JP3669485B2 - Winding method of flat wire - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
  The present invention provides a rectangular wire for producing a small and thin choke coil or a coil used for a transformer or the like.Winding methodRelated.
[0002]
[Prior art]
Conventionally, a method of winding a wire and a device thereof are known in a configuration in which a bobbin is attached to a rotating shaft and wound, and a configuration in which a bobbin is attached to a fixed shaft and a wire is wound by a fryer. It is also known to wind by attaching a core material such as a magnetic body instead of the bobbin, or to obtain an air core coil by winding without using a bobbin. In the feeding of these wire rods, the rotating shaft to which the wire rod supply reel is attached is torque controlled by an electric motor or the like to apply tension to the wire rod, or the wire rod is drawn out and unwound from the wire rod supply reel placed on the pedestal. There is known a configuration in which a brake means is applied to a pulley around which a wire is wound to apply tension to the wire, and the tension of the wire is detected by a swing arm or the like to control the brake means to apply a predetermined tension to the wire.
[0003]
Then, when winding around a circular bobbin or core, or winding a coil that becomes a circular air core, there is no sudden change in the running speed of the wire in one turn, but it is not circular When a coil is wound around a bobbin or a core material or a coil that becomes a non-circular air core is wound, a repetitive change occurs in the traveling speed of the wire during one turn of winding. As the winding speeds up, the wire travels in a vibrating state. Still, the swing arm etc. works as a buffer, and if the cross section of the wire is circular, the wound wire can be wound without breaking, but depending on the conditions, if the winding is made faster, the wound wire breaks or breaks . In addition, if the wire is a rectangular wire with a square cross section or a foil with a thin square on one side, even if the winding is extremely slow, it is not a practical speed and can be satisfied. Winding is not possible in the state.
[0004]
Recently, a coil using a rectangular wire has a higher space factor than a coil using a round wire having a circular cross section, and the need for a coil using a rectangular wire has increased. In other words, a coil using a round wire is a multi-layer winding in order to ensure the required number of turns, but there is a portion where the voltage difference increases between the windings in contact with each other. However, a coil using a rectangular wire has a high space factor and can secure the required number of turns with a single-layer winding, and there is no part where the winding is in contact with each other and the voltage difference is large. Further, edgewise winding in which the longitudinal direction of the flat wire is perpendicular to the central axis of the coil has a feature that the coil diameter does not increase. In order to reduce the size, an edgewise coil is applied to a trigger transformer of a discharge lamp.
[0005]
Regarding the method and apparatus for edgewise winding using a rectangular wire as a wire rod, the configuration in which a rectangular wire is edgewise wound around a winding shaft for winding a coil that becomes an air core is integrated with the winding shaft. Has a large flange, a support surface made of a flange surface perpendicular to the winding shaft is provided with a pressing piece slidable in the axial direction of the winding shaft, the pressing surface is pressed, and the flat wire is connected to the supporting surface. It is wound around the winding shaft between the pressing surfaces, but it is known to sandwich the flat wire wound between the supporting surface and the pressing surface and perform edgewise winding with the longitudinal direction perpendicular to the winding shaft. . As the winding progresses, the holding piece moves and the distance between the support surface and the pressing surface is separated. However, the coil shown in each example is a coil that becomes a circular air core, and there is no sudden change in the traveling speed of the rectangular wire in the winding of one turn. It is more difficult to do than a round wire. Moreover, when trying to wind a coil that has a non-circular air core, a repetitive change occurs in the traveling speed of the rectangular wire in the winding of one turn, and winding cannot be performed unless the traveling speed of the rectangular wire is extremely slowed down. It is not possible to produce at a very practical speed.
[0006]
[Problems to be solved by the invention]
  In view of the above points, the present invention performs edgewise winding on a wire using a flat wire.Method,In particular, the coil that becomes the air core is surely wound at a practical speed.methodFor the purpose of providing, in particular, winding a coil that becomes a non-circular air coreOn the wayThen, a flat wire winding that reliably winds a flat wire like a foil with one thin wire to edgewise winding at a practical speed.methodThe purpose is to provide.
[0007]
Other objects and novel features of the present invention will be clarified in embodiments described later.
[0008]
[Means for Solving the Problems]
  To achieve the above objective,The present inventionIn the winding method of the rectangular wire according to the above, a fixed piece having a first contact surface that is substantially orthogonal to the axial direction of the core shaft is provided so as to rotate integrally with the core shaft, and the first contact A pressing piece having a second contact surface facing the surface and substantially perpendicular to the axial direction of the core shaft and a hole fitted into the core shaft rotates together with the core shaft and slides in the axial direction. One side of the flat wire that is movably provided and edgewise wound around the core shaft is in contact with the first contact surface, and the pressing piece is pressed in the axial direction to the other side of the flat wire. In contact with the second contact surface, and the first contact surface and the second contact surface rotate the core shaft while sandwiching the rectangular wire, and When the rectangular wire is wound, the pressing piece is pushed in the axial direction and slides, and edgewise winding is performed between the first contact surface and the second contact surface. In case that, a brake means for producing a resistance to running of the rectangular wire in a predetermined position perpendicular to the axial direction of the winding core shaft,
  The brake means is integrated with the holding piece in the axial direction of the core shaft.Move using the pressure of the pneumatic cylinder,
  Execute edgewise winding in which the cross-sectional shape perpendicular to the axial direction of the core axis is not circular, but the traveling speed of the rectangular wire in a one-turn winding changes repeatedly.It is characterized by that.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
  Hereinafter, winding of a rectangular wire according to the present inventionWay ofEmbodiments will be described with reference to the drawings.
[0019]
FIG. 23 shows a coil 100 having a non-circular air core manufactured in the present embodiment. FIG. 23 (A) is a perspective view, FIG. 23 (B) is a side view seen from the direction of the air core, and FIG. C) is a front view seen from a direction orthogonal to the air core, and FIG. In FIGS. 5B to 5D, dimensions are shown in the drawings showing the coil 100 from three sides. Here, the flat wire 10 of the wire has a width of 1 mm and a thickness of 0.12 mm, and can be said to be a flat wire having a thickness smaller than the width. The non-circular air core has a width of 9.5 mm and a length of about 17 mm. Both ends of the air core are semicircular, and the flat wire 10 has a width of 1 mm with respect to the central axis of the coil 100. Vertical edgewise winding. Although the dimension shown here is an example, an embodiment of the coil 100 will be described.
[0020]
2 to 4 are external views showing the entire winding device. F denotes a floor surface, and the gantry 1 comes into contact with the floor F with legs 2 screwed to the lower surface, and the carrier 3 comes into contact with the floor F and can move freely by shortening the protrusion of the legs 2 to be screwed. The gantry 1 fixes the main mechanism of the winding device to the upper surface of the upper plate 4. That is, a winding mechanism 5, a feeding mechanism 6, a guide mechanism 7, a cutting mechanism 8, and an operation panel 9, which are shown in detail in FIGS. 1 and 5 to 10 showing the arrangement of main mechanisms on the upper surface of the gantry 1. Indicated. 11 and 12 show the feeding mechanism 6 in an enlarged manner. FIGS. 13 to 15 show the core shaft 11 of the winding mechanism 5 and its surroundings, and FIGS. 16 to 18 show similar parts, but are modified examples in which a part of the winding mechanism 5 is changed. Details will be described later. 19 shows the fixed piece 12 and the holding piece 110 integrated with the winding piece 5, FIG. 20 shows an example of the holding piece 13, FIG. 21 shows the contact surface of the fixed piece, and FIG. The pressing surface (contact surface) of the pressing piece 13 is different, and details will be described later.
[0021]
An outline of main mechanisms will be described with reference to FIGS. The operator faces in the posture toward the front of the gantry 1, the operation panel 9 is arranged at a position facing the operator, and the winding mechanism 5, the guide mechanism 7, and the feeding mechanism 6 are arranged from the front to the back. Is done. The reel 20 around which the flat wire 10 is wound is set in the feeding mechanism 6. The flat wire 10 drawn from the reel 20 reaches the winding mechanism 5 via the guide mechanism 7.
[0022]
The structure of the main mechanism will be described with reference to FIGS. In the winding mechanism 5, the legs 15 and 16 are erected on the upper surface of the gantry 1, and the plate 17 is fixed to the upper ends of the legs 15 and 16 in parallel with the upper surface of the gantry 1. A pulse motor PM for rotationally driving the core shaft 11 is attached to the lower surface of the plate 17. A hole is provided in the leg 15 and a rolling bearing is fitted. This rolling bearing rotatably supports the intermediate shaft 18. The left end of the intermediate shaft 18 is connected to the output rotation shaft of the pulse motor PM via a shaft coupling Cl. A light-shielding disc 19 is fitted on the left side of the intermediate shaft 18 and rotates integrally. The light-shielding disk 19 is in a position where the detection light of the photosensor HS attached to the leg 15 is shielded. The light-shielding disk 19 is provided with a concave portion through which the detection light passes, and a predetermined position at the rotation angle of the intermediate shaft 18 HS detects. Details of the right side of the intermediate shaft 18 will be described later with reference to FIGS. 13 to 15 or FIGS.
[0023]
As shown in FIG. 1 and the like, a linear guide rail Rl is fixed to the upper surface of the gantry 1 in parallel with the rotation center of the pulse motor PM and the intermediate shaft 18. A plurality of linear guides Gl that engage with the rail Rl and are slidable are provided, and the movable table 21 is placed on and fixed to the plurality of linear guides Gl so as to be slidable integrally on the rail Rl. A pneumatic cylinder S1 is mounted on the upper surface of the gantry 1 on the right side from the right end of the rail Rl. The piston shaft of the pneumatic cylinder S1 is connected to the right end of the moving base 21 via a joint Tl. The pneumatic cylinder S1 is driven on the rail Rl. The moving table 21 is configured to move left and right.
[0024]
The holder base 22 and the pneumatic cylinder S2 on the moving base 21 will be described. The rail R2 is placed on and fixed to the upper surface of the movable table 21 in parallel with the rail Rl. A linear guide G2 that engages with the rail R2 and is slidable is provided, and the holder base 22 is placed on the linear guide G2 and fixed, and the rail R2 is slidable integrally. A pneumatic cylinder S2 is mounted on the upper surface of the moving base 21 on the left side of the left end of the rail R2, and the piston shaft of the pneumatic cylinder S2 is connected to the left end of the holder base 22 via a joint T2, and the rail R2 is driven by the pneumatic cylinder S2. The holder base 22 moves left and right.
[0025]
The leg 23 and the contact / separation shaft 24 will be described. As shown in FIG. 1, a table 25 is fixed and erected on the right side of the movable table 21. The leg 23 is fixed to the base 25, but the fixing position of the leg 23 can be changed with respect to the base 25. A hole is provided in the leg 23 to fit a rolling bearing. The rolling bearing rotatably supports the contact / separation shaft 24. The rotation center of the contact / separation shaft 24 is an extension of the rotation center shared by the output rotation shaft of the pulse motor PM, the intermediate shaft 18 and the core shaft 11, and also shares the rotation center. Further, the contact / separation shaft 24 also protrudes to the right side of the leg 23, and is provided with a concave groove 24A at a predetermined position on the circumference of the protruding portion as shown in FIG. Then, the plate 26 is fixed to the upper surface of the leg 23 in parallel with the contact / separation shaft 24. The plate 26 protrudes to the right side of the leg 23, and a pneumatic cylinder S3 orthogonal to the contact / separation shaft 24 is attached to a hole provided in the protruding portion of the plate 26. The piston shaft of the pneumatic cylinder S3 protrudes downward, and the protruded piston shaft engages with the concave groove 24A to hold the contact / separation shaft 24 at a predetermined rotational position.
[0026]
The feeding mechanism 6 will be described. 5, 7 and 8 show the position on the top surface of the gantry 1, and FIGS. 11 and 12 show the details of the feeding mechanism 6. FIG. The two blocks 30 are fixed and erected on the upper surface of the gantry 1. As shown in the side view of FIG. 11, the upper surface of the block 30 has a step, the plate 31 is fixed to the lower upper surface of the block 30, and the torque motor TM is attached to the upper surface of the plate 31. On the other hand, a plate 32 is fixed to the high upper surface of the block 30, and two bearings 33 are attached to the upper surface of the plate 32, and the two bearings 33 rotatably support the reel shaft 34. The right end of the reel shaft 34 is connected to the output rotation shaft of the torque motor TM via a shaft coupling C2. The left side of the reel shaft 34 with respect to the two bearings 33 is configured to support the reel 20 in a cantilever manner. The flange 35 is fitted to the reel shaft 34 of the example closest to the bearing 33. A screw is provided from the left end of the reel shaft 34 to a predetermined position, and after the reel shaft 34 is fitted into the center hole of the reel 20, the holding nut 36 is screwed onto the screw of the reel shaft 34 to fix the reel 20. The reel 35 rotates the flange 35 and the reel 20 integrally, and the reel shaft 34 and the output rotation shaft of the torque motor TM also rotate together with the shaft coupling C2.
[0027]
As shown in FIG. 4 and the like, the guide mechanism 7 fixes the column stands 41 and 42 on the upper surface of the gantry 1 and erected the columns 43 and 44 by the column stands 41 and 42. As shown in FIGS. 2 and 3, the bar 45 is passed over the columns 43 and 44 and fixed in parallel with the upper surface of the gantry 1 via the metal fittings 46 and 47. A pulley 50 is rotatably fitted to the rod 45, and collars 51 and 52 are fitted to the left and right sides of the pulley 50 to fix the thrust direction. A groove having a semicircular or concave cross section is provided on the outer periphery of the pulley 50. The rectangular wire 10 pulled out from the feeding mechanism 6 is supported and guided by the groove of the pulley 50, and the rectangular wire 10 is drawn around the winding mechanism 5.
[0028]
As shown in FIGS. 4, 5, and 7 to 9, the cutting mechanism 8 fixes the base 60 on the upper surface of the gantry 1, fixes the rail R <b> 3 on the upper surface of the pedestal 60, and engages and slides on the rail R <b> 3. A movable linear guide is provided, a movable table 61 is mounted on the linear guide and fixed, and the movable table 61 can be moved back and forth by being guided by a rail R3. First and second pneumatic nippers 71 and 72 are placed on and fixed to the upper part of the moving table 61. The pneumatic nippers 71 and 72 are provided with a pneumatic cylinder at the rear, and when a pneumatic pressure is supplied to the pneumatic cylinder, a pair of blades on the tip side come into contact with each other. When the flat wire 10 is positioned between the pair of blades, the pair of blades can be cut while sandwiching the flat wire 10. The moving table 61 is connected to a piston shaft of a pneumatic cylinder (not shown) fixed to the table 60, and moves back and forth by driving the pneumatic cylinder.
[0029]
Details of the winding mechanism 5 will be described with reference to FIGS. 13 to 15 and FIGS. 19 to 21. In FIG. 13, the left end of the core shaft 11 is fixed to the right end of the intermediate shaft 18. The intermediate shaft 18 and the core shaft 11 share the same center of rotation. In addition, a contact / separation shaft 24 is shown at the right end. The fixed piece 12 is fixed to the left end of the contact / separation shaft 24. The contact / separation shaft 24 and the fixed piece 12 share the same center of rotation. Therefore, the intermediate shaft 18, the core shaft 11, the fixed piece 12, and the contact / separation shaft 24 are the same center of rotation. A rail Rl is fixed to the upper surface of the upper plate 4 of the gantry 1, and a movable table 21 is mounted and fixed on a linear guide Gl that can slide the rail Rl. The movable table 21 is slidable on the rail Rl. However, the rail R2 is fixed to the upper surface of the movable table 21 in parallel with the rail Rl. The linear guide G2 is slidably engaged with the rail R2, and the holder base 22 is placed and fixed on the linear guide G2 so that the rail R2 can be slid integrally. A concave holder plate 80 is bolted to the vertical portion of the holder base 22 as shown in FIG. The holder plate 80 is erected in a direction orthogonal to the rail R2. The holder 81 has a quadrangular shape with four corners chamfered when viewed from the extending direction of the core shaft 11, has a predetermined thickness when viewed from the direction orthogonal to the core shaft 11, and is substantially equal to the thickness. It has concave grooves 81A and 81B in the middle in the vertical direction.
[0030]
Although the width direction of the concave grooves 81A and 81B is not shown in FIG. 14, the width direction is shown in FIG. The holder 81 is positioned so as to fit into the concave shape of the holder plate 80, and the thickness of the holder plate 80 fits into each of the concave grooves 81A and 81B. That is, the holder plate 80 is configured to constrain the holder 81 in a direction parallel to the core shaft 11 and to slide in a direction perpendicular to the core shaft 11 along the concave grooves 81A and 81B.
[0031]
The holder 81 has a hole in the thickness direction, and a rolling bearing is fitted into the hole. The outer periphery (outer diameter) of the pressing piece 13 is fitted to the inner ring of the rolling bearing. The holding piece 13 includes a collar and a retaining ring groove. The rolling bearing is held by a retaining ring having one end abutting against the collar and the other attached to the retaining ring groove, and the retaining piece 13 is a rolling bearing fitted on the holder 81. It is held rotatably.
[0032]
The pressing piece 13 has the outer shape shown in FIG. 20, and is provided with a hole 13A in the center coaxially with the center of rotation by the rolling bearing on the holder 81 side. The hole 13A is fitted to the outer periphery (outer diameter) of the core 11. The outer periphery of the core 11 has an elliptical shape with a parallel surface equidistant from the center of the circle, and the hole 13A has an elliptical shape with a parallel surface equidistant from the center of the circle. The core shaft 11 is fitted in a relationship in which the hole 13A is slidable in the direction of the core shaft 11 but the rotational direction is restricted. That is, the pressing piece 13 is slidable in the direction of the core axis 11 but is restricted in the rotational direction. The fitting accuracy between the winding core 11 and the holding piece 13 is increased, and therefore the engagement relationship between the holder 81 and the holder plate 80 is the above-described configuration (the holder plate 80 restricts the direction of the holder 81 parallel to the winding shaft 11). In addition, the direction perpendicular to the core axis 11 is configured to be slidable along the concave grooves 81A and 81B), so that competition is not generated in unnecessary portions.
[0033]
As shown in FIG. 13, the core 11 includes a hole 11A in a direction orthogonal to the axis, an inclined groove 11C at the right end, and a slit 11B extending from the bottom of the inclined groove 11C to the hole 11A. This is a configuration in which both side pieces of the slit 11B can be bent with the hole 11A as a fulcrum in the core 11. The bending structure is used when the flat wire 10 is wound around the core shaft 11 and removed. The roles of the slit 11B and the inclined groove 11C will be described later.
[0034]
The left end of the contact / separation shaft 24 includes a protrusion 24A having the same rotation center and a narrow outer diameter. On the other hand, the fixing piece 12 is provided with a corresponding fitting hole, into which the protruding portion 24A is fitted, and is provided with a screw hole in a direction perpendicular to the fitting hole and fixed with a set screw. The contact / separation shaft 24 and the fixed piece 12 are rotating bodies having the same rotation center, and are integrally rotatable.
[0035]
The details of the fixed piece 12 are shown in FIG. 21, and the left end shown in FIG. 13 is provided with a recessed hole 12A into which the right end of the core 11 is fitted with a predetermined fitting accuracy. The core shaft 11, the fixed piece 12, and the contact / separation shaft 24 have a configuration in which the right end of the core shaft 11 is fitted into the recessed hole portion 12 </ b> A, and the rotation center is integrated and rotatable. Further, a screw hole 12B is provided on the bottom surface of the recessed hole portion 12A, and the piece 82 has a hole at the center and is fixed to the screw hole 12B with a bolt. The piece 82 has a trapezoidal shape, and the inclined surface is fitted to the inclined groove 11C at the right end of the core 11 with a predetermined accuracy. When the piece 82 is fitted into the inclined groove 11C, the right end of the core shaft 11 is held so as not to bend (the core shaft maintains a uniform outer peripheral shape in the axial direction). When the rectangular wire 10 is wound around the core shaft 11, it is held so as not to bend.
[0036]
The left end surface of the fixing piece 12 (a contact surface substantially orthogonal to the axial direction of the core axis) and the right end surface of the holding piece 13 (a contact surface substantially orthogonal to the axial direction of the core axis) are connected to the core shaft 11. When the flat wire 10 is wound by edgewise winding between the left end surface and the right end surface, the winding is sandwiched, and the left end surface and the right end surface work together so that the flat wire becomes a predetermined winding. Therefore, the right end surface and the left end surface are made to have corresponding shapes. That is, one side of the flat wire 10 that is edgewise wound around the core shaft 11 is in contact with the contact surface on the fixed piece 12 side, and the other side of the flat wire is in contact with the contact surface on the holding piece 13 side, By rotating and driving the core shaft 11 while the contact surfaces sandwich the flat wire, the flat wire 10 is wound around the core shaft 11, and accordingly, the holding piece 13 is moved in the axial direction of the core shaft 11. It slides and retreats when pushed by
[0037]
As shown in FIGS. 20A to 20C, the right end surface (contact surface) of the pressing piece 13 is a tapered surface 90 whose outer edge portion is gently retracted, and the inside thereof is shown in FIG. The flat surface 92 (the highest portion) except for the shaded portion 91 of FIG. In the hatched portion 91, as shown in the enlarged view of FIG. 20C, there is a step whose height decreases by one sheet of the flat wire 10 from the straight portion of the core shaft 11 to the rounded portion, approximately 90 degrees. The inclined surface gradually increases from the step position so as to be the same height as the flat surface 92 when rotated. The reason for this is that when the flat wire 10 is edgewise wound, the inner peripheral side of the flat wire 10 is distorted or tilted at the rounded portion, and the wall thickness is apparently increased, and this increase in wall thickness can be allowed. As described above, the step corresponding to the rounded portion (curved portion) of the flat wire is provided with a step having a lower height and the inclined surface following the step as shown by the hatched portion 91. If there is no dent in the shaded portion 91, the flat wire 10 is likely to protrude from the left end surface of the fixed piece 12 and the right end surface of the holding piece 13, and winding at a practical speed becomes difficult.
[0038]
As shown in FIG. 21 (A), the left end surface of the fixed piece 12 is a tapered surface 105 whose outer edge portion is gently retracted, and the height of the oblique line portion 106 on the inner end surface is the thickness of the flat wire 10. A step which is lowered by an amount corresponding to one sheet and an inclined surface following the step are formed. In other words, the position at which the winding start of the flat wire 10 indicated by the phantom line is located due to the step is low corresponding to the thickness of one flat wire 10, and as it goes around once as shown in FIG. The inclined surface of the hatched portion 106 is formed so that the height gradually increases. The reason for this is to avoid the problem that the flat wire 10 after being wound around the flat wire 10 at the beginning of winding is caught.
[0039]
As shown in FIG. 13, a portion having a reduced outer diameter is provided on the left side of the fixed piece 12, and a holding piece 110 having a Z-shaped outer shape with a hole at the center of rotation is fitted therein as shown in FIG. The fixed piece 12 and the holding piece 110 are configured to rotate integrally. The holding piece 110 is rotationally symmetric with respect to the hole. At one end thereof, a holding end 113 by a thumbscrew 112 for holding the winding end of the flat wire 10 is provided. After winding the end of the flat wire 10 with the holding end 113, the winding core shaft 11 is rotated and wound. Since the holding piece 110 has a rotationally symmetrical shape, it should keep the stopped position. However, if the holding piece 113 is provided, the weight of one of the holding pieces 113 is won. If the holding piece 110 is left as it is, the holding end 113 is located at the lowest position. . Therefore, since the holding end 113 is at the lower side, the position is fixed and an advantageous advantage is obtained when the work is started.
[0040]
Differences between FIGS. 13 to 15 and FIGS. 16 to 18 which are modifications of the portions will be described (mainly the brake means will be described).
[0041]
13 to 15, an L-shaped leg 114 is fixed and erected on the holder base 22. The plate 115 is fixed to the upper end of the leg 114 with a bolt. The bolt hole is a long hole, and the fixing position can be changed within a predetermined range. A brake substrate 116 is fixed to the tip of the plate 115 with a bolt. The bolt hole is a long hole, and the fixing position can be changed within a predetermined range. The board 116 has a screw hole and a brake push plate 117 is attached with bolts 117A and 117B. Brake sheets Bl and B2 are fixed to the opposing surfaces of the substrate 116 and the push plate 117, respectively, and the flat wire 10 is passed between the brake sheets Bl and B2. The board 116, the push plate 117, the brake sheets Bl and B2, respectively, and the fastening means for the board 116 and the push plate 117 constitute the brake means. For example, a felt sheet, a leather sheet, or a synthetic resin sheet is used as the brake sheets Bl and B2. The brake seats Bl, B2 and the flat wire 10 are rubbed to generate resistance in traveling. Since there are no inclusions, there is an advantage that a braking action can be directly exerted on the traveling of the flat wire 10. The amount of tightening of the bolts 117A and 117B is adjusted to change the distance of the pressing plate 117 with respect to the board 116, and the braking action is adjusted by adjusting the force with which the brake seats Bl and B2 clamp the flat wire 10.
[0042]
16 to 18, the brake 118 and the guide groove substrate 118 are fixed to the front end of the plate 115 with bolts. The bolt holes are the same as the substrate 116. The substrate 118 includes two portions on the top and bottom to sandwich the flat wire 10. The upper part is a part that forms a brake means and is provided with a screw hole, and a brake push plate 117 is attached with bolts 117A and 117B (in the drawing, a thumbscrew is used). Brake sheets Bl and B2 are fixed to the opposing surfaces of the board 118 and the board 117, respectively, and the flat wire 10 is passed between the brake sheets Bl and B2. The material and action of the brake seat are the same as those described in FIGS. The lower part is a part that forms a flat wire guide means, and a guide groove 118A through which the flat wire 10 passes is provided on the surface of the substrate 118. Screw holes are provided on the left and right of the guide groove 118A, and the cover plate 119 of the groove is attached with bolts 119A and 119B. The guide groove 118A is in a state where the cover plate 119 is covered and covered. The position of the flat wire 10 is determined by being guided through the groove 118A. In addition, in the modification of FIG. 16 thru | or FIG. 18, other structures are the same as that of FIG. 13 thru | or FIG. 15, The same code | symbol is attached | subjected to the same or an equivalent part, and description is abbreviate | omitted.
[0043]
The operation in the above configuration will be described. First, the side connected to the output rotation shaft of the pulse motor PM such as the core shaft 11 and the intermediate shaft 18 is at a predetermined rotation position by the pulse motor PM, and the other contact / separation shaft 24 is held in an unconstrained state. The weight of the end 113 works and this is in the lower position, and the piston shaft of the pneumatic cylinder S3 in FIG. In addition, the piston shaft of the pneumatic cylinder S1 in FIG. 1 is ejected, the moving base 21 moves to the left, and the right end of the core shaft 11 is pressed against the left end of the fixed piece 12. The winding core shaft 11 and the contact / separation shaft 24 are in a predetermined position in the rotational direction, and the fixed piece 12 fixed to the contact / separation shaft 24 is also in a predetermined position in the rotational direction and is wound at the predetermined position. The right end of the core shaft 11 is fitted into the recessed hole 12A of the fixed piece 12, and the core shaft 11 side and the contact / separation shaft 24 side are integrated in the rotational direction. Subsequently, the piston shaft of the pneumatic cylinder S <b> 2 is ejected, the holder base 22 moves to the right, the pressing piece 13 slides on the core shaft 11, and the pressing surface (contact surface) becomes the left end of the fixed piece 12. It abuts on the (abutment surface). First, the fixed piece 12 is pressed against the core 11 by the pneumatic cylinder S1, and the pressure at which the pressing surface of the pressing piece 13 comes into contact with the pressing surface of the fixed piece 12 is adjusted by the pneumatic cylinder S2.
[0044]
The rectangular wire 10 is sandwiched between the pressing surface of the fixed piece 12 and the pressing surface of the holding piece 13, and the coil 100 is obtained by winding the flat wire 10 around the core shaft 11. The holding piece 13 that holds the wire 10, that is, the coil 100, can slide back on the core shaft 11, and the force pressed by the holding piece 13 is generated by the air pressure applied to the pneumatic cylinder S <b> 2. This pressing force is set to such a force that the rectangular wire 10 is wound around the core 11 and the holding piece 13 is pushed back. Thus, unlike the biasing by the spring, the pressing force does not change depending on the position of the pressing piece 13, the setting of the pressing force is easy, and the pressing surface of the pressing piece 13 is changed from the pressing surface of the fixed piece 12. Will be separated with the winding.
[0045]
Subsequently, as shown in FIG. 5 and the like, when the reel 20 around which the flat wire 10 is wound as a wire is set on the reel shaft 34 and fixed with the holding nut 36, the reel 20 and the reel shaft 34 rotate integrally. The output rotation shaft of the torque motor TM also rotates integrally, and torque control can be performed in which the reel motor 34 is rotated forward or backward by controlling the torque motor TM. Then, the flat wire 10 is pulled out from the reel 20 and suspended on the pulley 50 of the guide mechanism 7 shown in FIG. A means for detecting the tension of the flat wire 10 suspended on the pulley 50 is added to the guide mechanism 7, and torque control of the torque motor TM is performed in confrontation with the detected tension signal, and the rectangular wire 10 suspended on the pulley 50 is It is also possible to feedback control the tension to a predetermined value. The leading end of the flat wire 10 suspended on the pulley 50 is guided to the winding mechanism 5. In the configuration shown in FIGS. 13 to 15 or the modified examples shown in FIGS. 16 to 18, the bolts 117A and 117B are loosened, and the push plate 117 is moved. The flat wire 10 is sandwiched between the brake seats Bl and B2. 16 to 18, the bolts 119A and 119B are loosened, the cover plate 119 is released, the bolts 119A and 119B are tightened after passing the flat wire 10 into the groove 118A. In the configurations of FIGS. 13 to 15 or FIGS. 16 to 18, the pressure with which the brake seats Bl and B2 clamp the flat wire 10 is changed and the frictional resistance that the flat wire 10 travels is changed by the strength with which the bolts 117A and 117B are tightened. be able to.
[0046]
The flat wire 10 that has passed through the brake seats Bl and B2 (and that has passed through the guide groove 118A in the modified examples of FIGS. 16 to 18) is along the left end surface (contact surface) of the fixing piece 12 before the core shaft 11. Pull down. The leading end of the pulled flat wire 10 is held and held at the holding end 113 between the holding piece 110 and the thumb screw rod. In addition, after attaching the winding start end of the flat wire 10, the torque motor TM is temporarily reversed so that the flat wire 10 is not slackened.
[0047]
Since pneumatic pressure is supplied to the pneumatic cylinder S2 at a predetermined pressure in advance, the holder base 22 and the integral part attached thereto are pressed to the right side, and the pressing surface of the pressing piece 13 is the same as that of the fixed piece 12. It is pressed while holding the flat wire 10 on the pressing surface. The flat wire 10 is held in a posture to start edgewise winding (one side of the flat wire starts to be in contact with the contact surface on the fixed piece side, and the other side is in contact with the contact surface on the holding piece side). Subsequently, the rectangular wire 10 is wound around the core shaft 11 that is driven to rotate according to a predetermined number of turns by the pulse motor PM. At this time, the core shaft 11 rotates while the contact surface on the fixed piece 13 side and the contact surface on the holding piece 13 side sandwich the flat wire 10, and the flat wire 10 is wound edgewise on the core shaft 11. As a result, the holding piece 13 is pushed in the axial direction of the core shaft 11 to slide and retreat, and winding is performed between the contact surfaces of both pieces. When the predetermined number of turns is reached, the holding piece 110 stops the core shaft 11 in such a posture that the holding end 113 is upward. This posture is 180 degrees opposite to the initial posture. In this state, the moving table 61 of the cutting mechanism 4 is moved forward. The second pneumatic nipper 72 cuts the flat wire 10 at the start of winding, and the first pneumatic nipper 71 cuts the flat wire 10 at the end of winding. The interval between the first and second pneumatic nippers 71 and 72 varies depending on the thickness of the rectangular wire 10 and the number of turns, and is set in advance to a predetermined interval corresponding to the number of turns.
[0048]
Next, an adhesive tape is affixed to the outer periphery of the coil 100 wound around the core shaft 11, and the shape is maintained. Thereafter, when the instruction button on the operation panel 9 is pressed, the operation of removing the coil 100 from the core shaft 11 is performed, the piston shaft of the pneumatic cylinder S2 is pulled in, and the holding piece 13 moves to the left, and then the pneumatic cylinder S1. The piston shaft is retracted, and the movable table 21 moves to the right. When the moving base 21 moves to the right, the right end of the core shaft 11 and the left end of the fixed piece 12 are separated, and at the same time, the holding piece 13 reaches the right end while sliding on the core shaft 11. In this process, the coil 100 is extracted from the core 11 to the right end. The coil 100 is extracted in a space where the right end of the winding core 11 and the left end of the fixed piece 12 are separated. When receiving means is provided under this space, the coil 100 is dropped and taken out. Instead of the receiving means, the operator may receive it by hand. The coil 100 is in a state in which the rectangular wire 10 is wound around the core shaft 11, and when the holding piece 13 slides on the core shaft 11, the coil 100 is extracted to the right end. The slit 11B is bent from 11A so that the coil 100 can be easily extracted from the core shaft 11.
[0049]
According to this embodiment, the following effects can be obtained.
[0050]
(1) When the flat wire 10 is wound edgewise, the contact surface of the fixed piece 12 and the contact surface of the holding piece 13 are provided substantially perpendicular to the axial direction of the core shaft 11, The rectangular wire 10 is sandwiched between the windings and wound around the core shaft 11. The contact surface of the pressing piece 13 holds the rectangular wire 10 with a predetermined pressing force, but the rectangular wire 10 is wound to the width of the coil. Even if the spread occurs, the pressing piece 13 can slide to maintain a predetermined pressure. Further, as the flat wire 10 is wound and the width of the coil is expanded, it is necessary to increase the distance between both contact surfaces to be sandwiched. Here, the contact surface of the fixed piece 12 is fixed and the holding piece 13 is fixed. The abutment surface slides while maintaining a predetermined pressure, and the brake means moves in the axial direction integrally with the sliding of the pressing piece 13. As a result, the position where the flat wire 10 is wound around the core shaft 11 is kept in the same positional relationship with the contact surface of the presser piece 13 in the axial direction, and edgewise winding can always be realized stably.
[0051]
It is more preferable that the position where the flat wire 10 passes through the brake means is set to be substantially on the extended surface of the contact surface of the pressing piece 13.
[0052]
Further, the distance to the position where the flat wire 10 is wound around the core shaft 11 and the brake means is shortened, and the tension necessary for the flat wire 10 when it is wound is sufficiently generated by the brake means and the core shaft 11. This configuration creates a state in which the flat wire 10 is tensionally independent between the brake means and the core shaft, and the flat wire between them has a small mass, and the inertia depending on the mass is extremely reduced. Since the mechanism can reduce the inertia, the core shaft 11 exhibits a great effect in edgewise winding in which the core 11 is not circular. In edgewise winding with a circular core axis, stable and high-speed winding that is not possible in the past is possible.
[0053]
(2) Further, the brake means imparts a predetermined friction to the flat wire 10 that travels when the flat wire 10 is wound with the flat wire 10 sandwiched between the brake seats B1 and B2, and has inertia with respect to the flat wire. The structure does not cause an increase, and the ultimate effect can be obtained as a means for applying an arbitrary tension to the rectangular wire.
[0054]
(3) The core shaft 11 is cantilevered by a bearing and protrudes, and is provided with a slit 11B in the axial direction toward the direction supported from the protruding end, and slides from the side where the holding piece 13 is supported toward the protruding end. Thus, when the coil 100 of the rectangular wire 10 wound edgewise on the winding core shaft 11 is extracted, the slit 11B is narrowed on the protruding end side, so that the coil can be easily extracted.
[0055]
(4) The contact surface of the pressing piece 13 is formed at least partially at a position corresponding to the rounded portion when the flat wire 10 is wound edgewise (shaded portion 91 in FIG. 20). In the rounded portion, the inner peripheral side of the flat wire 10 is distorted or tilted and the wall thickness is apparently increased. However, the increase in the wall thickness can be allowed because the abutting surface is lowered corresponding to the portion. Even in edgewise winding in which the end surface perpendicular to the axial direction of the core 11 is not circular such as an oval, winding can be performed at a practical speed.
[0056]
(5) The contact surface of the fixed piece 12 is formed low at the portion where the flat wire 10 starts to be wound as shown by the hatched portion 106 in FIG. It is possible to avoid the problem that the later flat wire portion is caught and to improve the winding speed.
[0057]
(6) By providing guide means (guide groove 118A and its periphery) for guiding the flat wire 10 adjacent to the brake means as in the modified examples of FIGS. 16 to 18, the position where the flat wire is wound is further stabilized. Can be
[0058]
(7) As shown in FIG. 14 and the like, the holder plate 80 constrains the holder 81 holding the holding piece 13 in a rotatable manner in a direction parallel to the core shaft 11, and the direction perpendicular to the core shaft 11 is a groove. By adopting a configuration that allows sliding along the lines 81A and 81B, competition is not caused in unnecessary portions.
[0059]
(8) By finely adjusting the pressure of the pneumatic cylinder S2, the length of the coil 100 (the 38.5 mm portion in FIG. 23C) can be finely adjusted.
[0060]
22 (A) to 22 (G) respectively show modified examples of the configuration of the contact surface of the pressing piece 13, and FIGS. 22 (A) to (C) show the case where the core shaft is oval. (D) and (E) are when the core axis is rectangular (rounded rectangle), and (F) and (G) are when the core axis is square (rounded square). It is. In these cases, the right end surface (contact surface) of the pressing piece 13 is a tapered surface 90 whose outer edge portion is gently retracted, and the inner side is a flat surface 92 except for the shaded portion 91. In the hatched portion 91, a portion having a height that is lowered by one sheet of the thickness of the flat wire 10 is formed low at a portion extending from the straight portion of the core 11 to the round portion (corresponding to the round portion of the flat wire). After that, the inclined surface gradually increases in height so as to approach the flat surface 92. The effect in this case is the same as that of FIG.
[0061]
Although the embodiments of the present invention have been described above, it will be obvious to those skilled in the art that the present invention is not limited to these embodiments, and various modifications and changes can be made within the scope of the claims.
[0062]
【The invention's effect】
As described above, according to the present invention, when a rectangular wire is wound edgewise, the contact surface of the fixed piece and the contact surface of the holding piece are provided substantially perpendicular to the axial direction of the core shaft. A rectangular wire is sandwiched between the contact surfaces and wound around the core shaft, and the contact surface of the pressing piece presses the rectangular wire with a predetermined pressing force. Even if the width is widened, the pressing piece can slide to maintain a predetermined pressure. Further, as the flat wire is wound and the width of the coil is widened, the interval between both contact surfaces is increased, but the contact surface of the pressing piece slides while maintaining a predetermined pressure, Brake means for generating resistance to the travel of the rectangular wire is provided at a predetermined position orthogonal to the axial direction of the core shaft, and the brake means moves in the axial direction integrally with the sliding of the pressing piece. As a result, the core shaft The distance between the brake means and the core shaft is reduced, the rectangular wire is tensionally independent, and the inertia acting on the flat wire between the brake means and the core shaft is extremely small. In addition, the position where the flat wire is wound around the core shaft is kept in the same positional relationship in the axial direction as the contact surface of the pressing piece, so that edgewise winding can be realized stably at all times.
[Brief description of the drawings]
FIG. 1 shows a rectangular wire winding according to the present invention.Way ofIt is an embodiment and is a front view showing a winding mechanism of the main composition.
FIG. 2 is a front view of the overall configuration.
FIG. 3 is a side view of the overall configuration.
FIG. 4 is a plan view of the overall configuration.
FIG. 5 is a plan view showing an arrangement of a winding mechanism, a feeding mechanism, and a cutting mechanism in the embodiment.
FIG. 6 is a plan view of a lower mechanism of the winding mechanism.
FIG. 7 is a left side view showing the arrangement of the winding mechanism, the feeding mechanism, and the cutting mechanism.
FIG. 8 is a right side view of the same.
FIG. 9 is a right side view showing the arrangement of the winding mechanism and the cutting mechanism.
FIG. 10 is a right side view showing a mechanism that maintains the rotational position of the core shaft at the right end of the winding mechanism.
FIG. 11 is a front view showing a cross section of a part of the feeding mechanism.
FIG. 12 is a plan view with a part in cross section.
FIG. 13 is a front sectional view showing a fixed piece and a holding piece in the winding mechanism and a peripheral mechanism thereof.
FIG. 14 is a right side sectional view.
FIG. 15 is a plan view showing brake means for generating resistance in running of a flat wire in the winding mechanism.
FIG. 16 is a front cross-sectional view showing a modification of the winding mechanism, showing the fixed piece, the holding piece and the surrounding mechanism in that case.
FIG. 17 is a right side cross sectional view.
FIG. 18 is a plan view showing brake means for generating resistance in traveling a rectangular wire in the modified example.
FIG. 19 is a right side view showing a holding piece provided on the fixed piece side in order to hold a winding end of a flat wire.
FIG. 20 is an explanatory diagram showing a configuration of the pressing piece.
FIG. 21 is an explanatory view showing a configuration of a contact surface of the fixed piece.
FIG. 22 is an explanatory view showing a configuration of a contact surface in a modified example of the pressing piece.
FIG. 23 is an explanatory diagram showing an example of a coil manufactured in an embodiment of the present invention.
[Explanation of symbols]
1 frame
4 Upper plate
5 Winding mechanism
6 Feeding mechanism
7 Guide mechanism
8 Cutting mechanism
9 Operation panel
10 Flat wire
11 Core axis
11A hole
11B slit
11C inclined groove
12 Fixed pieces
13 Presser piece
18 Intermediate shaft
20 reels
21, 61 Moving platform
22 Holder stand
24 Contact / separation axis
30 blocks
33 Bearing
34 reel shaft
41, 42 pillar
43,44 pillars
45 bars
50 pulley
71,72 Pneumatic nipper
80 Holder plate
81 holder
81A, 81B groove
90, 105 taper surface
91,106 hatched part
100 coils
110 Holding piece
113 Holding end
116 substrates
117 Brake push plate
B1, B2 Brake seat
G1 Straight guide
PM pulse motor
R1, R2, R3 Guide rail
S1, S2, S3 Pneumatic cylinder
TM Torque motor

Claims (1)

A fixed piece having a first contact surface substantially orthogonal to the axial direction of the core shaft is provided so as to rotate integrally with the core shaft, and faces the first contact surface so as to face the core shaft. A holding piece having a second contact surface substantially orthogonal to the direction and a hole fitted into the core shaft, which rotates integrally with the core shaft and is slidable in the axial direction; One side of the flat wire to be edgewise wound is in contact with the first contact surface, the pressing piece is pressed in the axial direction, and the other side of the flat wire is in contact with the second contact surface. Thus, the first contact surface and the second contact surface rotate the core shaft while sandwiching the rectangular wire, and the rectangular wire is wound around the core shaft so that the holding piece Is a method of winding a rectangular wire that is pushed in the axial direction and slides and edgewise wound between the first contact surface and the second contact surface. , A brake means for producing a resistance to running of the rectangular wire in a predetermined position perpendicular to the axial direction of the winding core shaft,
The brake means is moved integrally with the holding piece using the pressure of the pneumatic cylinder in the axial direction of the core shaft ,
A method of winding a rectangular wire, comprising performing edgewise winding in which a cross-sectional shape perpendicular to the axial direction of the core axis is not circular but the traveling speed of the rectangular wire is repeatedly changed in one turn of winding .

Images