JP4808480B2 - Coil component connecting device and connecting method - Google Patents

Description

  The present invention relates to a connecting device and a connecting method for coil parts using a laser welding method.

  It is not an exaggeration to say that, in the manufacturing process of coil parts, the connecting process for connecting the windings to the terminals is an essential process, and the reliability of this connection is related to the reliability of the entire part. In recent years, the use of laser welding as a lead-free, solder-free, non-contact processing method has been increasing due to the demand for smaller electronic components, reliability of connection, and social environment. .

For example, in a coil component in which a winding is wound around a drum core having a square rod, a manufacturing method that uses laser welding when connecting the winding to a metal terminal fitted to the square rod has been proposed (see Patent Document 1). ).
JP 2003-234218 A

  However, in order to perform laser welding joints with high reliability, it is necessary to reliably make an alloy with a joining material and a non-joining material, which includes the properties of the joining material and the material to be joined, The structure, arrangement, irradiation conditions such as laser type and energy are intricately related. Therefore, it is necessary to perform more reliable connection in accordance with the promotion of miniaturization of parts and the sophistication of requirements regarding external environmental conditions during use.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a coil component connecting device and a connecting method capable of reliably welding a winding and a metal terminal and improving the reliability of the connection.

In order to achieve the above object, the present invention provides a core comprising a core part, a pair of collar parts provided at both ends of the core part and having one surface, and a pair of collar parts, respectively. An opposing portion that contacts and opposes, a facing portion that extends from the opposing portion so as to be foldable, and faces one surface across the facing portion when bent, and a connecting portion that includes a non-facing region protruding from the contour of the one surface A pair of metal terminals and a winding wound around the winding core and disposed so that the end is in contact with and opposed to at least the non-facing region of the connecting portion between the facing portion and the connecting portion; A coil component connecting device is provided that connects an end portion of a winding of a coil component and a connecting portion. A coil component connecting device according to the present invention includes a laser oscillator for outputting laser light, an optical system for guiding the laser light to the coil component, and a coil component for irradiating a predetermined irradiation position of the coil component with the laser beam. Alternatively, a laser beam irradiation position adjusting device that moves at least one of the optical system, an imaging device that captures an image of the laser light irradiated surface of the coil component , and an image captured by the imaging device is analyzed to irradiate the coil component. A control device that determines the position, operates the laser beam position adjustment device to guide the laser beam to the irradiation position, outputs the laser beam to the laser oscillator, and controls the laser beam to irradiate the irradiation position. The irradiation position is a portion where the non-facing region of the connecting portion and the winding overlap.

  According to such a connecting device, since the coil part is connected by irradiating a laser to the non-facing region of the connecting part of the metal terminal, heat is diffused to the opposing part of the metal terminal and the coil part main body. Is suppressed, the position where the molten ball of the winding and the metal terminal is formed is stabilized, the alloy is efficiently formed, and both can be reliably welded.

Here, according to the diameter of the winding, the irradiation position is a portion where the non-facing region of the connecting portion and the winding overlap, and the direction from the connecting portion to the winding or the winding goes to the connecting portion. further comprising a switching means for switching so that the laser beam is irradiated in any direction, the control device in a state of bending the connecting wire portion, when the diameter of the winding is smaller than the predetermined length, the switching means , The non-facing area of the connecting portion and the winding overlap, and the irradiation position is determined so that the laser beam is irradiated in the direction from the connecting portion toward the winding , and the connecting portion When the winding diameter is equal to or longer than the predetermined length in the bent state, the switching means is operated so that the non-facing area of the connecting portion and the winding overlap and are connected from the winding. You may make it determine an irradiation position so that a laser beam may be irradiated to the direction which goes to a part .

According to such a configuration, when the diameter of the winding is equal to or less than a predetermined value , heat is appropriately supplied to the winding and the metal terminal by irradiating the laser from the metal terminal side, so that the stable position can be obtained. While a molten ball is formed, an alloy of a winding and a metal terminal is efficiently formed, and both can be welded. Further, a larger amount of heat can be efficiently supplied to the winding having a large heat capacity, and welding between the winding and the metal terminal is ensured. Further, even when various windings having different diameters are used, it is possible to cope with each other so that the connection can be surely performed, and the reliability with respect to the connection can be further improved.

  Further, the control device outputs the laser beam at the first average power during the first irradiation period when the diameter of the winding is equal to or greater than the predetermined length, and during the second irradiation period following the first irradiation time. It is preferable to control the laser oscillator to output with a second average power larger than the one average power.

  According to such a configuration, the winding and the metal terminal are preheated during the first irradiation time, and a state in which both are easily melted is formed. Therefore, there is no melting unevenness in the second irradiation time, welding can be performed reliably, and the reliability with respect to the connection can be further improved.

Further, the present invention provides a core composed of a core portion, a pair of flange portions each provided on both ends of the core portion, and a pair of flange portions, and a facing portion that is provided on each of the pair of flange portions and faces one surface in contact with each other. And a pair of metal terminals having a connecting portion including a facing region that extends from the facing portion so as to be bendable and faces one surface across the facing portion when bent, and a non-facing region that protrudes from the contour of the one surface; Winding of a coil component having a winding wound around the core and having an end disposed between the facing portion and the connecting portion so as to contact and face at least the non-facing region of the connecting portion. A connection method for connecting an end portion of a wire and a connection portion by a laser beam is provided. In this connection method, the imaging device captures an image of the laser light irradiated surface of the coil component, and the control device analyzes the image captured by the imaging device to determine the irradiation position on the laser light irradiated surface. An irradiation position determining step to determine; a laser beam irradiation position adjusting step in which the laser beam position adjusting device moves at least one of the coil component or the optical system so as to guide the laser beam to the irradiation position; And irradiating the irradiation position with the laser beam to join the connecting portion and the end of the winding, and in the connecting step, the non-facing region of the connecting portion and the winding It is characterized in that the laser beam is irradiated to the irradiation position which is a portion where and overlap.

  In such a connecting method, the irradiation position of the laser beam is determined in the portion where the coil part connection is overlapped with the non-facing region of the connecting portion of the metal terminal by the imaging step and the irradiation position determining step, In the laser beam irradiation position adjusting step and the connecting step, the connection is performed by irradiating a predetermined irradiation position with the laser beam. At this time, since the laser beam is irradiated to the portion where the non-facing region and the winding overlap, it is possible to suppress the heat diffusion to the facing portion of the metal terminal and the coil component body, and the molten ball of the winding and the metal terminal The position to be formed is stabilized, and an alloy is efficiently formed, so that both can be reliably welded.

  According to the coil component connecting device according to the present invention, welding between the coil component winding and the metal terminal is ensured, and the reliability of the connection can be improved.

  A coil component connecting apparatus and connecting method according to an embodiment of the present invention will be described with reference to FIGS. First, the coil component 51 handled by the connecting device will be described with reference to FIGS. 1 is an external perspective view of the coil component 51 before connection, FIG. 2 is an exploded perspective view of the coil component 51 in which the winding is not shown, and FIG. 3 is a cross-sectional view of the metal terminal and the sub barrel. FIG. 4 and FIG. 4 are enlarged views of the vicinity of the legs of the metal terminal.

  The coil component 51 is a common mode filter used for a differential signal interface, and its dimension is, for example, about 4 mm in the longitudinal direction. As shown in FIGS. 1 and 2, the coil component 51 includes a drum-type core 102, two windings 103, and metal terminals 109 and 110 that are electrodes. The core 102 is formed by a magnetic powder such as ferrite being compressed and sintered.

  As shown in FIG. 2, the core 102 is provided with a core portion 105 having a substantially rectangular cross section perpendicular to the longitudinal direction, and both ends of the core portion 105 in the longitudinal direction. Composed. Since the collars 104 and 104 have substantially the same shape, only one side will be described unless otherwise specified. Further, as shown in FIG. 2, the longitudinal direction of the core portion 105 is the x-axis direction, the width direction of the core portion 105 is the y-axis direction, and the direction orthogonal to the x-axis direction and the y-axis direction is the z-axis direction. Define and explain.

    As shown in FIG. 2, the flange portion 104 includes a main body portion 106 that is a portion connected to the core portion 105, a sub-body portion 107 that extends from the main body portion 106 in the y-axis direction, and a sub-body. It is composed of a sub barrel portion 108 extending in the direction opposite to the portion 107. The auxiliary body part 107 and the auxiliary body part 108 are configured to be plane-symmetric with respect to the zx plane passing through the center of the winding core part 105 in the width direction.

  The main body portion 106 has substantially the same width as the core portion 105 and has a substantially rectangular parallelepiped shape. The sub trunk section 107 and the sub trunk section 108 are formed in a substantially rectangular parallelepiped shape extending in the y axis direction from both side surfaces orthogonal to the y axis direction of the main trunk section 106 and having the z axis direction as a longitudinal direction. Moreover, the sub trunk | drum 107 and the sub trunk | drum 108 each have the end surface 107A orthogonal to the z-axis direction.

  As shown in FIG. 1, a metal terminal 109 and a metal terminal 110 are attached to the sub trunk portion 107 and the sub trunk portion 108. The metal terminal 109 is, for example, tin-plated on tough pitch copper, extends from both ends of a base portion 109B extending in the z direction, and has a substantially U-shape from a pair of leg portions 109A and 109C extending in the x direction. Yes. The metal terminal 109 is attached to the sub trunk section 107 with the leg section 109 </ b> A and the leg section 109 </ b> C holding a surface orthogonal to the z direction of the sub trunk section 107. The leg portion 109A is attached to face the one end surface 107A of the sub trunk portion 107.

  A section 109D extends from the side in the extending direction of the leg 109A so that it can be bent. A fixing portion 109F is provided on the free end side of the leg 109A of the section 109D, and a melting portion 109E is provided on the fixing base end side of the leg 109A. The melted portion 109E includes a facing region 109E1 that faces the leg portion 109A when bent, and a non-facing region 109E2 that extends in the x-axis direction from the sub trunk portion 107.

  The leg 109 </ b> C serves as a mounting portion that is electrically joined to an electrode on the substrate when the coil component 51 is mounted on a substrate (not shown). In addition, the metal terminal 109 and the metal terminal 110 have a mirror shape with a zx plane passing through the center in the width direction of the core portion 105 in a state where the metal terminal 109 and the metal terminal 110 are attached to the sub barrel portion 107 and the sub barrel portion 108, respectively. ing. Therefore, the metal terminal 110 also has a substantially U-shape from the pair of leg portions 110A and 110C extending from both ends of the base portion 110B, and the leg portion 110A is provided with a section 110D, a fixing portion 110F, and a melting portion 110E. ing. The metal terminal 110 is mounted on the sub barrel 108 in the same manner as the metal terminal 109 is mounted on the sub barrel 107. Note that the leg portion 110A is attached to face the one end surface 108A of the sub trunk portion 108 in the z-axis direction.

  The two windings 103 wound around the winding core portion 105 are each constituted by a core wire that is a copper wire and an insulating coating made of polyamideimide, and are bifilar wound. The winding 103 has an outer diameter of, for example, about 90 μm and a core wire diameter of about 70 μm. As shown in FIGS. 7 and 8, two windings 103 are arranged on the leg portion 109 </ b> A of the metal terminal 109 provided at one end on one flange portion 104, and provided on the other flange portion 104. It arrange | positions on the leg part 110A of the obtained metal terminal 110, and becomes a connection location. In the winding 103, the end 103A extends in the x-axis direction from the leg 109A or the leg 110A, that is, the outer end of the sub trunk 107 or 108 in the x-axis direction. It becomes a line part. The coil component 51 is in the state shown in FIG. 1 (the state where the winding 103 is disposed on the leg portion 109A of the metal terminal 109 and the leg portion 110A of the metal terminal 110). 62.

  Next, the configuration of the coil component connecting device will be described with reference to FIGS. 5 and 6. FIG. 5 is a schematic diagram of the coil component connecting device 1, and FIG. 6 is a schematic plan view of the coil component connecting device 1 from above FIG. 5. As shown in FIGS. 5 and 6, the connecting device 1 irradiates the coil component 51 placed on the rotary table 53 with the laser light output from the laser oscillator 3 via the laser head 47, and It is a device for connecting windings and metal terminals. The connecting device 1 is mainly configured by a laser irradiation unit 100 that emits a laser beam that irradiates the coil component 51, and a component conveyance unit 50 that conveys the coil component 51.

  The laser irradiation unit 100 mainly includes a laser oscillator 3, a guide laser oscillator 4, a main controller 7, an illumination 9, an observation unit 12, a head transport unit 40, and a laser head 47. The laser oscillator 3, the guide laser oscillator 4, and an image processing apparatus 15 to be described later are connected to and controlled by the main controller 7 via the wiring 8. The laser oscillator 3, the guide laser oscillator 4, and the illumination 9 are connected to a laser head 47 via fibers 5, 6, and 11, respectively. The laser head 47 includes lenses 19, 23, 25, 27 and half mirrors 21, 24, 27. The observation unit 12 includes a monitor 13, an image processing device 15, and a CCD camera 17. The CCD camera 17 is provided above the laser head 47 and is connected to the monitor 13 via the image processing device 15.

  The head transport unit 40 includes connection units 43 and 45, a Z-axis stage 41, a Y-axis stage 39, and an X-axis stage 37. The laser head 47 and the CCD camera 17 are fixed to the Z-axis stage 41, the Y-axis stage 39, and the X-axis stage 37 through connection parts 43 and 45. In FIG. 1, the horizontal direction of the paper surface is the X axis, the direction perpendicular to the paper surface is the Y axis, and the vertical direction of the paper surface is the Z axis. The Z-axis stage 41, the Y-axis stage 39, and the X-axis stage 37 are respectively rotated according to the rotation of the shafts 36, 32, and 30 that are rotated by driving the Z-axis motor 35, the Y-axis motor 31, and the X-axis motor 29. It is configured to move in the Z, Y, and X directions. Although not shown in FIG. 5, the Z-axis motor 35, the Y-axis motor 31, and the X-axis motor 29 are connected to the main controller 7, and are controlled and driven. Therefore, the main controller 7 moves the Z-axis stage 41, the Y-axis stage 39, and the X-axis stage 37 in the directions of the Z, Y, and X axes, respectively, thereby causing the laser head to pass through the connecting portions 43 and 45. 47 moves in the directions of the Z, Y, and X axes.

  The laser oscillator 3 is, for example, a YAG laser. The laser oscillator 3 is controlled by the main control unit 7 and outputs invisible laser light having a predetermined energy for a predetermined time. Laser light output from the laser oscillator 3 is incident on the laser head 47 via the fiber 5, collimated by the lens 23, reflected by the half mirror 24, transmitted through the half mirror 26, and condensed by the lens 27. Welding is performed by irradiating the coil component 51 with a predetermined spot diameter. Hereinafter, this laser beam is referred to as a welding laser beam.

  The guide laser oscillator 4 is a visible light laser. The guide laser light output from the guide laser oscillator 4 is incident on the laser head 47 through the fiber 6, collimated by the lens 25, reflected by the half mirror 26, and condensed by the lens 27. Irradiate with a spot diameter of. The guide laser light is adjusted so as to irradiate the same spot with an optical path substantially coaxial with the welding laser light, and the irradiation position of the welding laser light that is invisible light is confirmed by the position of the guide laser light that is visible light. Be prepared for.

  The illumination 9 is always turned on and emits illumination light when performing the connecting process. This illumination light is incident on the laser head 47 via the fiber 11, collimated by the lens 19, reflected by the half mirror 21, further transmitted through the half mirrors 24 and 26, and coiled in an optical path substantially coaxial with the welding laser light. The surface of the component 51 is irradiated. The illumination light reflected by the coil component 51 is transmitted again through the lens 27 and the half mirrors 26, 24, and 21, reaches the CCD camera 17, is detected as an image signal on the laser light irradiation side surface, and is input to the image processing device 15. The The image processing device 15 outputs the detected image signal to the monitor 13, and the monitor 13 displays an image of the surface of the coil component 51 on the laser light irradiation side. The image processing device 15 performs image processing for determining the irradiation position of the coil component 51 under the control of the main control device 7.

  The main control device 7 controls the laser oscillator 3 and the guide laser oscillator 4 to oscillate laser beams, respectively. Further, based on the result obtained by the image processing, the Z-axis motor 35, the Y-axis motor 31, and the X-axis motor 29 are adjusted so that the spot diameter of the laser light applied to the coil component 51 becomes a predetermined spot diameter. Driven, the Z-axis stage 41, the Y-axis stage 39, and the X-axis stage 37 are moved, and the laser head 47 is moved. Further, by moving the laser head 47, the laser beam irradiation position on the coil component 51 is adjusted to a predetermined position.

  As shown in FIGS. 5 and 6, the coil component conveyance system 50 mainly includes a rotary table 53, a chuck 52, a supply unit 60, and a discharge unit 70. In the coil component transport system 50, the coil component 51 transported from the supply unit 60 is subjected to a predetermined process on the rotary table 53 and is transported to the discharge unit 70.

  The rotary table 53 has a disk shape and is configured to be rotatable in the direction of an arrow R1 with a shaft 55 as a rotation axis. The rotary table 53 rotates once with the shaft 55 as a rotation axis by 12 intermittent rotation operations. That is, the rotary table 53 stops every time it rotates 30 degrees, and a predetermined process is performed at each stop. The coil component 51 is attracted or sandwiched by the chuck 52 disposed on the rotary table 53. The chucks 52 are component holding members that hold the coil components 51 by suction or pinching, and twelve chucks 52 are arranged on the outer periphery of the rotary table 53 at equal intervals.

  A supply unit 60 is provided on the rotary table 53 in the vicinity of the stop position P1 of the intermittently rotating chuck 52. The supply unit 60 is provided to supply the coil component 51 to the rotary table 53. In the supply unit 60, the magazine 61 stores a pallet 62 on which a plurality of coil components 51 before the connecting process are arranged in a matrix. The magazine 61 is, for example, an okamochi-shaped case that can store five pallets 62. One pallet 62 in the magazine 61 is transported onto an XY table (not shown) by a transport system (not shown). The XY table is movable in two directions orthogonal to each other, that is, in the directions of arrows 67a and 67b.

  The component moving device 64 is movable in the horizontal direction of the paper surface of FIG. 6, that is, in the direction of the arrow 66. When the rotary table 53 is stopped, the component moving device 64 sucks or holds a predetermined coil component 51 from the pallet 62 on the XY table. It is conveyed to the chuck 52 located at the stop position P1. The component moving device 64 sequentially carries the coil component 51 to the chuck 52 every time the rotary table 53 stops. When all the coil components 51 on one pallet 62 are conveyed to the rotary table 53 side, the pallet 62 is discharged to the upper pallet discharge side in FIG. 6, and another pallet 62 is supplied from the magazine 61.

  At the stop position P <b> 2 of the chuck 52 in the intermittent rotation operation of the rotary table 53, at the time of stop, forming for positioning the winding to the metal terminal is performed before connecting the coil component 51. The forming will be described with reference to FIGS. FIG. 7 is a perspective view showing a state where the winding 103 of the coil component 51 is positioned, and FIG. 8 is a view showing a state where the melting portion 109E of the metal terminal 109 is crimped to the winding 103. First, as shown in FIG. 7, the end portion of the winding 103 guided onto the leg 109A or the leg 110A is appropriately cut, and the fixing portion 109F or 110F is bent and caulked to perform positioning. Next, as shown in FIG. 8, the melting part 109 </ b> E or 110 </ b> E is bent and caulked to the end of the winding 103. The non-face-to-face regions 109E2 and 110E2 and the winding 1000 103 are in contact with each other by caulking the melting portion 109E or 110E to the winding 103. By this caulking, the forming is completed, and the coil component 51 is conveyed to the stop position P3 that is the stop position of the chuck 52 next to the stop position P2.

  Near the position P3, a laser irradiation unit 100 is provided. Here, the welding laser beam from the laser oscillator 3 is applied to the coil component 51. The welding laser beam is applied to a portion where the non-facing region 109E2 of the melting portion 109E and the winding 103 overlap. Similarly, welding laser light is irradiated on the melting portion 110E. By this welding laser light irradiation, both the melted portion 109E or 110E and the winding 103 are melted to form molten balls to form alloys 109G and 110G as shown in FIG. Are connected mechanically and electrically to complete the connection.

  As shown in FIG. 6, an NG discharging portion 59 is provided in the vicinity of the stop position P <b> 4 of the chuck 52. The NG discharging unit 59 includes a component moving device 68 and an NG magazine 69. When there is a defective (NG) product, the component moving device 68 moves in the radial direction of the rotary table 53 to suck or pinch the NG product held by the chuck 52 and discharge it to the NG magazine 69.

  In the vicinity of the stop position P5 of the chuck 52, a discharge unit 70 is provided. The discharge unit 70 is provided to discharge the coil component 51 that has been connected from the rotary table 53. In the discharge unit 70, a plurality of pallets 72 for supplying to an XY table (not shown) are arranged. The pallets 72 are conveyed one by one from an upper pallet supply side in FIG. 2 onto an XY table (not shown) by a conveyance system (not shown). The XY table is movable in two directions orthogonal to each other, that is, in two directions indicated by arrows 77a and 77b, and appropriately moves so that the coil components 51 are placed in a matrix.

  The component moving device 74 is movable in the horizontal direction of the sheet of FIG. 6, that is, in the direction of the arrow 76, and sucks or pinches the coil component 51 from the chuck 52 disposed at the position P5 when the rotary table 53 is intermittently rotated. The coil component 51 is transported to a predetermined position of the pallet 72 on the XY table. When the coil components 51 are arranged at all predetermined positions on one pallet 72, the pallet 72 is stored in the magazine 78 by a transport system (not shown), and another pallet 72 is supplied on the XY table. Is done. The magazine 78 has substantially the same configuration as the magazine 61.

  FIG. 10 is a block diagram showing the configuration of the control system of the connecting device 1. As shown in FIG. 10, the connecting device 1 has a CPU 71 for controlling the operation. The CPU 71 includes a laser oscillator 3, a guide laser oscillator 4, a memory 83, a transport system controller 85, an image processing device 15, and a laser head. A part drive system controller 89 is connected. The CPU 71 further controls the rotary table 53 via the transport system controller 85, the CCD camera 17 via the image processing device 15, the X-axis motor 29, the Y-axis motor 31 and the laser head drive system controller 89. It is connected to the Z-axis motor 35 to control each. Further, the CPU 71 controls the laser head 47 via the X-axis motor 29, the Y-axis motor 31, the Z-axis motor 35, and the laser head unit drive system control unit 89, and adjusts the irradiation position of the welding laser beam to the coil component 51. To do.

  The CPU 71 outputs an instruction such as intermittently rotating the rotary table 53 to the transport system control unit 85. In addition, the CPU 71 controls the camera 17 via the image processing device 15 to capture an image of the coil component 51, compares the captured image data with the data stored in the memory 83, and outputs an instruction to each unit. . Specifically, the X-axis motor 29, the Y-axis motor 31, and the Z-axis motor 35 are operated to guide the laser beam to the irradiation position determined by analyzing the captured image to the laser head drive system control unit 89. An instruction to output the laser head 47 is output, and the laser head 47 is moved to a predetermined position. An instruction for the intensity and irradiation time of the welding laser beam is output to the laser oscillator 3. The guide laser oscillator 4 outputs an instruction for outputting guide laser light. The CPU 71, the memory 83, the transport system control unit 85, and the laser head drive system control unit 89 are provided in the main control unit 7.

  Next, a method for connecting coil parts by the connecting device according to the present embodiment will be described with reference to FIGS. FIG. 11 is a flowchart showing a method of connecting coil components according to the present embodiment, and FIG. 12 is a diagram showing laser irradiation positions on the coil components.

  As shown in FIG. 11, first, a magazine is supplied. That is, for example, a magazine 61 storing, for example, five pallets is installed in the supply unit 60 (step 131). The pallet 62 is taken out from the magazine 61 and supplied onto the XY table. At this time, a transport system (not shown) takes out and moves the pallet 62 in the magazine 61 and places it on the XY table (not shown) (step 132).

  Next, the coil component 51 before the connecting process is taken out from the pallet 62 and supplied to the rotary table 53. At this time, the XY table is appropriately moved in the directions of arrows 67a and 67b and stopped at a predetermined position, and the component moving device 64 is moved in the direction of arrow 66 and stopped in the vicinity of the predetermined coil component 51. Adsorb or pinch. Thereafter, the component moving device 64 moves to the vicinity of the chuck 52 in the direction of the stop position P1 of the rotary table 53, and the chuck 52 sucks or clamps the coil component 51 (step 133). Step 133 is executed when intermittent rotation of the rotary table 53 is stopped. Hereinafter, processing performed on the coil component 51 will be described in sequence.

  When the rotary table 53 performs the intermittent rotation operation three times and the coil component 51 held by the chuck 52 in step 133 moves to the stop position P2 in FIG. 6, forming is performed. That is, as shown in FIGS. 7 and 8, the end of the winding 103 is crimped by bending the fixing portions 109F and 110F, and in the positioned coil component 51, the melting portions 109E and 110E are bent to The end is further crimped (step 134).

  Further, when the rotary table 53 performs one intermittent rotation operation and moves to the stop position P3, first, the image processing device 15 causes the camera 17 to capture an image of the surface of the coil component 51, that is, the laser light irradiated surface. (Imaging process). The image processing device 15 performs processing such as comparing the captured image data with an image held in the memory 83, and determines the irradiation position of the welding laser beam on the coil component 51 (irradiation position determination step). At this time, as shown in FIG. 12, the irradiation position is an intersection of the broken line 112 and the broken line 114, that is, a position where the melting portion 109E (or 110E) and the end of the winding 103 overlap, and the leg portion 109A ( Or a portion corresponding to the non-facing region 109E2 (or 110E2) extending from 110A). The CPU 71 outputs an instruction for moving the laser head 47 so that the welding laser beam is irradiated to the irradiation position to the laser head drive system controller 89, and the X-axis motor 29, the Y-axis motor 31, and the Z-axis motor. 35 is driven to move the laser head 47 (laser beam irradiation position adjusting step). At this time, the guide laser beam irradiates the irradiation position of the coil component 51 (step 135).

  When the laser head 47 moves to a predetermined position, welding laser light is output from the laser oscillator 3 (connection process). At this time, the CPU 71 outputs an instruction to output a welding laser beam having a predetermined time and power to the laser oscillator 3. The time and power of the welding laser beam are determined according to the diameter of the winding 103 and the like so that the winding 103 and the melted portion 109A or 110A have appropriate values for forming an alloy (step 136). ).

  Subsequently, the rotary table 53 is intermittently rotated once, and the connected coil component 51 is moved to the stop position P4, and when it is determined as a defective product by image processing, the component moving device 68 moves toward the chuck 52. The NG product coil component 51 is picked up or pinched. Further, it moves in the direction of the dedicated NG magazine 69 and discharges the NG product to the NG magazine 69. If not defective, the coil component 51 is held on the chuck 52 as it is (step 137).

  Next, when the rotary table 53 rotates intermittently once and moves to the stop position P5, the component moving device 74 moves toward the chuck 52, and the coil component 51 is attracted or pinched and moved toward the pallet 76. The pallet 76 is moved by an XY table (not shown) so that the coil component 51 can be placed at a position to be placed, and the component moving device 74 places the coil component 51 at a predetermined position on the pallet 76 (step 138). ).

  Further, the rotary table 53 rotates intermittently once and moves to the stop position P6. At this time, the coil component 51 is not held by the chuck 52. Subsequently, the rotary table 53 rotates intermittently five times and returns to the stop position P1.

  When a predetermined number of coil components 51 are placed on the pallet 76 by sequentially performing the above operations, the pallet 76 is moved and stored in the magazine 78 by a conveying means (not shown) (step 139). Further, the above operation is repeated, and when, for example, five pallets 76 are stored in the magazine 78, the magazine 78 is taken out from the discharge section 70 (step 140). The connection of the coil component 51 is completed through the above steps.

  As described above, according to the connecting device 1 for the coil component 51 according to the present invention, the image of the surface of the coil component 51 before the connecting step is analyzed, and the winding 103 and the metal terminals 109 and 110 overlap. In addition, the welding is applied to the non-face-to-face regions 109E2 and 110E2 where the metal terminals 109 and 110 extend from the flange portion 104, and the connection is performed. Therefore, it is possible to suppress the heat generated by the welding laser from diffusing into the coil component 51 main body, and to reliably form the molten ball generated by melting the winding 103 and the metal terminal 109 or 110 at a stable position. Therefore, it is possible to reliably form the alloy of both and to perform the connection reliably.

  In the above embodiment, one aspect of the present invention corresponds to the one end face 107A, 108A, the facing portion corresponds to the leg portions 109A, 110A, and the connecting portion corresponds to the melting portions 109E, 110E.

  The coil component 51 is a connecting method in the case where the diameter of the winding 103 is 100 microns or less in a state where the melting portion 109A or 110A is caulked. In the case of the winding 103 having a diameter larger than 100 microns, the heat capacity of the winding is large, and there are cases where the above method cannot be reliably connected. As a modification, a case where the diameter of the winding 103 is larger than 100 microns will be described below.

When the diameter of the winding 103 is larger than 100 microns and the connection cannot be reliably performed, the irradiation direction of the welding laser beam to the coil component 51 before the connection is reversed. That is, after forming, the rotary coil 53 is rotated 180 degrees around the radial direction of the rotary table 53 with the coil component 51 held between the chucks 52.
FIG. 13 is a diagram illustrating a laser irradiation position when the coil component 51 is rotated 180 degrees, and FIG. 14 is a diagram illustrating an example of an output of welding laser light. As shown in FIG. 13, the irradiation direction of the welding laser in this case is a direction from the winding 103 side toward the melting portions 109A and 110A. Further, the irradiation position is an intersection of the broken line 112 and the broken line 114, that is, a position where the melting portion 109E (or 110E) and the end of the winding 103 overlap with each other, and is a non-extending position extending from the leg portion 109A (or 110A). This is a portion corresponding to the facing region 109E2 (or 110E2).

  At this time, as shown in FIG. 14, during the first irradiation time T1 from the start of irradiation to time t1, a welding laser beam with an average power P1 is output, and during the second irradiation time T2 from time t1 to time t2. A laser beam having a second average power P2 larger than the first average power P1 is output. In the first irradiation time T1, preheating is generated in the winding 103 having a large heat capacity, and the winding 103 and the metal terminal 109 or 110 are easily melted. The preheating is performed in order to remove the insulating film of the winding 103. Therefore, the first average power is preferably an output at which the winding 103 and the metal terminal 109 or 110 are not melted. In the second irradiation time T2 following the first irradiation time T1, the welding laser is irradiated with the second average power P2 that is larger than the first average power P1, so that the alloy of the melted part 109A or 110A and the winding 103 is surely obtained. To make a connection. The change in laser power may be stepped as described above or triangular wave.

  As described above, when the diameter of the winding 103 is 100 microns or more, welding can be performed by irradiating the welding laser from the side of the winding 103 to reliably melt the winding 103 having a large heat capacity. . Furthermore, the welding laser beam output can be changed between the first irradiation time and the second irradiation time to facilitate alloying of dissimilar metals and to further improve the reliability of the connection.

  As described above, according to the coil component connecting device 1 of the present invention, the image of the surface of the coil component 51 before the connecting step is analyzed, and the winding 103 and the metal terminal 109 or 110 overlap with each other. The non-facing regions 109E2 and 110E2 in which the metal terminals 109 or 110 extend from the flange portion 104 are irradiated with a welding laser to perform connection. At this time, according to the diameter of the winding 103, the surface irradiated with the laser light is changed and heat is appropriately supplied, so that an alloy between the winding 103 and the metal terminal 109 or 110 is reliably formed and the connection is made. It is possible to perform reliably. As described above, since the connecting step can be performed by changing the irradiation direction of the welding laser beam depending on the diameter of the winding 103, it is not necessary to change the type of the metal terminal even if various types of windings are used.

  The coil component connecting device and the connecting method of the present invention are not limited to the above-described embodiments, and various modifications can be made without departing from the scope of the present invention. .

  For example, in the above embodiment, the position of the laser head 47 is adjusted in order to adjust the irradiation position of the welding laser, but the position of the coil component 51 is adjusted, for example, by adjusting the position of the chuck 52. Also good.

  In the above-described embodiment, the coil components 51 are supplied one by one from the pallet 62 to the chuck 52. However, the configuration may be changed so that forming and laser irradiation can be sequentially performed on the pallet 62.

  In order to make the welding laser irradiation in the direction from the winding 103 side toward the metal terminal, the chuck 52 is rotated and the coil component 51 is rotated 180 degrees, but the optical path is switched by providing, for example, two laser heads. Then, the welding laser may be irradiated from the opposite side. In this case, a half mirror and a shutter are provided at the connection portion of the laser oscillator 3 with the fiber 5, another second shutter and a second fiber are provided in the direction of the reflected light of the half mirror, and the second fiber is further provided. Is connected to another second laser head. At this time, the second laser head preferably has the same configuration as the laser head 47. The second laser head is also provided with a CCD camera connected to the image processing device 15.

  According to such a configuration, when the diameter of the winding 103 is, for example, 100 microns or more, the shutter on the fiber 5 side is closed and the laser beam is incident on the second laser head. The welding laser can be irradiated in a direction toward the terminal 109 or 110, and the connection can be reliably performed even when a winding having a predetermined diameter or more is used.

  If a total reflection mirror is provided instead of a half mirror and a shutter, and the welding laser beam is to be guided to the fiber 5, the total reflection mirror is removed from the optical path of the welding laser beam, and the welding laser beam is applied to the second fiber. When it is desired to guide, the welding laser beam may be reflected by a total reflection mirror and guided to the second fiber.

  Further, the diameter of the winding 103 may be measured by image processing, and the irradiation direction of the welding laser light may be changed according to the size of the diameter.

The external appearance perspective view of the coil components handled in embodiment of this invention. The disassembled perspective view which abbreviate | omitted the coil | winding of the coil components in embodiment of this invention. Sectional drawing of the metal terminal of the coil component of FIG. 1, and a sub trunk | drum. The enlarged view of the leg part vicinity of the metal terminal of FIG. 1 is a schematic view of a coil component connecting device according to an embodiment of the present invention. FIG. 6 is a schematic plan view from above of the coil component connecting device of FIG. 5. The figure which shows the state which performed the positioning of the coil | winding of the coil components of FIG. The figure which shows the state which crimped the fusion | melting part of the metal terminal of the coil components of FIG. The figure which shows the state after welding the fusion | melting part and coil | winding of the metal terminal of the coil components of FIG. The block diagram which shows the structure of the control system of the connection apparatus of the coil components by embodiment of this invention. The flowchart which shows the connection method of the coil components by embodiment of this invention. The figure which shows the laser irradiation position of the coil components in the connection method of the coil components by embodiment of this invention. The figure which shows the laser irradiation position at the time of rotating the coil components by 180 degree | times in the connection method of the coil components by embodiment of this invention. The figure which shows an example of the output of the welding laser beam in the connection method of the coil components by embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Connection apparatus 3 Laser oscillator 4 Guide laser oscillator 5, 11 Fiber 7 Main control apparatus 9 Illumination 12 Observation part 13 Monitor 15 Image processing apparatus 17 CCD camera 19, 23, 25, 27 Lens 21, 24, 26 Half mirror 29 X Axis motors 30, 32, 36 Axis 31 Y-axis motor 35 Z-axis motor 37 X-axis stage 39 Y-axis stage 40 Head transport unit 41 Z-axis stage 47 Laser head 51 Coil component 52 Chuck 53 Rotary table 102 Core 103 Winding 104 鍔Part 105 Core 107 One end face 109A, 110A Leg part 109E, 110E Melting part 109E1, 110E1 Face-to-face area 109E2, 110E2 Non-face-to-face area P1 First average power P2 Second average power T1 First irradiation time T2 Second irradiation time S135 Image processing S136 Laser irradiation

Claims (4)

A core composed of a core part, and a pair of flange parts each provided on both ends of the core part and having one surface;
An opposing portion provided in contact with and opposed to the one surface; and a facing region facing the one surface across the opposing portion when bent; and A pair of metal terminals having a non-facing region protruding from the contour, and a pair of metal terminals,
A winding wound around the winding core and having an end disposed between the facing portion and the connecting portion so as to contact and face at least the non-facing region of the connecting portion; A connecting device for connecting the end of the winding of the coil component and the connecting portion,
A laser oscillator that outputs laser light;
An optical system for guiding the laser beam to the coil component;
A laser beam irradiation position adjusting device that moves at least one of the coil component and the optical system in order to irradiate the predetermined irradiation position of the coil component with the laser beam;
An imaging device that captures an image of the laser light irradiated surface of the coil component;
Analyzing the image captured by the imaging device, determining the irradiation position on the coil component, operating the laser beam position adjusting device to guide the laser beam to the irradiation position, and outputting the laser beam to the laser oscillator And a control device that controls the laser beam to irradiate the irradiation position,
The irradiation position is a portion where the non-facing region of the connecting portion and the winding overlap with each other. Depending on the diameter of the winding, the irradiation position is a portion where the non-facing region of the connecting portion and the winding overlap, and the direction from the connecting portion toward the winding or from the winding Further comprising switching means for switching so that the laser beam is irradiated in any of the directions toward the connecting portion,
When the diameter of the winding is less than a predetermined length in a state in which the connecting portion is bent, the control device operates the switching means so that the non-facing region of the connecting portion and the winding And the irradiation position is determined so that the laser beam is irradiated in a direction from the connecting portion toward the winding, and the connecting portion is bent in a state where the connecting portion is bent. When the diameter is equal to or longer than a predetermined length, the switching means is operated so that the non-facing region of the connecting portion and the winding overlap, and the direction from the winding toward the connecting portion The coil component connecting device according to claim 1, wherein the irradiation position is determined so that the laser beam is irradiated onto the coil component. The control device outputs the laser beam at the first average power during the first irradiation period when the diameter of the winding is greater than or equal to a predetermined length, and during the second irradiation period following the first irradiation time. The coil component connecting device according to claim 2 , wherein the laser oscillator is controlled to output at a second average power larger than the first average power. A core composed of a core part, and a pair of flange parts each provided on both ends of the core part and having one surface;
An opposing portion provided in contact with and opposed to the one surface; and a facing region facing the one surface across the opposing portion when bent; and A pair of metal terminals having a non-facing region protruding from the contour, and a pair of metal terminals,
A winding wound around the winding core portion and having an end portion disposed between the facing portion and the connecting portion so as to contact and face at least the non-facing region of the connecting portion; A connecting method for connecting an end portion of the winding of the coil component and the connecting portion by a laser beam,
An imaging process in which the imaging device captures an image of the laser light irradiated surface of the coil component;
An irradiation position determination step in which a control device analyzes an image captured by the imaging apparatus and determines an irradiation position on the laser light irradiated surface;
A laser beam irradiation position adjusting step of moving at least one of the coil component or the optical system so that the laser beam position adjusting device guides the laser beam to the irradiation position;
A connecting step in which a laser oscillator outputs a laser beam to irradiate the irradiation position with the laser beam, and joins the connecting portion and an end of the winding;
Have
In the connecting step, the laser beam is irradiated to the irradiation position where the non-facing region of the connecting portion and the winding overlap.

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