JP3614642B2 - Inductance element manufacturing method and winding device used in the manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
【Technical field】
The present invention relates to a method of manufacturing an inductance element used in a DC / DC converter circuit, a power supply circuit, and the like, and a winding device used in the manufacturing method.
[0002]
[Prior art]
FIG. 5 is a partial sectional view of a conventional inductance element, and FIG. 6 is a side view showing a conventional method for manufacturing an inductance element. In the conventional inductance element, a metal plate terminal 57 is fixed to the bottom surface of the drum core 51. The drum-shaped core 51 is provided with flanges 53 and 54 at both ends of a shaft 52 to form a winding groove 55. In this winding groove 55, a winding 56 is wound in multiple layers to form a coil. Both ends of the winding 56 are connected to metal plate terminals 57, respectively. This inductance element has been manufactured by the following method. First, the drum core 51 is attached to a winding device (not shown) and, as shown in FIG. 6, after one end of the winding 56 is connected to the metal plate terminal 57, the drum core 51 is attached to the flange 54 of the drum core 51. Along the axis 52. Next, the winding 56 is wound in multiple layers in the winding groove 55 using a flyer (not shown) of the winding device. The other end of the winding 56 is connected to the metal plate terminal 57.
[0003]
[Problems to be solved by the invention]
In the inductance element thus formed, the winding start side of the winding 56 is guided to the shaft 52 along the flange 54 of the drum-shaped core 51, and the winding 56 is wound in multiple layers in the winding groove 55. The number of turns after the second layer is reduced by one on the winding start side of the winding 56. Therefore, the conventional inductance element has a problem in that the winding space factor in the winding groove 55 is low, so that the inductance value decreases and the DC resistance value increases. Further, in this inductance element, when the winding 56 is wound in the winding groove 55, the second layer of the winding 56 is wound on the winding start side of the winding 56, so that winding disturbance occurs. Therefore, there is a problem that the inductance value of the inductance element is likely to vary. In recent years, downsizing of this type of inductance element is strongly desired. Under such circumstances, when the width of the winding groove 55 of the drum-shaped core 51, that is, the interval between the flanges 53 and 54 is narrowed in order to reduce the shape, the shape is reduced, and the DC resistance value is reduced. Therefore, when the diameter of the winding 56 is increased, or when a flat wire is used as the winding 56, these problems are significant and predetermined characteristics cannot be obtained.
[0004]
The present invention provides an inductance element manufacturing method capable of increasing a winding space factor in a winding groove of a drum-shaped core, obtaining a predetermined inductance value even when downsized, and reducing a DC resistance value. It aims at providing the winding apparatus used for the manufacturing method. Another object of the present invention is to provide a method of manufacturing an inductance element that can eliminate the variation in inductance value of the inductance element due to winding disturbance, and a winding device used in the manufacturing method.
[0005]
[Means for Solving the Problems]
In the method of manufacturing an inductance element according to the present invention, a middle part of a winding supplied from a winding supply unit is brought into contact with a winding shaft of a coil winding unit held by a spindle of a winding device, and a predetermined number of turns The first step of fixing the end of the winding to the fryer equipped with the winding number setting means for stocking the winding of the minute, the flyer is rotated around the winding axis of the coil winding portion held by the spindle in the fixed state After the winding has been wound a predetermined number of times, the fixed spindle is allowed to rotate, the flyer is rotated in the same direction as the previous time, and the winding supply section is wound around the winding axis of the coil winding section. A second step of winding the wire;
[0006]
In addition, the winding device of the present invention includes a fryer provided with a winding number setting means for stocking a predetermined number of windings, and the winding number setting means has an end of a winding attached so as to be movable along the axis of the fryer. Wire holder for holding the part, the shaft is equipped with a stopper that stops the wire holder integrated with the fryer, the coil winding part is attached , the spindle that stops rotation and can be rotated, and the coil winding part has A winding supply unit for supplying windings is provided.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
The inductance element according to the present invention is manufactured as follows. First, the winding part of the coil supplied from the winding supply part is brought into contact with the winding axis of the coil winding part held by the spindle of the winding device, and the number of turns in which a predetermined number of turns are stocked. The ends of the windings are fixed to a fryer equipped with setting means. Next, after the flyer is rotated around the winding axis of the coil winding portion held by the spindle in a fixed state, the winding is wound a predetermined number of times, and then the coil winding fixed to the rotatable spindle is performed. By rotating the flyer in the same direction as the rotation direction, the winding is wound around the winding axis of the coil winding unit from the winding supply unit a predetermined number of times.
[0008]
The winding device of the present invention includes a fryer provided with a winding number setting means for stocking a predetermined number of windings, a spindle that is attached with a coil winding portion and can be rotated after the fryer has rotated a predetermined number of times, and a coil A winding supply unit for supplying windings to the winding unit is provided. The winding number setting means for stocking a predetermined number of windings of the fryer includes a shaft provided with a stopper integrated with the fryer, and a wire holder for holding the end of the winding mounted so as to be movable along the shaft. Prepare.
[0009]
【Example】
Hereinafter, a method of manufacturing an inductance element according to the present invention and a winding device used for the manufacturing will be described with reference to FIGS.
[0010]
The inductance element manufactured by the manufacturing method of the present invention includes a coil winding portion 11 and a winding 16 as shown in FIGS. The coil winding part 11 is formed by sintering magnetic powder, and a so-called drum-shaped core in which circular plate-shaped scissors 13 and 14 are provided at both ends of a cylindrical winding shaft 12 is used. A winding groove 15 is formed between the flanges 13 and 14. In the coil winding portion 11, the winding 16 is wound around the winding shaft 12. A so-called rectangular wire is used for the winding 16. For example, when the winding 16 is wound in three layers in the winding groove 15, three layers of the winding in which one end 16 </ b> A and the other end 16 </ b> B are wound in three layers in the winding groove 15. It is wound to come to the eyes. One end 16 </ b> A and the other end 16 </ b> B of the winding 16 are respectively connected to the metal plate terminal 17 attached to the end face of the coil winding portion 11.
[0011]
FIG. 3 is a side view showing an embodiment of a winding device used in the method for manufacturing an inductance element of the present invention.
The winding device includes a fryer 31, a spindle 35 to which the coil winding unit 11 is attached, and a winding supply unit (not shown) that supplies windings to the coil winding unit 11.
The flyer 31 is provided with a winding number setting means comprising a shaft 33 having both ends attached to a fryer frame body 32 and a wire holder 34 fixed to the end of the winding. It is done. In the flyer 31, the frame 32 rotates around the spindle 35 by a motor or the like. The spindle 35 is fixed while the flyer 31 rotates a predetermined number of times in one winding, and is freely released when the other winding is wound a predetermined number of times . The flyer 31 and the spindle 35 are arranged so that the rotation axis of the flyer 31 and the rotation axis of the spindle 35 are coaxial.
[0012]
FIG. 4 is a top view showing an embodiment of a method of manufacturing an inductance element according to the present invention.
The inductance element shown in FIGS. 1 and 2 is manufactured as follows using this winding device.
First, the coil winding part 11 is held by the spindle 35 of the winding device. Next, an intermediate portion of the winding 16 supplied from the winding supply unit (not shown) is brought into contact with the winding shaft 12 of the coil winding unit 11, and the end of the winding 16 is connected to the wire holder 34 of the fryer 31. The part is fixed.
At this time, the line holder 34 is moved on the shaft 33 of the frame 32 provided on the fryer 31 by a length L corresponding to the designated number of turns from the starting point of the stopper 32a. For example, the length of three rotations moves the line holder 34 to a position at a distance L from the stopper . In other words, for example, a winding having a length of 3 rotations (that is, 3 turns) is stocked in the number-of-turns setting means depending on the distance L of the wire holder.
[0013]
Accordingly, by rotating the flyer 31 a predetermined number of times while the spindle 35 is fixed so as not to rotate, the winding 16 stocked in the winding number setting means of the fryer 31 is placed in the winding groove 15 of the coil winding portion 11. A predetermined number of turns (for example, 3 turns) is wound on one of the heel sides. That is, when the wire holder 34 of the fryer 31 hits the stopper 32a, one winding is finished. Then, by releasing the fixed spindle 35 rotatably, the other winding rotates the flyer 31 a predetermined number of times in the same direction as the previous rotation direction, thereby rotating the flyer 31 (the line holder 34 is fixed). In this state, that is, a state where it hits the stopper 32 a), the spindle 35 is rotated via the winding 16. By rotating the spindle 35, the winding 16 is drawn from a winding supply section (not shown) which is the other winding 16, and a predetermined number of turns are wound on the other side of the winding groove 15 of the coil winding section 11. Turned.
[0014]
Accordingly, by rotating the flyer 31 a predetermined number of times, the winding 16 supplied from the winding supply unit (for example, 3 turns) is wound on the other side of the winding groove 15 of the coil winding unit 11. The
In this way, a coil is formed in the coil winding portion 11. Then, both ends of the winding 16 positioned on the outer periphery (for example, the third layer) of the coil are drawn from the winding groove 15 of the coil winding portion 11 and connected to the metal plate terminal 17 respectively. Reference numeral 41 denotes a pulley for guiding the winding 16 supplied from the winding supply unit to the coil winding unit 11.
As described above, the inductance element manufacturing method of the present invention can change the winding direction of the coil winding portion without changing the rotation direction of the fryer 31 by fixing and releasing the winding number setting means and the spindle 35. it can. Therefore, winding in both directions can be performed by simple rotation in one direction without taking a complicated rotation method of the operator or the motor.
As described above, it can be easily manufactured by a simple winding device. In particular, the manufacturing method and the winding device are suitable for an inductance used for a large current with a small number of turns, a choke coil for a DC-DC converter, and the like.
[0015]
As mentioned above, although the Example of the manufacturing method of the inductance element of this invention and the winding apparatus used for the manufacturing method were described, it is not restricted to these Examples. For example, the flyer of the winding device may be provided with a bobbin for stocking a predetermined length of winding on the frame or the rotating shaft of the fryer to form the winding number setting means. The terminal of the inductance element may be attached to the coil winding part after winding the winding, or may be attached to the coil winding part in advance. Furthermore, a wire having a round cross section may be used for the winding.
[0016]
【The invention's effect】
In the inductance element manufacturing method of the present invention, both ends of the winding can be positioned on the outermost periphery of the winding wound in multiple layers in the winding groove of the coil winding portion. The winding space factor can be improved by about 50% from the conventional one. Therefore, the inductance element according to the present invention can increase the inductance value as compared with the conventional case even when a winding or a rectangular wire having a large diameter is used to reduce the DC resistance value. Therefore, it is possible to reduce the width of the winding groove of the coil winding part and make it smaller than the conventional one.
[0017]
In addition, according to the method of manufacturing an inductance element of the present invention, the middle of the winding is brought into contact with the winding shaft of the coil winding portion, and both ends of the winding are positioned on the outermost circumference of the winding wound in multiple layers. The winding disturbance when winding the winding in the winding groove can be prevented. Therefore, variation in the inductance value of the inductance element due to winding disturbance can be eliminated.
[0018]
The winding device of the present invention can supply windings from a fryer and a winding supply unit having a winding number setting means for stocking windings for a predetermined number of turns to a coil winding unit attached to a spindle. By making the middle of the wire come into contact with the coil winding portion, both ends of the winding can be positioned on the outermost periphery of the winding wound in multiple layers in the winding groove of the coil winding portion.
In addition, the winding device of the present invention can set the length of the winding stocked in the winding setting means of the fryer and the rotational speed of the fryer on one side of the winding groove of the coil winding portion. The number of windings to be wound and the number of windings wound on the other side can be made the same or different.
[Brief description of the drawings]
FIG. 1 is a side view of an inductance element manufactured by a manufacturing method of the present invention.
FIG. 2 is a partial cross-sectional view of FIG.
FIG. 3 is a side view showing an embodiment of a winding device used in the method for manufacturing an inductance element of the present invention.
FIG. 4 is a top view showing an embodiment of a method of manufacturing an inductance element according to the present invention.
FIG. 5 is a partial cross-sectional view of a conventional inductance element.
FIG. 6 is a side view of a conventional method for manufacturing an inductance element.
[Explanation of symbols]
11 Coil winding part 13, 14 鍔 15 Winding groove 16 Winding

Claims (2)

A winding number setting means for bringing a winding portion of a coil supplied from a winding supply portion into contact with a winding axis of a coil winding portion held by a spindle of a winding device and stocking a predetermined number of windings. A first step of fixing the end of the winding to the fryer equipped with the winding, rotating the flyer around the winding axis of the coil winding portion held by the spindle in a fixed state, and winding the winding a predetermined number of times After winding , the spindle in the fixed state is made rotatable, the flyer is rotated in the same direction as the previous time, and the winding is wound around the winding axis of the coil winding unit. A method for manufacturing an inductance element, comprising a second step. A fryer equipped with a winding number setting means for stocking a predetermined number of windings, and the winding number setting means is a wire holder for holding the end of the winding mounted movably along the axis of the fryer The shaft is provided with a stopper for stopping the wire holder integrated with the fryer, a coil winding part is mounted, a spindle which stops rotation and can be rotated, and supplies windings to the coil winding part A winding apparatus comprising a winding supply section.

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