JP3570946B2

JP3570946B2 - Winding method, winding jig and winding device

Info

Publication number: JP3570946B2
Application number: JP2000008676A
Authority: JP
Inventors: 秀樹関
Original assignee: Nittoku Engineering Co Ltd
Current assignee: Nittoku Engineering Co Ltd
Priority date: 2000-01-18
Filing date: 2000-01-18
Publication date: 2004-09-29
Anticipated expiration: 2020-01-18
Also published as: JP2001203120A

Description

【０００１】
【発明の属する技術分野】
本発明は、コイルの整列巻きを行う巻線方法と巻線治具および巻線装置の改良に関するものである。
【０００２】
【従来の技術】
従来、例えば図８に示すように、コイルの整列巻きを行うのに用いられる巻線治具１は、その外周に線材５を巻回する巻芯２と、巻芯２の両端にコイルを挟むように配置される第一、第二フランジ３，４とを備える。巻線治具１が線材５を繰り出すノズル（図示せず）に対して相対回転することにより、巻線治具１に対して線材５が多層に巻回され、コイルが形成される。
【０００３】
各層の巻数を同数にする整列巻きを行う場合、下層の巻線間に形成される螺旋溝状の窪みをガイドとして、その上層の巻線が配置されるため、１層目の巻数が２層目以降の巻数より１回多くなっている。
【０００４】
【発明が解決しようとする課題】
しかしながら、このような従来の巻線方法にあっては、１層目の巻線に合わせて第一、第二フランジ３，４の間隔を一定にしているため、３層目の巻線と第一フランジ３との間に大きな隙間が生じ、４層目の巻線が矢印で示すように落ちてしまう可能性があり、コイルの整列巻きが難しいという問題点があった。
【０００５】
本発明は上記の問題点を鑑みてなされたものであり、線材の巻き崩れを防止して整列巻きが行える巻線方法と巻線治具および巻線装置を提供することを目的とする。
【０００６】
【課題を解決するための手段】
第１の発明は、巻芯の両端に配置される第一、第二フランジを備え、巻芯に線材を多層状に巻回する巻線方法に適用する。
【０００７】
そして、１層目の巻数より２層目以降の巻数を１回減らし、２層目以降で各層の巻数を同数とし、前記第二フランジには段差の無いガイド面を形成し、前記第一フランジには少なくとも１層目の巻線に対峙する内周ガイド面と少なくとも４層目の巻線に対峙する外周ガイド面とを所定の段差Ｓを持って形成し、第一、第二フランジが１層目の巻線を挟む間隔を４層目の巻線を挟む間隔より大きくして巻き崩れを防止することを特徴とするものとした。
【０００９】
第３の発明は、巻芯の両端に配置される第一、第二フランジを備え、巻芯に線材を多層状に巻回する巻線治具に適用する。
そして、１層目の巻数より２層目以降の巻数を１回減らし、２層目以降で各層の巻数を同数とし、前記第二フランジには段差の無いガイド面を形成し、前記第一フランジには少なくとも１層目の巻線に対峙する内周ガイド面と少なくとも４層目の巻線に対峙する外周ガイド面とを所定の段差Ｓを持って形成し、第一、第二フランジが１層目の巻線を挟む間隔を４層目の巻線を挟む間隔より大きくして巻き崩れを防止することを特徴とするものとした。
【００１３】
第３の発明は、第２の発明に記載の巻線治具を備え、巻線治具に線材を巻回する巻線装置を特徴とするものとした。
【００１４】
【発明の作用および効果】第１、第２の発明によると、第一、第二フランジが下層の巻線を挟む間隔を上層の巻線を挟む間隔より大きくして巻き崩れを防止することにより、コイルの整列巻きが確実に行われ、品質向上がはかれる。
【００１５】
第１、第２の発明によると、第一、第二フランジが１層目の巻線を挟む間隔を４層目の巻線を挟む間隔より大きくして巻き崩れを防止することにより、コイルの同数整列巻きが確実に行われ、品質向上がはかれる。
【００１７】
第３の発明によると、線材の巻き崩れを防止して整列巻きが行える巻線装置を提供できる。
【００１８】
【発明の実施の形態】
以下、本発明の実施の形態を添付図面に基づいて説明する。
【００１９】
図１に示すボビンレスコイルの巻線装置１０は、線材５を所定の張力をもって供給するノズル６と、ノズル６に対して矢印で示すように回転する巻線治具１を備える。なお、フライヤー方式の巻線装置の場合、巻線治具に対してノズルが回動する。
【００２０】
図２に示すように、巻線治具１は、その外周に線材５を巻回する巻芯２と、巻芯２の両端にコイルを挟むように配置される第一、第二フランジ３，４とを備える。ノズル６に対して巻線治具１を回転させることにより、巻芯２の外周には第一、第二フランジ３，４の間に線材５が多層に巻回され、コイルが形成される。
【００２１】
軸芯２は第二フランジ４と一体形成される。軸芯２は第一フランジ３に対して軸方向に移動可能に設けられ、巻線が終了したコイルが軸芯２から抜き取られるようになっている。ボビンレスコイルは巻線が終了した後に熱風が吹き付けられ、その表面材が硬化することにより自立する。
【００２２】
図３に示すように、巻芯２に対して線材５を螺旋状に巻回し、巻線間に構成される螺旋溝状の窪みをガイドとして、その上層の巻線を配置する整列巻きが行われる。そして、１層目の巻数を２層目の巻数より１回多くし、２層目以降で各層の巻数を同数にする同数巻きが行われる。
【００２３】
本発明の要旨とするところであるが、第一、第二フランジ３，４が１層目の巻線を挟む間隔を４層目の巻線を挟む間隔より大きく形成し、４層目の巻き崩れを防止する。
【００２４】
第二フランジ４の端面には段差の無いガイド面４０が形成される。一方、第一フランジ３の端面には少なくとも１層目の巻線に対峙する内周ガイド面３１と、少なくとも４層目の巻線に対峙する外周ガイド面３２とが所定の段差Ｓを持って形成される。各ガイド面３１，３２，４０はそれぞれ巻芯２の回転軸と略直交する平面状に形成される。
【００２５】
ガイド面４０と内周ガイド面３１の間で１層目の巻線を挟む間隔は、ガイド面４０と外周ガイド面３２の間で４層目の巻線を挟む間隔より段差Ｓだけ大きく形成される。前述したように、１層目の巻数を２層目の巻数より１回多くし、２層目以降で各層の巻数を同数にする同数巻きが行われるため、段差Ｓは線材５の線径ｄの略半分に設定される。
【００２６】
巻芯２の断面は略三角形に形成される。内周ガイド面３１の外形は巻芯２の断面と同じく略三角形に形成され、巻芯２の外周面と内周ガイド面３１および段差部３３によって略一定の開口幅Ｌを持つ環状溝３４が形成される。この開口幅Ｌは、線径ｄの略１倍以上かつ略３．５倍以下の範囲に形成され、１層目の巻線端部が内周ガイド面３１に当接し、４層目の巻線端部が外周ガイド面３２に当接するように構成する。本実施の形態では、開口幅Ｌを線径ｄの略２倍とする。
【００２７】
外周ガイド面３２には線材５を環状溝３４に導くガイド溝３５が形成される。ガイド溝３５は環状溝３４から半径方向に延び、部分的に線径ｄより深く形成され、ガイド溝３５に収まった線材５が外周ガイド面３２から突出して４層目の巻線端部に当たらないようにする。環状溝３４とガイド溝３５は、掘り込み加工により形成される。
【００２８】
ガイド面に対する段差の形成は、巻線方向によって第一、第二フランジ３，４のいずれかに異なる。すなわち、第１層と第３層の巻線端面が軸方向について同一位置となる側のフランジは段差の無いガイド面とし、異なる側のフランジは段差のあるガイド面とする。
【００２９】
以上のように構成されて、次に作用について説明する。
【００３０】
巻線作業にあたっては、線材５の端部をガイド溝３５に係合させて、ノズル６に対して治具１を相対回転させる。これにより、巻芯２の外周には第一、第二フランジ３，４の間に線材５が多層に巻回され、コイルが形成される。
【００３１】
１層目の巻線は巻芯２の外周に螺旋状に巻回され、内周ガイド面３１とガイド面４０の間に隙間無く配置される。２層目以降の巻線は下層の巻線間に形成される螺旋溝状の窪みに配置される。このため、１層目の巻数が２層目以降の巻数より１回多くなっている。
【００３２】
第一、第二フランジ３，４が１層目の巻線を挟む間隔を４層目の巻線を挟む間隔より大きく形成していることにより、巻き崩れを防止する。すなわち、４層目の巻線端部は外周ガイド面３２に当接することにより３層目の巻線上から崩れることが防止され、コイルの整列巻きが確実に行われる。
【００３３】
なお、環状溝３４の開口幅Ｌは線径ｄの略１倍以上かつ略３．５倍以下の範囲で任意に設定されるが、実験により開口幅Ｌを線径ｄの略１．５倍に設定すると、安定した巻回が行われることがわかっている。
【００３４】
次に図４、図５に示す他の実施の形態は、軸芯２の先端面２１から例えば矩形断面を持つ凸部２２を突出させる一方、第一フランジ３の内周ガイド面３１に凸部２２を受け入れる凹部３６を形成するものである。
【００３５】
この場合、凸部２２が凹部３６に嵌合することにより、第一、第二フランジ３，４が一体となって回転する。
【００３６】
次に図６に示す他の実施の形態は、第一、第二フランジ３，４が巻線を挟む間隔を部分的に可変にするものである。
【００３７】
内周ガイド面３１を有する可動部材３７を備え、第一フランジ３には可動部材３７を軸方向に摺動可能に嵌合させる穴３８が形成される。穴３８の底面と可動部材３７の間にはスプリング３９が介装される。
【００３８】
１層目から３層目の巻線が行われる場合、図６に示すように、内周ガイド面３１が外周ガイド面３２と同一面上にあり、段差Ｓを零とする。４層目の巻線が行われる場合、図７に矢印で示すように、第二フランジ４を軸方向に所定量だけ移動させ、巻芯２によって可動部材３７を穴３８に押し込み、段差Ｓを線径ｄの略半分の寸法にする。これにより、４層目の巻線端部が外周ガイド面３２に当接し、３層目の巻線上から崩れることが防止される。
【００３９】
この場合、線径ｄに応じて第一、第二フランジ３，４間の段差Ｓを調節することができ、一つの巻線治具１によって幅広い太さの線材に対応できる。
【００４０】
本発明は上記の実施の形態に限定されずに、その技術的な思想の範囲内において種々の変更がなしうることは明白である。
【図面の簡単な説明】
【図１】本発明の実施の形態を示す巻線治具等の斜視図。
【図２】同じく巻線治具の分解斜視図。
【図３】同じく巻線治具等の側面図。
【図４】他の実施の形態を示す巻線治具の分解斜視図。
【図５】同じく巻線治具等の側面図。
【図６】さらに他の実施の形態を示す巻線治具等の側面図。
【図７】同じく巻線治具の動きを示す側面図。
【図８】従来例を示す巻線治具等の側面図。
【符号の説明】
１巻線装置
２巻芯
３第一フランジ
４第二フランジ
５線材
３１内周ガイド面
３２外周ガイド面
３３段差部
３４環状溝[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a winding method for aligning and winding coils, a winding jig, and an improvement in a winding device.
[0002]
[Prior art]
Conventionally, as shown in FIG. 8, for example, a winding jig 1 used to perform aligned winding of a coil has a winding core 2 around which a wire 5 is wound, and a coil sandwiched between both ends of the winding core 2. And first and second flanges 3 and 4 arranged as described above. When the winding jig 1 relatively rotates with respect to a nozzle (not shown) that feeds out the wire 5, the wire 5 is wound around the winding jig 1 in multiple layers to form a coil.
[0003]
When performing the aligned winding in which the number of turns of each layer is the same, the winding of the upper layer is arranged using the spiral groove-shaped recess formed between the windings of the lower layer as a guide, so that the number of turns of the first layer is two layers. It is one more than the number of turns after the first.
[0004]
[Problems to be solved by the invention]
However, in such a conventional winding method, since the distance between the first and second flanges 3 and 4 is made constant in accordance with the winding of the first layer, the winding of the third layer and the second flange are fixed. There is a possibility that a large gap is generated between the first flange 3 and the winding of the fourth layer, as shown by an arrow, and the coil is difficult to align and wind.
[0005]
The present invention has been made in view of the above problems, and an object of the present invention is to provide a winding method, a winding jig, and a winding device capable of preventing winding collapse of a wire and performing aligned winding.
[0006]
[Means for Solving the Problems]
The first invention is applied to a winding method including first and second flanges arranged at both ends of a core and winding a wire around the core in a multilayered manner.
[0007]
The number of turns of the second and subsequent layers is reduced by one from the number of turns of the first layer, and the number of turns of each layer is the same in the second and subsequent layers. A guide surface having no step is formed on the second flange, and the first flange is formed. The first and second flanges are formed with a predetermined step S between an inner peripheral guide surface facing at least a first layer winding and an outer peripheral guide surface facing at least a fourth layer winding. The spacing between the windings of the fourth layer is made larger than the spacing between the windings of the fourth layer to prevent winding collapse.
[0009]
The third invention is applied to a winding jig provided with first and second flanges disposed at both ends of a winding core, and winding a wire around the winding core in a multilayer shape.
The number of turns of the second and subsequent layers is reduced by one from the number of turns of the first layer, and the number of turns of each layer is the same in the second and subsequent layers. A guide surface having no step is formed on the second flange, and the first flange is formed. The first and second flanges are formed with a predetermined step S between an inner peripheral guide surface facing at least a first layer winding and an outer peripheral guide surface facing at least a fourth layer winding. The spacing between the windings of the fourth layer is made larger than the spacing between the windings of the fourth layer to prevent winding collapse.
[0013]
According to a third aspect of the invention, there is provided a winding device that includes the winding jig according to the second aspect of the invention and winds a wire around the winding jig.
[0014]
SUMMARY OF THE INVENTION AND EFFECT] first, according to the second invention, the first, by the second flange to prevent collapse winding to greater than the distance sandwiching the underlying winding layer of the winding apart sandwiching the In addition, the coils are aligned and wound reliably, and the quality is improved.
[0015]
First, according to the second invention, by first, second flange to prevent collapse winding made larger than the interval sandwiching fourth layer windings apart sandwiching the first layer of the winding, the coil The same number of aligned windings is reliably performed, and quality is improved.
[0017]
According to the third aspect of the invention, it is possible to provide a winding device that can perform aligned winding while preventing winding of the wire.
[0018]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.
[0019]
A bobbin-less coil winding device 10 shown in FIG. 1 includes a nozzle 6 that supplies a wire 5 with a predetermined tension, and a winding jig 1 that rotates as shown by an arrow with respect to the nozzle 6. In the case of a flyer-type winding device, the nozzle rotates with respect to the winding jig.
[0020]
As shown in FIG. 2, the winding jig 1 has a winding core 2 around which a wire 5 is wound, and first and second flanges 3 arranged on both ends of the winding core 2 so as to sandwich a coil. 4 is provided. By rotating the winding jig 1 with respect to the nozzle 6, the wire 5 is wound around the outer periphery of the core 2 between the first and second flanges 3 and 4 in multiple layers to form a coil.
[0021]
The shaft core 2 is formed integrally with the second flange 4. The shaft core 2 is provided so as to be movable in the axial direction with respect to the first flange 3, and the coil whose winding has been completed is extracted from the shaft core 2. The bobbin-less coil is self-supported by blowing hot air after the winding is completed and hardening its surface material.
[0022]
As shown in FIG. 3, a wire 5 is spirally wound around the winding core 2, and a spiral groove-shaped recess formed between the windings is used as a guide to arrange the windings in the upper layer. Is Then, the number of turns of the first layer is increased by one more than the number of turns of the second layer, and the same number of turns of the same number of turns are performed on the second and subsequent layers.
[0023]
The first and second flanges 3 and 4 are formed so that the interval between the first-layer windings is larger than the interval between the fourth-layer windings. To prevent
[0024]
A guide surface 40 having no step is formed on the end surface of the second flange 4. On the other hand, at the end face of the first flange 3, an inner peripheral guide surface 31 facing at least the first layer winding and an outer peripheral guide surface 32 facing at least the fourth layer winding have a predetermined step S. It is formed. Each guide surface 31, 32, 40 is formed in a planar shape substantially orthogonal to the rotation axis of the core 2.
[0025]
The interval between the guide surface 40 and the inner peripheral guide surface 31 that sandwiches the first layer winding is formed to be larger by the step S than the interval between the guide surface 40 and the outer peripheral guide surface 32 that sandwiches the fourth layer winding. You. As described above, since the number of turns of the first layer is larger than the number of turns of the second layer by one, and the number of turns of each layer is the same for the second and subsequent layers, the step S is the wire diameter d of the wire 5. Is set to about half.
[0026]
The cross section of the winding core 2 is formed in a substantially triangular shape. The outer shape of the inner peripheral guide surface 31 is formed in a substantially triangular shape similarly to the cross section of the core 2, and an annular groove 34 having a substantially constant opening width L is formed by the outer peripheral surface of the core 2, the inner peripheral guide surface 31, and the step portion 33. It is formed. The opening width L is formed in a range of approximately 1 times or more and approximately 3.5 times or less of the wire diameter d, and the winding end of the first layer abuts against the inner circumferential guide surface 31 and the winding width of the fourth layer d. The end of the wire is configured to contact the outer peripheral guide surface 32. In the present embodiment, the opening width L is approximately twice the wire diameter d.
[0027]
A guide groove 35 for guiding the wire 5 to the annular groove 34 is formed on the outer peripheral guide surface 32. The guide groove 35 extends in the radial direction from the annular groove 34 and is partially formed deeper than the wire diameter d. When the wire 5 accommodated in the guide groove 35 projects from the outer peripheral guide surface 32 and hits the winding end of the fourth layer. Not to be. The annular groove 34 and the guide groove 35 are formed by digging.
[0028]
The formation of the step with respect to the guide surface depends on one of the first and second flanges 3 and 4 depending on the winding direction. That is, the flange on the side where the winding end faces of the first layer and the third layer are at the same position in the axial direction is a guide surface without a step, and the flange on the different side is a guide surface with a step.
[0029]
The operation as described above will now be described.
[0030]
In the winding operation, the end of the wire 5 is engaged with the guide groove 35, and the jig 1 is relatively rotated with respect to the nozzle 6. As a result, the wire 5 is wound around the outer periphery of the core 2 between the first and second flanges 3 and 4 in multiple layers to form a coil.
[0031]
The first-layer winding is spirally wound around the outer periphery of the winding core 2 and is disposed between the inner peripheral guide surface 31 and the guide surface 40 without any gap. The windings of the second and subsequent layers are arranged in spiral groove-shaped depressions formed between the windings of the lower layer. Therefore, the number of turns of the first layer is one more than the number of turns of the second and subsequent layers.
[0032]
Since the first and second flanges 3 and 4 are formed so that the interval between the first-layer windings is larger than the interval between the fourth-layer windings, winding collapse is prevented. That is, the winding end of the fourth layer is prevented from collapsing from the third layer winding by contacting the outer circumferential guide surface 32, and the winding of the coils is reliably performed.
[0033]
The opening width L of the annular groove 34 is arbitrarily set within a range of about 1 to 3.5 times the wire diameter d. It has been found that stable winding is performed when set to.
[0034]
Next, in another embodiment shown in FIGS. 4 and 5, a convex portion 22 having, for example, a rectangular cross section is projected from a front end surface 21 of the shaft core 2, while a convex portion A recess 36 for receiving the recess 22 is formed.
[0035]
In this case, the first and second flanges 3 and 4 rotate integrally by fitting the protrusion 22 into the recess 36.
[0036]
Next, in another embodiment shown in FIG. 6, the interval between the first and second flanges 3, 4 sandwiching the winding is made partially variable.
[0037]
The first flange 3 is provided with a hole 38 for fitting the movable member 37 slidably in the axial direction. A spring 39 is interposed between the bottom surface of the hole 38 and the movable member 37.
[0038]
When the winding of the first to third layers is performed, as shown in FIG. 6, the inner peripheral guide surface 31 is on the same plane as the outer peripheral guide surface 32, and the step S is set to zero. When the winding of the fourth layer is performed, the second flange 4 is moved in the axial direction by a predetermined amount, and the movable member 37 is pushed into the hole 38 by the winding core 2 as shown by an arrow in FIG. Make the dimension approximately half the wire diameter d. This prevents the end of the fourth layer winding from coming into contact with the outer circumferential guide surface 32 and prevents the third layer winding from collapsing.
[0039]
In this case, the step S between the first and second flanges 3 and 4 can be adjusted according to the wire diameter d, and a single wire jig 1 can be used for a wire having a wide thickness.
[0040]
It is apparent that the present invention is not limited to the above-described embodiment, and that various changes can be made within the scope of the technical idea.
[Brief description of the drawings]
FIG. 1 is a perspective view of a winding jig and the like showing an embodiment of the present invention.
FIG. 2 is an exploded perspective view of the same winding jig.
FIG. 3 is a side view of a winding jig and the like.
FIG. 4 is an exploded perspective view of a winding jig showing another embodiment.
FIG. 5 is a side view of the winding jig and the like.
FIG. 6 is a side view of a winding jig and the like showing still another embodiment.
FIG. 7 is a side view showing the movement of the winding jig.
FIG. 8 is a side view of a conventional example of a winding jig.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Winding apparatus 2 Core 3 First flange 4 Second flange 5 Wire 31 Inner peripheral guide surface 32 Outer peripheral guide surface 33 Step 34 Annular groove

Claims

In a winding method including first and second flanges disposed on both ends of a core and winding a wire around the core in a multilayer shape, the number of turns of the second and subsequent layers is reduced by one from the number of turns of the first layer The second and subsequent layers have the same number of turns in each layer, the second flange has a guide surface without a step, and the first flange has at least an inner peripheral guide surface facing the winding of the first layer. The outer circumferential guide surface facing the fourth layer winding is formed with a predetermined step S, and the interval between the first and second flanges sandwiching the first layer winding is the interval between the fourth layer winding. A winding method characterized by being made larger .

A winding jig provided with first and second flanges disposed at both ends of a winding core and winding a wire in a multilayer shape around the winding core, wherein the number of turns of the second and subsequent layers from the first layer is one. The number of turns of each layer is reduced to the same number in the second and subsequent layers, a guide surface having no step is formed on the second flange, and the first flange has an inner peripheral guide surface facing at least the first layer winding. An outer circumferential guide surface facing at least the fourth layer winding is formed with a predetermined step S, and the first and second flanges sandwich the first layer winding so as to sandwich the fourth layer winding. A winding jig characterized by being larger than the interval.

A winding device comprising the winding jig according to claim 2, wherein a wire is wound around the winding jig.