JP4003367B2 - Coil manufacturing equipment - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
In the present invention, a wire rod is sequentially wound from one end portion to the other end portion of the winding body portion, and a winding start lead wire of the wire rod and a pair of electrodes provided on the flange portion of the other end portion The present invention relates to a coil manufacturing apparatus for connecting winding end lead wires.
[0002]
[Prior art]
FIG. 17 is a perspective view showing an example of a chip coil L used as an inductor, and FIG. 18 is a right side view of FIG. This chip coil L includes flange portions 1 and 3 at both ends, and a wire 7 is wound around a winding drum portion 5 between the flange portions 1 and 3. A pair of electrodes 9 and 11 are formed as recesses on one flange 1.
[0003]
Among these, the winding end lead wire 13 of the wire 7 is guided and soldered to one electrode 9. Further, the winding start lead wire 15 extends to the other electrode 11 from the flange portion 3 side beyond the winding drum portion 5 around which the wire 7 is wound, as shown in FIG. 19 which is a left side view of FIG. Then, it is handed over to the collar 1 side, guided to the electrode 11 and soldered.
[0004]
[Problems to be solved by the invention]
By the way, in such a conventional chip coil, as shown in FIG. 19, the winding start lead wire 15 of the wire 7 is passed from the flange 3 side to the flange 1 side beyond the winding body 5. Therefore, a substantially triangular space 17 is formed between the winding start lead wire 15 and the wire rod 7 wound around the winding body portion 5.
[0005]
If such a space 17 is formed, the lead wire 15 at the beginning of winding is in a floating state. Therefore, if a force is applied to this portion, disconnection is likely to occur, leading to a decrease in reliability. In addition, when the chip coil is molded with resin after the winding start lead wire 15 is soldered to the electrode 11, the floated winding start lead wire 15 is disconnected due to shrinkage of the resin during molding or the like. There is a fear.
[0006]
In view of this, the present invention provides a method in which when the winding start lead wire is guided to the electrode of the flange portion on the side to which the winding end lead wire is connected, the winding start lead wire is wound on the winding body portion. The purpose is to prevent them from floating away.
[0013]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a pair of electrodes that are wound around a winding drum portion sequentially from one end portion to the other end portion, and are provided on the flange portion of the other end portion. Further, in the coil manufacturing apparatus for connecting the winding start lead wire and the winding end lead wire, respectively, a holding mechanism that moves to the terminal side while holding the winding start lead wire, and this holding mechanism A revolving mechanism for revolving along the periphery of the winding drum while holding the lead wire and winding the winding start lead wire around the winding drum, and a movement for moving the holding mechanism in the axial direction of the winding drum And the holding mechanism is located on the rear side in the turning direction of the holding mechanism by the turning mechanism, and a holding part that holds the winding start lead wire movably in front and rear in the axial direction of the winding body part, Touch the lead wire at the beginning of winding when turning It is constituted to have a contact portion.
[0014]
According to the above configuration, the holding mechanism holding the winding start lead wire is swung along the periphery of the winding drum portion by the turning mechanism, and the axial direction of the winding drum portion, that is, one of the winding drum portions is moved by the moving mechanism. By moving from one end to the other end, the holding mechanism moves to the terminal side while holding the winding start lead, and the winding start lead is wound around the winding body. Further , the holding mechanism turns along the periphery of the winding body portion so that the holding portion holds the winding start lead wire and the contact portion supports the winding start lead wire from the rear side in the turning direction.
[0015]
Further, in the present invention , the holding portion has a receiving portion that receives the winding start lead wire on one end side of the winding drum portion, and a movable portion that can move toward and away from the receiving portion, The part is located on the terminal side of the lead wire starting from the holding part and is configured integrally with the receiving part.
[0016]
According to the above configuration, when the movable portion approaches the receiving portion, the winding start lead wire is held, and when the holding mechanism turns around the winding drum portion in this state, the contact portion is held. The winding starts at the end of the lead wire from the part and comes into contact with the lead wire.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
[0018]
FIG. 1 is a configuration diagram of an entire winding apparatus including a forming machine 21 which is a coil winding terminal processing apparatus according to an embodiment of the present invention. This winding apparatus has an index mechanism having a rotating plate 25 that rotates at a predetermined angle in the clockwise direction in FIG. 1 around a horizontal axis 23 that extends in a direction orthogonal to the paper surface in FIG. A plurality of collet chucks 27 are attached to the outer periphery of the rotating plate 25 at a predetermined angle in the circumferential direction.
[0019]
As shown in FIG. 3 to be described later, the chip coil L used as an inductor has a core 35 having flange portions 31 and 33 at both ends of a winding drum portion 29 around which a wire 41 is wound. A pair of electrodes 37 and 39 are formed as recesses on the flange 33 of the core 35, and the collar 31 on the side not provided with the electrodes 37 and 39 is chucked and fixed by the collet chuck 27.
[0020]
At a position facing the outer peripheral surface of the rotating plate 25 to which the collet chuck 27 is attached, a core loading process A for transferring the core 35 to the collet chuck 27 in order from the left side in FIG. A wire rod winding step B for winding the wire rod 41 around the body portion 29, a wire rod cutting step C for cutting the wire rod 41 between the wound cores 35 (chip coils L), and a winding start portion of the wire rod 41 on the core 35 A terminal processing step D which is a constituent part of the present invention for performing the terminal processing, a soldering step E for soldering both end portions on the winding start side and winding end side of the wire 41 to the core 35, and a chip coil after soldering A discharge step F for removing L from the collet chuck 27 and discharging it is provided.
[0021]
In the core loading process A, a plurality of cores 35 are arranged in series in the left-right direction in the drawing with the collar portion 31 on the collet chuck 27 side on the work placing table 47 installed on the holding block 45 on the apparatus base 43. The foremost part of the plurality of cores 35 is transferred to the collet chuck 27 by a workpiece transfer device (not shown).
[0022]
At this time, the collet chuck 27 keeps the chuck portion open by the chuck release mechanism 51 fixed to the inner wall surface of the device frame 49 formed on the upper portion of the device base 43. In the chuck release mechanism 51, the opening claw 53 at the tip is driven by a drive mechanism such as a cylinder, and the flange 55 of the collet chuck 27 is resisted against the elastic force of the return spring 56 shown in FIG. Then, the chuck part is opened by moving it in the right direction (left direction in FIG. 7). The chuck part chucks and fixes the collar part 31 by retracting the opening claw part 53 in a state where the collar part 31 of the core 35 is inserted in the opened chuck part.
[0023]
The collet chuck 27 to which the core 35 has been transferred sequentially rotates by a predetermined angle as the rotating plate 25 rotates, and reaches the upper wire winding step B in the drawing. The wire winding process B is performed by a winding machine 57 attached to the upper inner wall of the device frame 49. The winding machine 57 includes a flyer 59 for feeding the wire 41 at the lower end. The flyer 59 includes a short arm 61 and a long arm 63 and is rotatable about the vertical direction as a central axis in FIG. 1, and is provided at the tip of the long arm 63 as shown in detail in FIG. The wire 41 is sequentially fed out from the nozzle 65. The flyer 59 is also movable in the vertical direction in FIG. However, in FIG. 2, one collet chuck 27 between the wire cutting process C and the terminal processing process D in FIG. 1 is omitted.
[0024]
3 to 6 show the winding operation by the winding machine 57. FIG. First, as shown in FIG. 3, the flyer 59 approaches the core 35 so that the nozzle 65 is on the upper side (right side in FIG. 1) of the flange portion 31. At this time, the wire 41 at the tip of the nozzle 65 is connected to the winding end portion of the chip coil L in which the wire 41 has already been wound and moved to the next working position.
[0025]
In this state, when the flyer 59 rotates in the direction of the arrow G, the wire 41 starts to be wound from the position close to the flange 31 on the winding drum portion 29 of the core 35 as shown in FIG. Thereafter, the flyer 59 retreats in the direction indicated by the arrow H in FIG. 4 in accordance with the rotation operation, whereby the wire 41 is sequentially wound around the winding body portion 29, and rotates and retracts when reaching a predetermined number of turns. Stop moving. The stop position of the nozzle 65 at this time is a position above the electrode 37 in FIG. 5 and a position where the chip coil L does not interfere with the flyer 59 due to the rotation of the rotating plate 25.
[0026]
Then, when the rotating plate 25 rotates by a predetermined angle, the wire 41 is guided to one electrode 37 in the flange portion 33 as shown in FIG. 5 and the winding operation of the wire 41 is finished as shown in FIG. L moves to the next work position. On the other hand, the flyer 59 leaves the chip coil L for which the winding work has been completed, and waits for the next approach of the core 35 around which the wire 41 is wound.
[0027]
By repeating such operations, the wire 41 is sequentially wound around the core 35, and between the adjacent cores 35, as shown in FIG. A connecting wire 41m is formed to connect the winding end portion and the winding start portion for the core 35 that performs the next winding operation.
[0028]
The wire cutting process C includes a cutting machine 67 that cuts the connecting wire 41m. The cutting machine 67 is installed in a main body 69 fixed to the apparatus frame 49 side at a predetermined interval so that the two cutters 71 and 73 can move toward and away from the rotating plate 25. As shown in FIG. 2, the cutter 71 positioned on the front side in the rotation direction of the rotary plate 25 cuts the wire 41 guided by the electrode 37 in the vicinity of the flange portion 33. The end of the wire 41 guided to the electrode 37 by this cutting becomes a winding end lead wire 41e.
[0029]
On the other hand, the cutter 73 located on the rear side in the rotation direction of the rotating plate 25 is cut so that the wire 41 protrudes upward from the core 35 by a predetermined length as shown in FIG. This protruding portion becomes the winding start lead wire 41s in the chip coil L. This winding start lead wire 41 s is guided to the electrode 39 in the flange portion 33 of the core 35 by the forming machine 21 in the terminal processing step D which is the next work step.
[0030]
The forming machine 21 has a main body 75 mounted on the inner wall surface of the frame 49, and the detailed structure of the forming machine 21 including the internal structure of the main body 75 is shown in FIG. 8 to 10 show a terminal processing operation by the forming machine 21, which will be described with reference to this as well.
[0031]
The center shaft 77 extended in the left-right direction in FIG. 7 can be moved in the axial direction by spline fitting in the bush 79, and the bush 79 can rotate with respect to the movable block 83 via a bearing 81. It is.
[0032]
A movable pin 87 as a movable portion is attached to the left end of the center shaft 77 in the drawing via a connecting arm 85. On the other hand, a connecting rod 91 is connected to the left end of the bush 79 in the drawing via a connecting arm 89, and a fixing pin 95 as a receiving portion is provided to the tip of the connecting rod 91 via a block piece 93. ing. The winding lead lead 41s of the wire 41 is held by the side of the fixed pin 95 and the tip of the movable pin 87. Accordingly, both the pins 87 and 95 constitute a holding portion 96 that holds the winding start lead wire 41s before and after the winding drum portion 29 in the axial direction. The holding operation by the holding portion 96 does not firmly fix the winding start lead wire 41s, but holds it with a force that can be easily removed when the winding start lead wire 41s is pulled.
[0033]
When the bush 79 rotates together with the center shaft 77 in the direction of arrow I in FIG. 8 and the holding portion 96 at the tip also rotates in the same direction, the connecting rod 91 described above is behind the winding lead wire 41s in the rotational direction. Touch at. Accordingly, the connecting rod 91 constitutes a contact portion. The contact portion and the holding portion 96 constitute a holding mechanism that moves to the terminal side while holding the winding start lead wire 41s.
[0034]
A first motor 97 is installed on the upper right side of the movable block 83, and a driven pulley 103 is connected to a drive pulley 99 attached to the first motor 97 via a belt 101. The driven pulley 103 is movable in the axial direction by spline fitting with the center shaft 77. That is, when the first motor 97 is driven, the center shaft 77 rotates together with the bush 79 with respect to the movable block 83, and accordingly, the tip holding mechanism turns around the chip coil coil L.
[0035]
A second motor 105 is installed at the lower right side of the movable block 83, and a ball screw 107 protruding to the right side in the drawing is interlocked with the second motor 105. A nut 109 screwed into the ball screw 107 is fixed to a connecting ring 113 that is rotatably attached to a rear end portion on the right side of the center shaft 77 in FIG. That is, the rotation of the ball screw 107 driven by the second motor 105 causes the nut 109 to move along the ball screw 107, and the connecting ring 113 and the center shaft 77 move in the left-right direction together with the nut 109. To do.
[0036]
The movable block 83 is formed with a nut portion 115 projecting downward at the lower left portion in FIG. 7, and the nut portion 115 is movable in the left-right direction in the drawing along the guide rail 119 on the main body 75. . A ball screw 121 is screwed into the nut portion 115, and the ball screw 121 is rotated by a third motor 123 installed on the main body 75. That is, when the third motor 123 is driven, the ball screw 121 is rotated, and the movable block 83 including the nut portion 115 screwed to the ball screw 121 moves in the left-right direction.
[0037]
Next, operation | movement of the terminal processing process D by the above-mentioned forming machine 21 is demonstrated. When both ends of the wire 41 wound around the chip coil L are cut by the cutting machine 67 and the wire cutting process C is completed, the rotating plate 25 rotates by a predetermined angle so that the chip coil L faces the forming machine 21. Become.
[0038]
In this state, the movable block 83 moves forward by the driving of the third motor 123. In this advancement direction, the holding mechanism at the tip slightly rotates in the direction opposite to the arrow I from the position in FIG. The holding mechanism makes it easy for the lead wire 41 s to enter between the movable pin 87 and the fixed pin 95 when the movable pin 87 moves backward and starts to wind.
[0039]
After the holding mechanism is moved forward to the above-mentioned position as the movable block 83 moves forward, the first motor 97 is driven and the center shaft 77 rotates in the direction of arrow I together with the bush 79. The winding start lead wire 41 s enters between the movable pin 87 and the fixed pin 95. At this time, the connecting rod 91 is in contact with the winding start lead wire 41s. Next, the second motor 105 is driven to advance the center shaft 77, and the winding start lead wire 41 s is held between the movable pin 87 and the fixed pin 95 by the advancement of the movable pin 87 associated therewith.
[0040]
When the winding start lead wire 41 s is held, the center shaft 77 is rotated in the direction of arrow J together with the bush 79 as shown in FIG. 9 by driving the first motor 97, and is movable by driving the third motor 123. The block 83 is moved backward to move the holding mechanism to the right in FIG. As a result, the holding mechanism turns around the core 35, and the winding start lead wire 41 s is wound on the wire 41 wound around the winding body portion 29. Therefore, the forming machine 21 rotates the holding mechanism around the winding drum portion 29 while holding the winding start lead wire 41s, and turns the winding start lead wire 41s around the winding drum portion 29. The moving mechanism for moving the holding mechanism in the axial direction of the winding drum portion 29 is provided.
[0041]
Then, when the holding mechanism makes one round around the chip coil L and reaches below the electrode 39 of the chip coil L, the third motor 123 is driven to move the movable block 83 backward, as shown in FIG. Thus, the holding mechanism is moved backward in the direction of arrow K. In this state, the winding plate lead wire 41s is guided to the electrode 39 by rotating the rotary plate 25 by a predetermined angle and moving the chip coil L downward in FIG.
[0042]
At this time, the winding start lead wire 41 s has such a length that the terminal slightly protrudes upward from the electrode 39, and when the holding portion 96 reaches above the electrode 39, the holding mechanism is moved in the direction opposite to the arrow K. The lead wire 41 s at the start of winding is pushed into the electrode 39 by moving forward. The terminal protruding upward from the electrode 39 is cut by, for example, a cutter (not shown) provided in the forming machine 21.
[0043]
As shown in FIG. 11, the tip coil L in which the winding start lead wire 41 s is terminal-processed by the forming machine 21, when guiding the winding start lead wire 41 s to the electrode 39 of the flange portion 33, as shown in FIG. 11. The winding start lead wire 41s at 29 is wound around the wire 41 and does not float as in the prior art. For this reason, even if force is applied to this part, reliability is improved without disconnection, and when the chip coil L is molded with resin or the like, even if the resin contracts during molding, the winding start lead wire The disconnection of 41s can be prevented.
[0044]
The chip coil L subjected to the terminal processing of the lead wire 41 in this way moves to the soldering process E by the rotation of the rotating plate 25. In the soldering process E, the solder tank 133 can be moved up and down by a drive mechanism 135 installed on the apparatus base 43.
[0045]
In a state where the solder bath 133 is in a position lowered from the state of FIG. 1, the rotary plate 25 rotates and the chip coil L after the terminal processing is positioned on the solder bath 133. In this state, the solder bath 133 is raised. Then, the winding end lead wire 41e and the winding start lead wire 41s guided by the two electrodes 37 and 39, respectively, are immersed in the solder solution and soldered.
[0046]
After the soldering, the chip coil L moves to the discharge process F when the rotating plate 25 rotates by a predetermined angle. In the discharging process F, a discharging box 137 is installed on the holding block 45, and a chuck opening mechanism 139 similar to that in the core loading process A is fixed to the inner wall surface of the apparatus frame 49. When the opening claw portion 141 at the tip of the chuck release mechanism 139 moves forward, the chuck portion of the collet chuck 27 is opened, and the held chip coil L is discharged to the discharge box 137.
[0047]
As a method for securely bringing the winding end lead wire 41e and the winding start lead wire 41s into close contact with the electrodes 37 and 39, the operations shown in FIGS.
[0048]
As shown in FIG. 12, with the chip coil L moved above the solder bath 13, the solder bath 13 rises and the winding end lead wire 41e and the winding start lead wire 41s become the solder solution as shown in FIG. Soaked. From this state, as shown in FIG. 14, the solder bath 13 is slightly lowered so that the solder liquid is connected to the winding end lead wire 41e and the winding start lead wire 41s by surface tension.
[0049]
In the state shown in FIG. 14, the pin member 143 made of, for example, a piano wire or the like extended in a direction orthogonal to the paper surface in the drawing is replaced with a winding end lead wire 41e and a winding start lead wire as shown in FIGS. While being pressed against 41s, it is moved in the right direction in the drawing, and the winding end lead wire 41e and the winding start lead wire 41s are securely brought into close contact with the electrodes 37 and 39, and the parts connected by the surface tension of the solder liquid are separated. .
[0053]
【The invention's effect】
As described above , according to the present invention, the holding mechanism holding the winding start lead wire is swung around the winding drum portion by the turning mechanism, and the axial direction of the winding drum portion is moved by the moving mechanism. Therefore, the winding start lead wire can be wound around the winding body while moving toward the electrode side. Since the holding mechanism holds the winding start lead wire and the contact portion contacts the winding start lead wire on the rear side in the turning direction of the holding mechanism, the holding mechanism turns around the winding drum portion. The holding part can be reliably moved to the terminal side while holding the winding start lead wire.
[0054]
Further, according to the present invention, when the movable portion approaches the receiving portion, the winding start lead wire is held between the receiving portion and the movable portion, and in this state, the holding mechanism extends along the periphery of the winding drum portion. The contact part contacts the winding start lead wire on the terminal side of the winding start lead wire from the holding part, so when the holding part moves to the terminal side of the winding start lead wire, the holding operation is performed. Is made more reliably.
[Brief description of the drawings]
FIG. 1 is a configuration diagram of an entire winding apparatus including a forming machine that is a terminal processing apparatus for coil windings according to an embodiment of the present invention.
FIG. 2 is an enlarged perspective view of a main part of the winding device.
FIG. 3 is an operation explanatory diagram showing a state before starting winding in the winding device;
FIG. 4 is an operation explanatory diagram showing a state during operation in the winding device.
FIG. 5 is an operation explanatory diagram showing a state after the end of winding in the winding device;
FIG. 6 is an operation explanatory diagram showing a state in which the chip coil is separated from the winding device after the winding in the winding device is completed.
FIG. 7 is a sectional view showing a detailed structure of the forming machine.
FIG. 8 is an operation explanatory diagram at the start of the operation of the forming machine.
FIG. 9 is an operation explanatory diagram during the operation of the forming machine.
FIG. 10 is an operation explanatory diagram at the end of the operation of the forming machine.
FIG. 11 is a front view of the chip coil after being subjected to terminal processing by the forming machine.
FIG. 12 is a diagram for explaining an operation in a state in which a chip coil is moved onto a solder bath, showing a method for reliably bringing a winding end lead wire and a winding start lead wire into close contact with the corresponding electrodes, respectively.
13 is an operation explanatory diagram in a state in which the solder bath is raised from the state of FIG. 12 and the winding end lead wire and the winding start lead wire are immersed in the solder liquid.
14 is an operation explanatory diagram in a state where surface tension is generated in the solder liquid by slightly lowering the solder bath from the state of FIG. 13;
15 is an operation explanatory diagram of a state in which a piano wire is pressed against a winding end lead wire and a winding start lead wire from the state of FIG. 14;
16 is an operation explanatory diagram in a state in which the surface tension portion of the solder liquid is separated by moving the piano wire from the state of FIG. 15;
FIG. 17 is a perspective view showing a state of a chip coil used as a conventional inductor before terminal processing of a winding start lead wire.
18 is a right side view of the chip coil of FIG. 17. FIG.
19 is a left side view of the chip coil of FIG. 17 after terminating the winding start lead wire.
[Explanation of symbols]
29 Winding body portions 31, 33 鍔 portions 37, 39 Electrode 41 Wire material 41s Winding start lead wire 41e Winding end lead wire 87 Movable pin (movable portion)
91 Connecting rod (contact part, holding mechanism)
95 Fixing pin (receiving part)
96 Holding part (holding mechanism)

Claims (2)

  A wire rod is sequentially wound from one end portion to the other end portion of the winding drum portion, and a winding start lead wire and a winding end of the wire rod are provided on a pair of electrodes provided on the flange portion of the other end portion. In a coil manufacturing apparatus for connecting lead wires to each other, a holding mechanism that holds the winding start lead wire and moves to the terminal side, and this holding mechanism holds the winding start lead wire around the winding drum section. And a moving mechanism for moving the holding mechanism in the axial direction of the winding drum portion, and the holding mechanism includes a winding drum. A holding portion that movably holds the winding start lead wire before and after the axial direction of the portion, and a contact portion that is located on the rear side in the turning direction of the holding mechanism by the turning mechanism and contacts the winding start lead wire during turning Having a Le of manufacturing equipment. The holding part has a receiving part that receives the winding start lead wire on one end side of the winding body part, and a movable part that can move toward and away from the receiving part, and the contact part is the holding part The coil manufacturing apparatus according to claim 1 , wherein the coil manufacturing apparatus is integrated with the receiving portion and is located closer to a terminal side of the winding start lead wire.

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