary to separate the winding process, and it has been necessary to perform winding by a dedicated winding machine for each wire diameter. In other words, when a round wire having two kinds of wire diameters is used, two processes are required. Therefore, it is necessary to carry out operations such as transfer, delivery, and positioning between the two processes twice using a jig or the like. Increases in equipment costs and equipment installation locations, etc., have caused cost increases. The present invention has been made in order to solve the above-described problems, and an object of the present invention is to wind a plurality of types of coil wires having different cross-sectional areas around a winding frame in the order of larger cross-sectional area. In the case of winding, it is wound on a bobbin without exhibiting a turbulent state, and the dimensions of the outer diameter of the winding and the coil resistance are constant, and there is no need to separate the winding process. Is to provide a line method.

[Means for Solving the Problems]

The configuration of the invention for solving the above-mentioned problem is a multi-coil winding having different wire diameters in which a plurality of types of coil wires having different cross-sectional areas are sequentially wound around a winding frame from a coil wire having a larger cross-sectional area. In the wire method, a cross-sectional shape of a first coil wire wound first on the winding frame is substantially hexagonal having three sets of parallel planes, and the first coil wire wound adjacently in the same winding layer is used. Of the coil wires of the first row are brought into contact with each other so that a pair of parallel planes of the coil wires of the first row are perpendicular to the winding direction. Switching between the coil wires having different cross-sectional areas is performed from both end surfaces of the winding frame. It is characterized by being continuously wound without being separated at any of the inner end face positions.

[Action]

A pair of parallel planes having a substantially hexagonal cross-sectional shape having three sets of parallel planes of the first coil wire is used.
The required winding layer is wound around the first coil wire at the pitch according to the width of the parallel plane of the set. The switching between the coil wires having different cross-sectional areas reduces the cross-sectional area at any one of the end face positions inside the both end faces of the bobbin with a cross-sectional shape that can be formed and changed without separating the coil wire. Since the coil wire having the reduced cross-sectional area is wound along the thread-shaped valley formed by the other two sets of parallel planes of the first coil wire, the multi-row alignment is performed. It becomes winding.

【Example】

Hereinafter, the present invention will be described based on specific examples. First, the sectional shapes of the first coil wire 2 and the second coil wire 3 will be described with reference to FIG. A vertically elongated hexagonal shaped wire having the same conductor cross-sectional area as a round wire having a wire diameter d is manufactured, and a pair of parallel planes is manufactured so as to have a width of 0.9d. This vertically long hexagonal forming wire is further formed into a horizontally long hexagonal forming wire having the same conductor cross-sectional area as a round wire having a wire diameter of 0.65d, and is manufactured so that the width becomes 0.75d. The coil wire 3 is used. FIG. 1 shows two types of coil wires having different cross-sectional areas by using the multi-wire coil winding method having different wire diameters according to the present invention. It is a longitudinal cross-sectional view at the time of winding the 2nd coil wire material 3 which is a coil wire material to the winding frame 1 by 4 winding layers at a time. Winding start 2a in the first winding layer of the first coil wire 2
Is wound around the groove 1a having a pitch of 0.9d formed integrally with the winding frame 1 so that a set of parallel planes of the first coil wire 2 is at right angles to the winding direction to form aligned winding. . When the first coil wire 2 is wound up to 2f, which is the sixth turn in the fourth winding layer of the first coil wire, the first coil wire 2 has been wound, and once the first coil wire 2 has been wound. Is removed from the winding end 2b to the outer peripheral portion of the winding 1. The winding frame 1 is provided with a relief groove (not shown) for removing the coil wire 2 from the winding frame 1 at the end 2b of winding of the first coil wire 2. Next, as switching between coil wires having different cross-sectional areas, 1
The change from the coil wire 2 of the first line to the coil wire 3 of the second line will be described with reference to FIG. 1 and FIG.
Here, FIG. 3 is a longitudinal sectional view taken along the line III-III of FIG. As described above, the first wire coil wire 2 immediately after being removed from the bobbin 1 is a vertically long hexagonal shaped wire, and its cross-sectional shape is a vertically long hexagonal shape, but the connection is switched from the first wire to the second wire. From the middle of the wire 10, the second coil wire 3 is formed into a hexagonal shaped wire having a horizontally long hexagonal shape, which is the second coil wire material 3, and 2
The wire is advanced to 3a where winding of the coil wire 3 starts. Here, with reference to FIG. 2, which is an enlarged view of a portion A in FIG. 1, alignment of the fourth winding layer of the first coil wire 2 and the first winding layer of the second coil wire 3 in winding. The state will be described. As described above, the first coil wire 2 is a vertically long hexagonal forming wire, and the winding pitch H is equal to its horizontal width 0.9d,
The second coil wire 3 is a horizontally long hexagonal molded wire,
Its width is 0.75d. Here, since the gap between the sixth turn 2f in the fourth turn layer of the first coil wire 2 and the winding frame 1 is 0.45d, the first turn of the second turn of the coil wire 3 in the first turn layer is made. The winding 3e does not fall into the groove U formed by the gap. Then, a gap in the lateral direction parallel to the winding direction of the second coil wire 3 generated by the first winding 3e and the second winding 3g in the first winding layer of the second coil wire 3 V is as follows: V = (0.9d−0.75d) + (0.9d−0.75d) /2=0.225d. That is, the gap between the first turn and the second turn in each of the same winding layers of the second coil wire 3 is equal to the value of V. The gap W between the other turns in the same winding layer of the second coil wire 3 is W = 0.9d−0.75d = 0.15d. From the above description, when the second coil wire 3 is wound, it does not fall into the gap winding V or W in the winding layer before the winding of the second coil wire 3 having a width of 0.75d. Therefore, even if coil wires having different cross-sectional areas are sequentially wound from multiple coil wires having a larger cross-sectional area on a bobbin over multiple strips,
Since the second and subsequent coil wires do not exhibit a turbulent winding state, the dimensions of the winding outer diameter are constant, and there is no product defect exceeding the allowable dimensional tolerance. Further, if no turbulent winding occurs, the winding length becomes constant, and the coil resistance does not exceed the allowable value, so that the product performance can be stabilized. Further, since the first coil wire and the second coil wire can be set to have a cross-sectional shape capable of winding without dividing the winding process, the equipment cost and the installation location of the equipment can be reduced, thereby reducing the product cost. . The present invention is not limited to the combination of the coil wires made of the hexagonal shaped wires described above, but also includes the second coil wire material combined with the first hexagonal shaped wire having a substantially hexagonal shape as shown in FIG. A round wire as shown in FIG. 5B or a square shaped wire having a substantially square shape can also be applied.

【The invention's effect】

According to the present invention, the cross-sectional shape of the first coil wire is formed into a substantially hexagonal shape having three sets of parallel planes. The coil wires with different cross-sectional areas can be switched so that the cross-sectional area is reduced without being cut off within the winding range of the bobbin, and continuously wound around the bobbin. As a result, the coil wires having different cross-sectional areas follow the thread-shaped valleys formed by two sets of parallel planes in the winding direction of the first coil wire, thereby enabling multi-row winding. Therefore, since the dimensions of the winding outer diameter and the coil resistance value of the product are constant, product defects exceeding the allowable dimensional tolerance do not occur and the product performance is stabilized.
Further, since there is no need to separate the winding steps, there is an effect that an increase in product cost can be suppressed.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view showing a case in which two types of coil wires having different cross-sectional areas are wound using a multi-strip coil winding method having different wire diameters according to a specific embodiment of the present invention. FIG. 2 is an enlarged sectional view of a portion A in FIG. FIG. 3 is a longitudinal sectional view taken along the line III-III of FIG. FIG. 4 is a sectional view showing two types of coil wires used in the embodiment. FIG. 5 is an explanatory view showing the cross-sectional shapes of other coil wires that can be used in carrying out the method of winding a multi-strand coil having a different wire diameter according to the present invention, and combinations thereof. FIG. 6 is a longitudinal sectional view showing a case where two types of round wires having different wire diameters are wound around a winding frame in a conventional winding method. FIG. 7 is an enlarged sectional view of a portion B in FIG. FIG. 8 is an enlarged sectional view of a portion C in FIG. 1 ... reel, 2 ... 1st coil wire 3 ... 2nd coil wire, 10 ... connecting wire

Claims (1)

(57) [Claims] 1. A multi-row coil winding method having a different wire diameter, wherein a plurality of types of coil wires having different cross-sectional areas are sequentially wound from a coil wire having a larger cross-sectional area onto a bobbin over multiple turns. The cross-sectional shape of the first coil wire wound first on the bobbin has a substantially hexagonal shape having three sets of parallel planes. A pair of parallel planes of the first coil wire are brought into contact with each other so as to be perpendicular to the winding direction, and the switching between the coil wires having different cross-sectional areas is performed at any one of end face positions inside both end faces of the winding frame. A multi-layer winding method for coil wires of different diameters, characterized in that the coils are wound continuously without cutting.