JP3665942B2 - Flat coil winding device and flat coil manufacturing method - Google Patents

Description

[0001]
[Industrial application fields]
The present invention relates to a winding device and a manufacturing method for a flat rectangular coil used in, for example, a noise filter, a line filter, a transformer, and the like, and more particularly to a device suitable for manufacturing a thin vertical coil.
[0002]
[Prior art]
A flat vertical winding coil is wound around a winding shaft so that the long side (vertical side) of the cross section of the flat wire is substantially perpendicular to the winding core. Since the empty space is reduced as compared with a general round wire coil, the winding density is high. For example, in the case of the same L value characteristic, it is possible to design a coil that is small and has a larger current capacity. In addition, surface mount type transformers and the like are particularly required to be small and have a large wattage. Even in this case, a small and high power can be realized by using a thin rectangular wire.
[0003]
In order to wind such a rectangular vertical winding coil, the present inventor has already developed a winding device and a manufacturing method of the rectangular coil, and proposed in Japanese Patent Application No. 8-103300.
[0004]
This winding device has the configuration shown in FIGS. That is, as shown in FIGS. 4 and 6, the attachment 30 rotated with the mounting shaft 30 a fitted to the rotating shaft 29 has a mounting hole 32 for the winding shaft 31, and the mounting shaft 32 has the mounting shaft 32. The front end fitting part 31a of 31 is detachably fitted by a detent structure. Around the winding shaft mounting hole 32 of the attachment 30, a guide portion 34 having a receiving surface (guide surface) 33 that makes contact with the surface of the flat wire 4 on the winding start side is integrally formed.
[0005]
When performing the winding work using this winding device, as shown in the plan view of FIG. 6, the end of the flat wire 4 is bent and locked to the locking portion 35 provided on the attachment 30 to be fixed. At the same time, the vicinity of the tip of the flat wire 4 is applied to the winding start side receiving surface a of the guide surface 33, and the flat wire 4 is directed toward the guide surface 33 by the side pressing roller 7 as shown in FIG. As shown in FIG. 6, with the tension indicated by the arrow e applied to the rectangular wire 4, the winding shaft 31 is rotated together with the attachment 30, and the side presser roller 7 is moved in synchronization with the coil winding speed. Thus, the flat wire 4 is wound around the winding shaft 31 to manufacture a coil.
[0006]
[Problems to be solved by the invention]
In the case of manufacturing a winding using the rectangular wire 4 as described above, as shown in FIG. 5B, the thickness x of the rectangular wire 4 becomes relatively small, and the ratio y / x to the width y increases. A small coil with a large number of turns can be obtained. However, when the ratio y / x increases, a large bending force is required, and thus a large tension is required for the flat wire 4. However, when a large tension is applied to the flat wire 4, the flat wire 4 is twisted or disconnected.
[0007]
In order to solve such a problem, as shown in the side view of FIG. 5A and the plan view of FIG. 6, the winding is performed while pressing the rectangular wire 4 from the outer peripheral side of the rectangular wire 4 by the pressing roller 5. If it does, it will become easy to obtain the coil of the diameter as designed, without making tension too much, ie, without causing a disconnection or twist by excessive tension, and without causing the coil to swell.
[0008]
However, as shown in FIG. 6, in order to cope with further miniaturization of the coil, if a small coil is to be manufactured using a thin flat wire 4 having a thickness x of less than 0.3 mm, the flat wire 4 is placed outside. The rectangular wire 4 is easily detached from the outer periphery pressing roller 5 that is pressed from the outer periphery.
[0009]
That is, in particular, the thin rectangular wire 4 has rounded both end faces as shown in FIG. 5C in order to make it easy to attach the insulating coating at the corner. For this reason, in the case of a thin flat wire having a thickness of less than 0.3 mm, there is almost no flat portion at the outer peripheral end. For example, when winding a flat wire having a thickness x of 0.1 mm shown in FIG. The width f of the presser part 5 must be smaller than the thickness x = 0.1 mm of the flat wire 4. In this case, f needs to be about 0.07 mm, but in reality, the end face of the wire is R Due to the shape, the thickness i of the portion that can be pressed by the outer periphery pressing roller 5 is only about 0.02 mm, and it is easily disengaged due to a slight deviation of the roller feed, the falling of the wire, the variation, etc. It was difficult.
[0010]
As shown by a two-dot chain line in FIGS. 5A and 6, the outer periphery of the rectangular wire 4 is placed at the center of the outer periphery pressing roller 5 so that the outer periphery pressing roller 5 does not come off so as to completely cover the rectangular wire 4. When the presser roller 5 is set in contact, the winding start portion 4 a of the flat wire 4 interferes with the presser roller 5 as the attachment 30 and the winding shaft 31 rotate, and the flat wire 4 is disconnected or the winding shaft 31 rotates. Is impossible. For these reasons, it has been difficult to manufacture a coil using a rectangular wire having a thickness of less than 0.3 mm.
[0011]
In view of the above-described problems, an object of the present invention is to provide a winding device for a rectangular coil and a method for manufacturing a rectangular coil, which can be manufactured even when a thin rectangular wire is used.
[0012]
[Means for Solving the Problems]
The winding device for a rectangular coil according to claim 1 is a helical winding device for a flat rectangular coil,
One end is inserted into the winding shaft mounting portion provided on the attachment mounted on the rotating shaft of the winding device , or is concentric with the winding shaft mounting portion, and a rectangular wire is formed from the winding shaft mounting portion. A winding shaft with a radius smaller by the width is provided ,
A guide surface is provided on the winding shaft side end of the winding shaft mounting portion so as to abut one turn of the coil winding start side end surface;
The guide surface has a step substantially equal to the thickness of a flat wire between the receiving surface on the winding start side and the receiving surface at the end of one turn,
A groove for inserting and setting a bent portion on the leading end side of the flat wire in the longitudinal direction of the winding shaft from the coil receiving surface on the winding start side of the guide surface is provided in the winding shaft mounting portion,
The winding shaft mounting portion is provided with a fixing means for fixing the flat wire attached to the groove,
Wherein the side pressing roller for pressing the flat wire from the coil front side, the flat wire is characterized by comprising an outer peripheral pressing roller for pressing the outer periphery of a portion bent is supplied to the winding shaft.
According to a second aspect of the present invention, there is provided a winding device for a rectangular coil according to the first aspect, wherein the fixing means is provided on the winding shaft attaching portion, and includes a push claw that presses and fixes the bent portion of the rectangular wire with a spring.
It is characterized by that.
[0013]
The method for manufacturing a rectangular coil according to claim 3 is provided on the attachment of the winding device , and the winding shaft mounting portion provided integrally or concentrically with the winding shaft receives one turn of the coil on the winding start side . And while forming the guide surface which has the level | step difference for the thickness of a substantially flat wire between the winding start side receiving surface and the receiving surface of the end part of 1 round ,
Said winding shaft attachment portion of the attachment, the groove having a slightly larger width than the thickness of the flat wire, is provided on the longitudinal direction of the winding shaft from the winding start side of the coil receiving surface of the guide surface, to the winding axis mounting portion , A fixing means for fixing the flat wire set in the groove is provided ,
Insert the bent portion on the front end side of the flat wire into the groove, and fix and set by the fixing means , and apply the vicinity of the bent portion of the flat wire to the winding start side receiving surface of the guide surface,
The flat wire is pressed against the guide surface by a side press roller that presses the flat wire from the front surface, the outer presser roller is pressed against the outer periphery of the flat wire, and the winding shaft is rotated while the winding device is rotated. A coil is formed by winding a flat wire around the wire .
[0014]
[Action]
In the present invention, the bent portion of the flat wire is set by being fitted in the groove provided in the longitudinal direction of the winding shaft at the winding shaft mounting portion of the attachment. The starting part does not protrude from the outer surface. For this reason, even if the rectangular wire is pressed from the outside of the coil at the center of the outer circumferential pressing roller while rotating the winding shaft, the winding start side of the rectangular wire does not interfere with the outer circumferential pressing roller.
[0015]
【Example】
1A and 1B are a plan view and a side view, respectively, showing an embodiment of a winding device according to the present invention. In FIG. 1, the attachment 2 is detachably attached by fitting its attachment shaft 8 to the rotating shaft 3 of the winding device and fixing it with a bolt 9. As shown in the perspective view of FIG. 2 (A) and the front view of FIG. 2 (B), the attachment 2 is provided with the attachment portion 10 of the winding shaft 1 protruding. The mounting portion 10 has a cylindrical shape with an outer diameter substantially the same as the outer diameter of the coil to be manufactured, and the tip fitting portion 1a of the winding shaft 1 is detachably attached with a non-rotating structure and concentrically with the mounting portion 10. Is done.
[0016]
As shown in FIGS. 1 (A) and 1 (B), the guide roller 6 of the flat wire 4, the side presser roller 7 for pressing the flat wire 4 from the front side of the coil, and the flat wire 4 on the outer peripheral side of the coil (this embodiment) The outer periphery pressing roller 5 that is pressed from the upper side in the example is attached to a common feeding member 14.
[0017]
A screw rod 15 is provided in parallel with the winding shaft 1. A screw hole of a feed base 16 is screwed into the screw rod 15, and the feed member 14 is fixed to the feed base 16. The feed member 14 moves along a guide rod (not shown) installed in parallel with the screw rod 15, and the feed member 14 is rotated by rotating the screw rod 15 in conjunction with the rotary shaft 3. Retreat along the guide rod. The retraction speed of the feed member 14 is made to coincide with the winding advance speed of the corresponding coil.
[0018]
The winding shaft 1 is slidably inserted into a cylindrical slide guide 17. When the coil is removed, the winding shaft 1 is detached from the attachment portion 10 of the attachment 2 by a winding shaft advancement / retraction device (not shown). Let
[0019]
As shown in FIGS. 2 (A) to 2 (C), a spiral guide surface 11 in which a surface of one turn on the winding start side of the flat wire 4 is brought into contact with the tip of the winding shaft mounting portion 10 of the attachment 2. Are integrally formed.
[0020]
As shown in FIGS. 2 (B) and 2 (C), between the coil receiving surface a on the winding start side and the coil receiving surface b at the end of one turn of the coil, a substantially flat angle in the axial direction of the winding shaft 1. It has a difference c of the same width as the thickness x of the line 4 (see the plan view of FIG. 3A).
[0021]
The winding shaft attachment portion 10 of the attachment 2 are shaped cut grooves 19 of the rectangular wire having a slightly wider width w than the thickness x of the flat wire 4 from the winding start side receiving surface a guide surface 11, the winding axis 1 It is provided in the longitudinal direction . The groove 19 is formed by removing the entire thickness of a part of the cylinder of the winding shaft attachment portion 10 in the radial direction. As shown in FIG. 2C, in this embodiment, the groove 19 is formed in a direction perpendicular to the plane perpendicular to the core (θ≈90 degrees), but is not necessarily 90 degrees. It is not necessary to limit to, and it is not always necessary to form it linearly. Furthermore, when the flat wire is extremely thin, even if the coil receiving surfaces a and b are the same plane and there is no difference c, almost no winding distortion occurs.
[0022]
As shown in the front sectional view of FIG. 3A, the difference ΔR between the radius of the winding shaft 1 and the radius of the winding shaft attachment portion 10 is set to be approximately equal to the width y of the vertical side of the flat wire 4.
[0023]
A presser claw 20 as a means for pressing and fixing the flat wire distal end side is attached to the root part of the winding shaft mounting part 10 so as to be rotatable about a shaft 21, and the presser claw 20 is a press spring. 22 is urged so that the flat wire 4 is pushed into the groove 19 side.
[0024]
The attachment 2 is prepared with various settings of the guide surface 11, the difference c, and the groove 19 depending on the shape of the coil to be manufactured and the thickness of the rectangular wire 4.
[0025]
When performing a winding operation using this winding apparatus, an attachment 2 or a winding shaft mounting portion 10 corresponding to the shape and dimensions of the coil to be manufactured and the flat wire 4 as a material thereof is prepared and the rotating shaft 3 is provided. As shown in FIGS. 3A and 3B (plan view), the initial rotation position of the attachment 2 is set so that the groove 19 faces upward, and the presser claw 20 is pushed open to open the groove. 19, the bent portion 4 c on the front end side of the flat wire 4 is fitted, and when the presser claw 20 is released, the bent portion 4 c of the flat wire 4 is received and fixed in the groove 19 by the presser claw 20. At this time, the inner end face of the bent portion 4 c of the flat wire 4 hits the outer periphery of the winding shaft 1.
[0026]
Next, the winding shaft 1 is inserted into the winding shaft mounting portion 10, and the side surfaces of the rectangular wire 4 and the outer surface serving as the outer peripheral surface of the coil are pressed by the pressing rollers 5 and 7, and the winding shaft 1 together with the attachment 2 is rotated by the rotation of the rotating shaft 3. And the rectangular wire 4 is wound around the winding shaft 1 while moving the feed member 14 in synchronization with the coil winding speed, thereby forming a coil.
[0027]
After winding a predetermined pitch, the rotation of the rotating shaft 3 and the feeding of the feeding member 14 are stopped, the end of the coil is cut, the winding shaft 1 is extracted from the attachment 2 and the coil is taken out. Such a winding operation can be performed manually or by an automated manufacturing apparatus.
[0028]
Thus, since the front end side bent portion 4c of the flat wire 4 is fitted in the groove 19, the outer periphery pressing roller 5 is not interfered with the winding start side of the flat wire 4, and the flat wire 4 is sufficiently The coil can be manufactured by pressing, and even if the thickness x of the flat wire 4 is less than 0.3 mm, the flat wire 4 can be wound around the coil. Of course, the present invention can be applied to the case where a coil is manufactured by a rectangular wire 4 having a thickness of 0.3 mm or more.
[0029]
Further, a guide surface 11 is provided on the winding start side, and in this embodiment, a difference corresponding to the thickness x of the rectangular wire 4 is approximately between the winding start side receiving surface a and the receiving surface b at the end of one round. The guide surface 11 is formed so as to have c, and the flat wire 4 is brought into contact with the guide surface 11 so that the surface opposite to the guide surface 11 of the flat wire 4 and the end of one turn of the guide surface 11 are obtained. The receiving surface b of this portion is substantially the same surface, and the end portion of one round of the flat wire 4 is supported by the receiving surface b. Therefore, as shown in FIG. Even in the overlapping portion of the portion 4a and the end portion 4b of one turn, no distortion deformation occurs. For this reason, the winding is not disturbed, and each layer can be wound uniformly, and the dimensional accuracy is easily obtained. Further, since there is no winding disturbance, there is no fear of damage to the winding, and the electrical insulation is not impaired. Moreover, since it is not necessary to pay attention to the winding disturbance, the workability of the winding work is improved, and the work efficiency can be improved.
[0030]
Moreover, when implementing this invention, unlike the said Example, you may comprise the attachment 2 and the winding shaft 1 integrally. Further, the winding shaft mounting portion 10 is made detachable with respect to the attachment 2, and the dimensions of the groove 19 are variously set according to the shape of the coil to be manufactured and the thickness of the rectangular wire 4 as the winding shaft mounting portion 10. Things may be prepared. Further, the shape of the bent portion 4c can be variously changed.
[0031]
【The invention's effect】
According to the present invention, since the groove for setting and fitting the bent portion on the front end side of the flat wire is provided in the attachment shaft mounting portion of the attachment, the front end side of the flat wire fits in the groove, and the winding start side is the outer periphery presser roller. Therefore, it is possible to work by setting the flat wire to a position where it does not come off from the outer periphery presser roller, and it is possible to wind the coil even with a thin flat wire, producing a small vertical coil It becomes possible to do.
[Brief description of the drawings]
1A and 1B are a plan view and a side view, respectively, showing an embodiment of a winding device according to the present invention.
2A is a perspective view showing an attachment and a winding shaft of the present embodiment, FIG. 2B is a front view of a winding shaft mounting portion of the present embodiment, and FIG. 2C is a plan view of FIG.
3A is a side view showing a state in which a flat wire is applied to the guide surface of the attachment of the present embodiment, and FIG. 3B is a perspective view showing a state in the middle of manufacturing the winding according to the present embodiment.
FIG. 4 is a perspective view showing a conventional attachment and a winding shaft.
5A is a side view showing a conventional winding device, FIG. 5B is a perspective view showing a state in the middle of manufacturing a winding by the winding device of FIG. 5A, and FIG. 5C is a wound coil; (D) is a dimensional relationship diagram between the outer periphery pressing roller and the rectangular wire when the thickness of the rectangular wire is small.
6 is a plan view showing a winding start state by the winding device of FIG. 5 (A). FIG.
[Explanation of symbols]
1: winding shaft, 2: attachment, 3: rotating shaft, 4: flat wire, 4c: bent portion, 5: outer periphery pressing roller, 6: guide roller, 7: side pressing roller, 8: mounting shaft, 10: winding Axis mounting portion, 11: guide surface, 14: feed member, 15: screw rod, 16: feed base, 17: slide guide, 19: groove, 20: presser claw a: coil receiving surface on the winding start side, b: coil Coil receiving surface at the end of one turn, c: difference, x: thickness, y: vertical width

Claims (3)

In the winding device of helical- shaped flat vertical coil,
One end is inserted into the winding shaft mounting portion provided on the attachment mounted on the rotating shaft of the winding device , or is concentric with the winding shaft mounting portion, and a rectangular wire is formed from the winding shaft mounting portion. A winding shaft with a radius smaller by the width is provided ,
A guide surface is provided on the winding shaft side end of the winding shaft mounting portion so as to abut one turn of the coil winding start side end surface;
The guide surface has a step substantially equal to the thickness of a flat wire between the receiving surface on the winding start side and the receiving surface at the end of one turn,
A groove for inserting and setting a bent portion on the leading end side of the flat wire in the longitudinal direction of the winding shaft from the coil receiving surface on the winding start side of the guide surface is provided in the winding shaft mounting portion,
The winding shaft mounting portion is provided with a fixing means for fixing the flat wire attached to the groove,
The flat and side pressing roller for pressing the rectangular wire from the coil front side, the winding of the rectangular coil in which the rectangular wire is characterized by comprising an outer peripheral pressing roller for pressing the outer periphery of a portion bent is supplied to the winding shaft apparatus. In the winding device of a flat coil according to claim 1,
The fixing means includes a push claw provided on the winding shaft mounting portion and pressing and fixing the bent portion of the flat wire with a spring.
A winding device for a flat rectangular coil. The winding shaft mounting portion provided on the attachment of the winding device and provided with the winding shaft integrally or concentrically with the winding shaft receives one turn of the winding start side of the coil , and the winding start side receiving surface and the end of the first turn. A guide surface having a step corresponding to a thickness of a substantially rectangular wire is formed between the receiving surface and the receiving surface ,
Said winding shaft attachment portion of the attachment, the groove having a slightly larger width than the thickness of the flat wire, is provided on the longitudinal direction of the winding shaft from the winding start side of the coil receiving surface of the guide surface, to the winding axis mounting portion , A fixing means for fixing the flat wire set in the groove is provided ,
Insert the bent portion on the front end side of the flat wire into the groove, and fix and set by the fixing means , and apply the vicinity of the bent portion of the flat wire to the winding start side receiving surface of the guide surface,
The flat wire is pressed against the guide surface by a side press roller that presses the flat wire from the front surface, the outer presser roller is pressed against the outer periphery of the flat wire, and the winding shaft is rotated while the winding device is rotated. A method of manufacturing a rectangular coil, comprising: forming a coil by winding a rectangular wire around the coil.

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