JP4997074B2 - Connecting coil forming method and connecting coil forming apparatus - Google Patents

Description

  The present invention relates to a connecting coil forming method and a connecting coil forming apparatus, and more particularly to a connecting coil forming method and a connecting coil forming apparatus suitable for use as a reactor coil.

A reactor generally includes a winding core and a magnetic core, and an inductance is obtained by forming a coil by winding a winding around the core.
Conventionally, a reactor is used for a booster circuit, an inverter circuit, an active filter circuit, and the like. As such a reactor, one that houses a core and a coil wound around the core together with other insulating members in a case of metal or the like is often used.
And, for example, in a reactor used in an in-vehicle booster circuit, in order to obtain a high inductance value in a high current flow region, two single coils formed with a predetermined winding diameter and number of turns are formed in parallel, and both coils flow. Constituent coils connected (connected) so that current directions are opposite to each other are used.

As a conventional example of the coil as described above, the above-described two coils are formed by separate windings, and the connecting ends of the windings are connected by welding via a connecting terminal. (See, for example, Patent Document 1).
As another conventional example, two coils in the same winding direction arranged in parallel are formed by edgewise winding of one flat wire, and a rectangular wire spanned between the two continuous coils is also formed. There is also known a configuration in which the connecting portion is folded in half along the longitudinal direction and is accommodated in the outer shape of the end faces of both coils (see, for example, Patent Document 2).

JP 2003-1224039 A Japanese Patent No. 3737461

Since, for example, a substantially ring-shaped core is inserted into the two coils of the reactor, the two coils are required to have high arrangement accuracy. However, in the conventional coil described above, since the ends of the windings of the two coils are connected to each other via the connecting terminal, the arrangement of the two coils is likely to vary, and the core is It may not be possible to insert.
Moreover, in the coil of the said patent document 1, in order to connect both coils and a connection terminal, first, the film | membrane of the connection side edge part of each coil | winding and a connection terminal is peeled off, and the said location is welded on it. As a result, the manufacturing work has become very complicated.
Furthermore, since the two coils formed by the individual windings are electrically connected by welding via the connection terminal, the reliability of the welded part inevitably becomes a problem. There was also a problem that the characteristics varied.

Further, in the coil of Patent Document 2, since the two coils are formed by the same winding and the connecting portion is folded in two, the variation in the arrangement of the two coils hardly occurs. However, a space for the folded portion is required, and there is a possibility that the electrical characteristics of the coil may vary depending on the state of the folded portion.
Moreover, although the process of connecting both the coils and the communication terminal is not necessary, the above-described work process for turning back is required, and thus there is a problem that the manufacturing work becomes complicated accordingly.

  An object of the present invention is to provide a connected coil forming method and a connected coil forming apparatus capable of ensuring a high accuracy in the distance between first and second coils formed by bending a rectangular wire into a rectangular tube shape and a parallel shape. It is to be.

  Another object of the present invention is to easily form a connecting portion for connecting the first and second coils formed in a rectangular tube shape and in parallel by bending a flat wire without requiring welding or turning. It is providing the connection coil formation method and connection coil formation apparatus which can do.

In order to achieve the above object, the connecting coil forming method according to the present invention comprises a rectangular winding formed by rectangularly winding a single flat wire from one end and the other end. The first coil and the second coil are formed, and the rectangular wire portion located between the coils is used as a connecting portion for connecting the coils on the same surface, and the coils are arranged in parallel with each other. A connecting coil forming method comprising:
Forming a first coil from one end of the rectangular wire and forming a second coil from the other end;
In this coil forming step, the first coil is completed before the second coil is completed, and the length of the connection portion is measured after the first coil is completed and immediately before the second coil is completed. The length of the length measurement step and the length of the measured connection portion allocated to the coil spacing including the coil spacing including the two-coil arrangement interval specified in advance and the rectangular wire adjustment set in the second coil Corresponding to the divided length dimension, the connecting portion is formed on one piece of the last square winding portion of the second coil and connected on the same plane as the last square winding. and the final angle winding step of setting the arrangement intervals and the coils provided an offset portion for adjusting the distance between the first and second coils, and characterized in that it comprises.

  Here, in the length distribution step, the length dimension for adjusting the rectangular wire including the length of the coil side two or more turns before the last two turns set in the second coil is determined in advance. It is set as the dimension obtained by calculating from the length dimension for arrangement | positioning space | interval, and the measured length dimension of the connection part (Claim 2).

  Further, the length measuring step for measuring the length of the connecting portion is performed in a state in which two or more turns immediately before the completion of winding in the step of forming the second coil are left, and in the final square winding step, In the second turn immediately before the completion of winding of the second coil, an offset portion is provided in one piece of the last square winding portion of the second coil, and subsequently, in the first turn immediately before completion of winding of the second coil. You may comprise so that the length dimension for arrangement | positioning space | intervals of the said both coils may be set (Claim 3).

  Further, in the coil forming step, a first coil forming step of forming a first coil from one end portion of the flat wire, and a second coil is formed from the other end portion of the flat wire after forming the first coil. A second coil forming step, and in the second coil forming step, the length measuring step, the length distribution step, and the final square winding step are executed in the final winding step. Good (Claim 4).

Further, in the connecting coil forming step, in the coil forming step, the first coil forming step and the second coil using a connecting coil forming device provided with a set of winding head mechanisms for bending the rectangular wire by 90 degrees . The coil forming step is sequentially executed.

  Further, in the coil forming step, a connected coil forming device having two sets of winding head mechanisms is used, and the first coil forming step is performed by causing the one set of winding head mechanisms to function, The second coil forming step may be performed by causing the other set of winding head mechanisms to function.

  Further, between the first coil forming step and the second coil forming step, after the first coil is formed at one end, the flat wire is pulled out from the material supply region and the length of the flat wire is set to the first coil forming step. You may provide the 2nd coil rectangular wire setting process set to the length required for formation of 2 coils (Claim 7).

  Further, in the coil forming step, a connected coil forming apparatus including two movable winding head mechanisms and two winding processing lines provided to share these winding head mechanisms is used. The first coil forming step is performed by operating the one set of winding head mechanisms in the one winding processing line, and then the other set of windings in the one winding processing line. The second coil forming step is performed by operating a head mechanism. In the other winding processing line, the one set is set after completion of the first coil forming step in the one winding processing line. The winding head mechanism is moved to the other winding processing line to execute the first coil forming step in the other winding processing line, and the second coil forming in the one winding processing line is performed. After the end of the process, the other set of winding head mechanisms may be moved to the other winding machining line to execute the second coil forming step in the other winding machining line ( Claim 8).

  Further, in the one winding processing line and the other winding processing line, the first coil is formed at one end portion between the first coil forming step and the second coil forming step, respectively. A rectangular wire setting step for the second coil may be provided in which the rectangular wire is pulled out from the material supply region in a state and the length of the rectangular wire is set to a length necessary for forming the second coil. 9).

The first coil and the second coil are formed in a state in which square winding portions formed by square winding a single rectangular wire from one end side and the other end side thereof are stacked in a rectangular tube shape, and each of these coils. A rectangular coil portion positioned between each other is a connecting portion for connecting the coils on the same plane, and the connecting coils are formed by arranging the coils in parallel with each other.
In the coil forming step, a first coil forming step for forming the first coil from one end of the flat wire, and a second coil from the other end of the flat wire separately from the first coil forming step. A second coil forming step to be formed, and in the final winding step in the second coil forming step, the length measurement step, the length distribution step, and the final square winding step are executed, In the coil forming step, one winding head mechanism mounted on each of one and the other in advance, and one winding arranged on the same line while holding each winding head mechanism separately. Using a connected coil forming device having a processing line and the other winding processing line, operating the one winding head mechanism in the one winding processing line to execute the first coil forming step; At the same time It may be configured to execute the second coil forming step by operating the other winding head mechanism at the other winding processing line (Claim 10).

  Further, the length measuring step, the length distribution step, and the final square winding step executed in the final winding step in the second coil forming step include the one winding processing line and the other winding processing line. So that the first coil portion is transferred to the other winding processing line side through a rectangular wire conveyance unit previously provided between the first winding portion and the second winding processing line. You may comprise (Claim 11).

  In the coil forming step, the rectangular wire having a length necessary for the connecting portion set between the first coil, the second coil, and the coils is pulled out from the material supply area, and the one and the other are You may provide the rectangular wire arrangement | positioning process arrange | positioned on each winding process line prior to each said 1st and 2nd coil formation process (Claim 12).

The connected coil forming apparatus of the first invention of the present invention forms a first coil which is a rectangular tube-shaped rectangular wire coil formed by sequentially winding one end of a rectangular wire as a coil material, and the other end. Similarly, a second coil that is a flat wire coil is formed in the part, and the first coil and the second coil are connected by a connecting part that is continuous with both coils, and are installed in parallel with each other. In the connected coil forming apparatus, a direction including the length of the connecting portion before the final two turns or more in the second coil immediately after the completion of the first coil and immediately before the completion of the second coil and orthogonal to the connecting portion. And measuring the parallel spacing between corresponding coil sides of each coil positioned as a connection part length, and providing the connection part length measuring means for sending this to the main control unit, and the first or second coil Form of At the time, the flat wire introduced from the material supply region is arranged linearly along the winding processing line and supports the wire feeding unit, and the rectangular wire introduction direction ahead on the winding processing line A winding head mechanism disposed on the downstream side of the wire feeding unit, and an apparatus main body that supports the wire feeding unit and the winding head mechanism, wherein the winding head mechanism is a rectangular wire that is the coil material. A winding head section for performing 90-degree bending, and a machining position setting section for variably setting a processing position for 90-degree bending with respect to the winding head section along the winding processing line; A coil forming function for driving the winding head portion to form a second coil when a rectangular wire having the first coil formed at an end thereof is fed onto the winding processing line; Setting The machining position setting operation is variably controlled at a predetermined timing based on externally input control information, and the length of the connecting portion is adjusted to set the arrangement interval between the first coil and the second coil to a desired dimension. The main controller to be set is provided in the winding head mechanism (claim 13).

According to this invention, the machining position setting operation of the machining position setting unit can be variably controlled by the main control unit, so that the arrangement interval between the first coil and the second coil matches the preset dimension. At that point, 90-degree bending can be performed. As a result, the distance between the first and second coils formed in a rectangular tube shape and in parallel by bending a rectangular wire can be ensured with high accuracy, and thereby, in the two coils of the reactor, for example, A substantially ring-shaped core can be easily inserted.
Moreover, since the connection part which connects a 1st coil and a 2nd coil is continuously provided in both coils, a connection part can be formed easily, without welding and a return | turnback.
Furthermore, since only one winding head mechanism is required, the apparatus can be miniaturized.

  The winding head mechanism is controlled by the main control unit when the rectangular wire that is the material of each of the first or second coil is square-wound to be processed into a rectangular tube shape. A rectangular wire transfer function may be provided for transferring the rectangular wire by a necessary length along the winding processing line during the 90-degree bending process.

  According to the present invention, since the winding head mechanism has a flat wire transfer function, even when the action of the wire feed unit that transfers the flat wire along the winding processing line is not effective, the winding is performed until the final winding. be able to.

Further, the main control unit adjusts the measurement data of the connecting part length measured by the connecting part length measuring means for the arrangement interval between the two coils and the rectangular wire adjustment set in the second coil. A measurement data distribution function that distributes to the coil side including the control, and the operation of the machining position setting unit is controlled based on the distributed measurement data, and a predetermined one piece is applied to the last square winding portion of the second coil. An offset amount setting function for setting an offset amount and an arrangement interval setting control function for setting an arrangement interval between the two coils may be provided.

According to the present invention, the measurement data of the connecting part length measured by the connecting part length measuring means before the last two turns or more in the second coil is used for the arrangement interval of both coils and the rectangular angle set in the second coil. Since the offset amount and the arrangement interval between the two coils are set based on this data, the offset amount and the arrangement interval between the two coils can be accurately ensured.
In addition, an offset portion is provided in one piece of the last square winding portion of the second coil, and the length dimension for the arrangement interval of both coils is set in the first turn immediately before the completion of the winding of the second coil. The distance between the first and second coils can be ensured with high accuracy, and the arrangement interval between the first and second coils can also be ensured accurately.

The connected coil forming apparatus according to the second invention of the present invention forms a first coil which is a rectangular tube-shaped rectangular wire coil formed by sequentially winding one end of a rectangular wire as a coil material. Similarly, in the connected coil forming apparatus having a parallel installation function of forming a second coil, which is a flat wire coil, at the other end portion and installing the second coil in parallel with each other, the second coil after the completion of the first coil. The parallel part between the corresponding coil sides of each coil located in the direction orthogonal to the connecting part including the length of the connecting part before the last two turns or more in the second coil immediately before the completion of the coil is connected. The connecting portion length measuring means for measuring the length as a length and sending it to the main control unit is provided, and the rectangular wire introduced from the material supply region is wound when the first or second coil is formed. On line And a wire feeding unit for supporting the wire feeding unit and the wire feeding unit on the winding processing line, and on the winding processing line corresponding to the rectangular wire introduction side. Each of the first and second winding head mechanisms, and an apparatus main body that supports the wire feeding unit and each winding head mechanism, wherein the first and second winding head mechanisms are made of the coil material. A winding head section that sequentially executes 90 degree bending of a rectangular wire, and a 90 degree bending processing position is variably set along the winding processing line by changing the flat wire feed length of the wire feeding unit. An end portion of the rectangular wire that urges the winding head portion and the processing position setting portion when a rectangular wire having a predetermined length is fed onto the winding processing line. No. from the side A main control that has a coil forming function for forming a coil and a second coil from the other end side, and controls the machining position setting operation of the machining position setting unit at a predetermined timing based on externally input control information. A part may be provided in each of the first and second winding head mechanisms (claim 16).

According to this invention, each 1st or 2nd winding head mechanism arrange | positioned on a winding process line is arrange | positioned, These winding head mechanisms have a winding head part and a process position setting part, The machining position setting operation of the machining position setting unit is driven and controlled at a predetermined timing by the main control unit. Thereby, 90 degree | times bending process can be implemented when the arrangement | positioning space | interval of a 1st coil and a 2nd coil corresponds with the dimension set beforehand. As a result, it is possible to secure the distance between the first and second coils formed in a rectangular tube shape and in parallel by bending a flat wire with high accuracy.
Moreover, since the connection part which connects a 1st coil and a 2nd coil is continuously provided in both coils, a connection part can be formed easily, without welding and a return | turnback.
Furthermore, since the second coil can be formed immediately after the formation of the first or second winding head mechanism and the first coil arranged on the winding processing line, efficient production becomes possible.

  In addition, each coil located in a direction perpendicular to the connecting portion includes the length of the connecting portion that is two or more turns before the final completion of the second coil after the completion of the first coil. A parallel part interval between corresponding coil sides is measured as a connection part length, and it is provided with a connection part length measurement means for sending this to the main control part, and the main control part is the connection part length measurement means. A measurement data distribution function for allocating measurement data of the measured connection part length to the coil interval including the arrangement interval of the two coils specified in advance and the rectangular wire adjustment set to the second coil; An offset amount setting function for controlling the operation of the first and second winding head mechanisms based on the distributed measurement data and setting a predetermined offset amount in a piece of the last square winding portion of the second coil. A preliminary the arrangement interval setting control function for setting control the placement distance between the coils may be provided (claim 17).

  According to the present invention, the measurement data of the connecting part length measured by the connecting part length measuring means before the last two turns or more in the second coil is used for the arrangement interval of both coils and the rectangular angle set in the second coil. Since the offset amount and the arrangement interval between the two coils are set based on this data, the offset amount and the arrangement interval between the two coils can be accurately ensured.

  Each of the second winding head mechanisms is controlled by the main control unit when the rectangular wire that is the material of the corresponding first or second coil is square-wound and processed into a rectangular tube shape. It may be provided with a rectangular wire transfer function for moving the rectangular wire to each coil side by the length necessary for the rectangular winding processing along the winding processing line when bending 90 ° of the rectangular wire. Claim 18).

According to the present invention, since the winding head mechanism has a flat wire transfer function, even when the action of the wire feed unit that transfers the flat wire along the winding processing line is not effective, the winding is performed until the final winding. be able to.
According to the present invention, the first coil forming step can be executed by one set of winding head mechanisms and then the second coil forming step can be executed by the other set of winding head mechanisms. It can be formed efficiently.

  In addition, a cutter mechanism for cutting the rectangular wire in accordance with a command from the main control unit is provided on the material introduction region side of the winding processing line, and the main control unit is provided at one end of the rectangular wire. After the first coil is completed, the rectangular wire is cut into the cutter mechanism when a rectangular wire having a predetermined length necessary for forming the second coil and completing the connecting coil is introduced from the material supply area. May be provided with a rectangular wire cutting control function (command 19).

  According to this invention, the connecting coil forming device is equipped with a cutter mechanism for cutting according to the command of the main control unit, and further provided with a rectangular wire cutting control function in the main control unit. In addition, the flat wire can be cut accurately and reliably.

  The connecting coil forming apparatus of the third invention of the present invention is a movable winding head mechanism capable of reciprocating the first and second winding head mechanisms in a direction perpendicular to the winding machining line. The winding processing line is two winding processing lines that share the respective winding head mechanisms, and the wire feed unit corresponds to the two winding processing lines and from the winding processing line. The main control unit is configured to include first and second wire feeding units configured to be individually retractable, and the main control unit performs the first and second winding head mechanisms and the wire feeding according to preset commands. You may provide the cooperation control function which carries out cooperation control of each operation | movement of a unit (Claim 20).

According to this invention, each 1st or 2nd winding head mechanism arrange | positioned on a winding process line is arrange | positioned, These winding head mechanisms have a winding head part and a process position setting part, The machining position setting operation of the machining position setting unit is driven and controlled at a predetermined timing by the main control unit. Thereby, 90 degree | times bending process can be implemented when the arrangement | positioning space | interval of a 1st coil and a 2nd coil corresponds with the dimension set beforehand. As a result, it is possible to secure the distance between the first and second coils formed in a rectangular tube shape and in parallel by bending a flat wire with high accuracy.
Moreover, since the connection part which connects a 1st coil and a 2nd coil is continuously provided in both coils, a connection part can be formed easily, without welding and a return | turnback.
Furthermore, since the first or second winding head mechanism on each winding processing line can start forming the second coil immediately after forming the first coil, it is possible to manufacture efficiently.
Also, the first coil forming process and the second coil forming process are executed in one winding processing line, and the first coil forming process and the second coil forming process are executed in the same manner in the other winding processing line. Since the connecting coil can be formed in each winding processing line, the production efficiency can be improved.

  Further, when the main control unit drives and controls the one set of winding head mechanisms on the one winding processing line, the one set of winding head mechanisms is turned on. At the same time as moving to the other winding processing line and operating as a winding head mechanism for forming the first coil in the other winding processing line, the second coil forming line is operated on the one winding processing line. A first crossover control function for driving and controlling the other set of winding head mechanisms for forming the second coil, and when the other set of second coils is formed on the one winding processing line A winding head mechanism for forming the second coil in the other winding machining line after moving the other winding winding mechanism to the other winding machining line and forming the first coil in the other winding machining line. As up and running At the same time, after the first coil is formed on the other winding processing line, the one winding head mechanism is returned to the one winding processing line to form the first coil in the one winding processing line. And a second crossing control function for controlling the driving of the vehicle (claim 21).

  According to the present invention, one winding machining line and the other winding machining line share one winding head mechanism and the other winding head mechanism. By the control of the main control unit having one crossover control function and the second crossover control function, it can be moved to one of the winding processing lines and the other winding processing line. On the line, a first coil and a second coil can be formed to form a connection coil. As a result, it is possible to improve the production efficiency of the connected coil and to simplify the structure because one winding head mechanism and the other winding head mechanism are shared in two winding processing lines. Can be planned.

  Further, after each rectangular wire on each winding processing line is introduced and set to a required length, a cutter mechanism that is energized by the main control unit and cuts each winding processing line individually is provided. You may equip in the said raw material supply area | region of a line (Claim 22).

  According to the present invention, the connecting coil forming device is equipped with a cutter mechanism that individually cuts each winding processing line in accordance with a command from the main control unit. The line can be cut.

  According to a fourth aspect of the present invention, there is provided an apparatus for forming a connecting coil, wherein the wire feeding unit is provided at the center along the winding processing line, and the first winding head mechanism first is provided on one side. And a second sliding guide for the second winding head mechanism on the material supply region side, which is the other side, respectively, and the main control unit is provided with the first and second sliding guides. A simultaneous machining control function may be provided for controlling the driving so that the first and second coil machining operations are executed in the same time zone for each of the winding head mechanisms.

  According to the present invention, since the first coil and the second coil can be simultaneously processed from both ends of the rectangular wire, respectively, compared with the case where the second coil is formed after the formation of the first coil. Thus, since the connecting coil can be formed in approximately half the time, productivity can be improved.

  In addition, the main control unit performs at least the first coil machining operation by the first winding head mechanism at least 1/2 turn (two turns) of the completion of the second coil by the second winding head mechanism. The length of the connecting portion is orthogonal to the connecting portion before the final two turns in the second coil immediately after completion of the second coil after completion of the first coil. The connecting part length measuring means for measuring the parallel distance between the corresponding coil sides of each coil located in the direction as the connecting part length and sending it to the main control unit is inserted into and removed from the second sliding guide. Arranged freely, the main control unit sets the measurement data of the connecting part length measured by the connecting part length measuring means for the arrangement interval of the two coils and the second coil specified in advance. Coil including rectangular wire adjustment A measurement data distribution function that distributes to each other, and controls the operation of the machining position setting unit based on the distributed measurement data to set a predetermined offset amount in one piece of the last square winding portion of the second coil An offset amount setting function and an arrangement interval setting control function for setting an arrangement interval between the two coils may be provided.

  According to the present invention, the measurement data of the connecting part length measured by the connecting part length measuring means before the last two turns or more in the second coil is used for the arrangement interval of both coils and the rectangular angle set in the second coil. Since the offset amount and the arrangement interval between the two coils are set based on this data, the offset amount and the arrangement interval between the two coils can be accurately ensured.

  Further, the connecting part length measuring means is configured to measure a parallel interval between corresponding coil sides of each coil as a connecting part length based on a reference point set on the apparatus body, and the main control unit The measurement data of the connection part length measured by the connection part length measuring means is for the arrangement interval of the two coils specified in advance and for the coil side including the adjustment of the rectangular wire set in the second coil And a measurement data distribution function for distributing to each other, and controlling the operation of the machining position setting unit based on the distributed measurement data to vary the flat wire feed amount of the wire feed unit, thereby making the last square winding of the second coil An offset amount setting function for setting a predetermined offset amount in one piece of the portion and an arrangement interval setting control function for setting the arrangement interval between the two coils may be provided.

  According to the present invention, since the measurement data of the connected part length is measured based on the reference point set on the apparatus main body, more accurate measurement data can be obtained.

Since the connected coil forming apparatus of the first invention of the present invention is configured and functions as described above, according to this, the machining position setting operation of the machining position setting unit can be variably controlled by the main control unit. When the arrangement interval between the first coil and the second coil coincides with a preset dimension, the 90-degree bending process can be performed. As a result, it is possible to secure the distance between the first and second coils formed in a rectangular tube shape and in parallel by bending a flat wire with high accuracy.
Moreover, since the connection part which connects a 1st coil and a 2nd coil is continuously provided in both coils, a connection part can be formed easily, without welding and a return | turnback.
Furthermore, since only one winding head mechanism is required, the apparatus can be miniaturized.

  Since the connecting coil forming apparatus of the second invention of the present invention is configured and functions as described above, according to this, a part of the effect of the first invention can be obtained and arranged on the winding processing line. Each of the first and second winding head mechanisms is provided, and the formation of the second coil by the second winding head mechanism can be started immediately after the formation of the first coil by the first winding head mechanism. Therefore, efficient production becomes possible.

Since the 3rd connection coil formation apparatus of this invention is comprised and functions as mentioned above, according to this, in addition to being able to acquire a part of effect of the said 1st invention, on each winding processing line Since the first or second winding head mechanism can start forming the second coil immediately after forming the first coil, efficient production becomes possible.
Also, the first coil forming process and the second coil forming process are executed in one winding processing line, and the first coil forming process and the second coil forming process are executed in the same manner in the other winding processing line. Since the connecting coil can be formed in each winding processing line, the production efficiency can be improved.

  Since the 4th connection coil formation apparatus of this invention is comprised as mentioned above and functions, according to this, in addition to being able to acquire a part of effect of the said 1st invention, from each end of a flat wire, it is 1st, respectively. Since the first coil and the second coil can be processed at the same time, the connection coil can be formed in approximately half the time compared to the case where the second coil is formed after the first coil is formed. Thus, productivity can be improved.

Hereinafter, the 1st-4th embodiment of the formation method of a connection coil and the connection coil formation device concerning the present invention is described based on a drawing.
First, based on FIGS. 1 and 2, a reactor in which the connecting coil formed by the connecting coil forming method and the connecting coil forming apparatus is applied as a reactor coil will be described.
FIG. 1 is a perspective view of a reactor 1, and FIG. 2 is a perspective view of a reactor coil (hereinafter referred to as a connecting coil) 10.

As shown in FIG. 1, the reactor 1 is used, for example, in an electric circuit of a device having a forced cooling means, and includes a connecting coil 10, a reactor core 2, a bobbin (not shown), a heat conductive case 3, and an insulation / function (not shown). It is configured including a heat dissipation sheet and the like.
The reactor 1 as described above has a configuration in which the reactor core 2 is inserted into the connecting coil 10 and these are accommodated in the heat conductive case 3, and then the filling material 4 is poured therein and fixed. The reactor fixing holes 3A at the four corners of the heat conductive case 3 are screw holes for fixing the heat conductive case 3 to, for example, a forcedly cooled housing.

The connecting coil 10 is a first coil formed in a state in which one rectangular wire W is square-wound from one end and the other in the length direction and the square-wound portions are stacked in a rectangular tube shape. 11 and the second coil 12 are formed.
A connecting portion 13 is provided between the first coil 11 and the second coil 12 to connect the coils 11 and 12 on the same plane, and the connecting portion 13 is located between the coils 11 and 12. It is formed by the rectangular wire W that is a material. The first coil 11 and the second coil 12 are arranged in parallel with each other.
Here, square winding refers to winding a coil in a rectangular tube shape, and is contrasted with round winding in which a coil is wound in a round shape.

The lead portions 11A and 12A, which are the end portions of the first coil 11 and the second coil 12 of the connecting coil 10, peel off the coating of the flat wire W, and the conductor is exposed. Is provided so as to be connected to other electrical components and the like.
Moreover, the flat wire W is obtained by coating a conducting wire having a rectangular cross section.

  As will be described in detail later, a portion (hereinafter referred to as an offset portion) 14 on the second coil 12 side in the vicinity of the connecting portion 13 between the first coil 11 and the second coil 12 is formed when the connecting coil 10 is formed. In order to eliminate the variation in the distance between the axial center of the first coil 11 and the axial center of the second coil 12 generated in the winding, the winding is made to protrude outward from the outer shape of the rectangular tube shape. Hereinafter, it is referred to as offset winding). The offset portion 14 also serves as a connecting portion 13 that connects the first coil 11 and the second coil 12.

As shown in detail in FIG. 2, the first coil 11 and the second coil 12 of the connecting coil 10 are formed in parallel and have the same winding direction.
In addition, since the lead portions 11A and 12A of the two coils 11 and 12 are on the same side in the axial direction of the coils 11 and 12, even when a terminal (not shown) is attached to the distal end portion of the lead portions 11A and 12A, It is possible to align the terminals.

The connecting coil 10 is bent at approximately 90 degrees by projecting the flat wire W from the second coil 12 side by a gap length between the coils 11 and 12 at the winding end 12B of the second coil 12, The first coil 11 is stacked such that the second coil 12 is stacked in the same direction (indicated by arrow B in FIG. 2) as the stacking direction of the first coil 11 (indicated by arrow A in FIG. 2). When the second coil 12 is wound, the first coil 11 and the second coil 12 are continuously connected in parallel via the connecting portion 13 by being angularly wound in the direction opposite to the winding direction of Is formed.
Since the connecting portion 13 is formed in the same direction as the lead portions 11A and 12A of the first coil 11 and the second coil 12, when the connecting coil 10 is assembled as shown in FIG. There is no interference with the protrusions formed on the bottom surface of the conductive case 3. This eliminates the need for restricting the position and shape of the protrusion formed on the bottom surface of the case 3 because of the connecting portion 13, thereby obtaining an effect of increasing the degree of freedom in design.

As described above, the connecting coil 10 is formed by sending out the rectangular wire W having a length necessary to squarely wind the second coil 12 in advance after the square winding of the first coil 11 is completed. This is a double connected coil 10 formed by squarely winding a second coil 12 from the other end of the flat wire W having the coil 11 at one end.
For this reason, the accumulation of the wire feeding error when forming each side during the square winding process of the second coil 12 results in variations in the distance between the axis of the first coil 11 and the axis of the second coil 12. May appear.

As described above, since the two straight portions of the substantially ring-shaped reactor core 2 are inserted into the first coil 11 and the second coil 12, the axis of the first coil 11 and the second coil 12 are The distance from the shaft center requires high dimensional accuracy.
Therefore, in order to eliminate the accumulation of wire feeding errors, the offset portion 14 on the second coil 12 side forming the connecting portion 13 between the first coil 11 and the second coil 12 is replaced with the first coil 11 and the second coil 12. It is provided as a surplus part for adjusting the distance between them, and is square-wrapped. And as mentioned above, the square winding of the part containing this offset part 14 is called offset winding.

  Next, based on FIGS. 3-15, 1st Embodiment of the formation apparatus of the connection coil of this invention which forms the said connection coil 10 is described.

In the first embodiment, the connecting coil 10 is formed by using a connecting coil forming apparatus 20 including a set of winding head mechanisms 25.
That is, the connecting coil forming device 20 forms the first coil 11 in the shape of a rectangular tube formed by sequentially winding one end of a rectangular wire W as a coil material with a set of winding head mechanisms 25. In addition, after the first coil 11 is formed, the second coil 12 is continuously formed at the other end in the same manner, and the first coil 11 and the second coil 12 are installed in parallel with each other. It has a function, and forms the connection coil 10 by this.
1 and 2, the first coil 11 and the second coil 12 have a substantially square rectangular tube shape. In the embodiment, however, the first coil 11 has a rectangular shape composed of a long side and a short side. 11 and the second coil 12 are connected coils 10.

  More specifically, the connecting coil forming device 20 is a flat angle introduced from the outside, that is, the material supply region B, when forming the first coil 11 and the connecting portion 13 and the second coil 12 continuous to the first coil 11. The wire W is arranged on a straight line along the winding processing line A, and the wire feeding unit 21 that supports the wire W, and the downstream side of the wire feeding unit 21 in the flat wire introduction direction K on the winding processing line A. The winding head mechanism 25 disposed in the apparatus, the apparatus main body 30 that supports the wire feeding unit 21 and the winding head mechanism 25, and an arithmetic control unit 35 that is a main control unit that controls the entire connected coil forming device 20. And is configured.

In addition, on the apparatus main body 30 and on the upstream side in the flat wire introduction direction K of the wire feeding unit 21, the second coil 12 is formed along with the winding processing of the winding head mechanism 25 and the like when the second coil 12 is formed. An arrival detection sensor 31 that detects the arrival of the first coil 11 that moves to the side is disposed along the winding processing line A.
Further, a cutter unit 32 as a cutter mechanism is disposed on the apparatus main body 30 and on the upstream side of the arrival detection sensor 31. Further, the material supply region B for supplying the flat wire W is provided at a position away from the cutter unit 32 on the upstream side in the flat wire introduction direction K. In the material supply region B, for example, a bobbin (not shown) is provided. Has been placed.

The wire feeding unit 21 includes a mounting base 22 and a wire feeding pulley 23 provided on the mounting base 22 so as to be movable in the Y-axis direction (a direction perpendicular to the flat wire introduction direction K) as shown in FIG. It is prepared for.
The mounting base 22 includes two fixing portions 22A disposed at positions opposite to each other across the flat wire W, and two guide portions 22B spanned between the fixing portions 22A. . In addition, one of the pair of wire feed pulleys 23 arranged so as to be opposed to the vertical direction of the flat wire W has a concave cross-sectional shape including the pulley flange 23A, and the other pulley has a convex shape fitted to the pulley. The flat wire W is sent out by sandwiching the flat wire W by a cylinder (not shown) and rotating the upper and lower pulleys in opposite directions by a drive motor (not shown).
As shown in FIG. 3 and the like, the wire feeding unit 21 has a function of the edge feeding that intermittently feeds the long side or short side dimension of the first coil 11 and the like, and the first coil 11 as shown in FIG. Regardless of the long side or short side dimension, etc., the lead wire feeding function is provided for continuous feeding. Such a wire feeding unit 21 is controlled by the arithmetic control unit 35 as will be described in detail later. Is done.

  The wire feed pulley 23 and the pulley flange 23A of the wire feed unit 21 as described above can be lowered with respect to the flat wire W by a known mechanism (in FIG. 3, the direction perpendicular to the paper surface), and The wire feed pulley 23 and the pulley flange 23A can move in the Y-axis direction along the guide portion 22B of the mounting base 22 as shown in FIG.

The winding head mechanism 25 has a winding head portion 26 for performing a 90-degree bending process on the rectangular wire W, and a processing position for the 90-degree bending process with respect to the winding head section 26 to the winding processing line A. A head main body 27 that is a machining position setting section that is variably set along, and a mounting base 28 that supports the head main body 27 in a predetermined range along the flat wire introduction direction so as to be reciprocally movable as indicated by an arrow S. I have.
The winding head mechanism 25 drives the winding head portion 26 and the head main body 27 when the rectangular wire W having the first coil 11 formed at the rear end thereof is fed onto the winding processing line A. The coil forming function for forming the second coil 12 is provided. This coil forming function refers to a function of forming the second coil 12 from the front end portion of the flat wire W in which the first coil 11 is formed at the rear end portion.

The winding head portion 26 of the winding head mechanism 25 is composed of a fixing jig 26A and a winding jig 26B. These fixing jig 26A and winding jig 26B are provided on the head body 27. Yes. The fixing jig 26A guides the fed rectangular wire W and fixes the side surface on one end side in the width direction when bending the rectangular wire W. Further, the winding jig 26B is configured to press the other end side surface in the width direction to the fixing jig 26A side during the bending process of the flat wire W, and to rotate approximately 90 degrees in the bending process direction of the flat wire W. It has become.
Here, for the rotation of the winding jig 26B for the 90-degree bending process, for example, the winding jig 26B fixed to the mounting member 29 of the head body 27 is moved by the motor, pulley, etc. (not shown). 3 is configured to rotate in the direction of arrow R in FIG. However, another mechanism may be used.

  The mounting base 28 includes two fixing portions 28A provided along the flat wire introduction direction K and at a predetermined interval, and two guides that are spanned between the fixing portions 28A and are parallel to the flat wire introduction direction K. The head main body 27 can reciprocate in the direction of the arrow S in FIG. 3 as described above along the guide portion 28B.

In addition, the winding head mechanism 25 operates under the control of the main control unit 35 when the rectangular wire W is square-wound and processed into a rectangular tube shape, and when the rectangular wire is bent 90 degrees, the winding processing line A As described above, a rectangular wire transfer function for reciprocating in the direction of the arrow S and transferring the rectangular wire W by the required length, that is, by the long side or the short side is provided.
As shown in FIGS. 9 to 14, this flat wire transfer function is used to fix the flat wire W by the fixing jig 26 </ b> A and the winding jig 26 </ b> B when the action of the wire feeding unit 21 stops when the flat wire W is fed. While being sandwiched or released, the head main body 27 reciprocates along the guide portion 28B between the fixed portions 28A of the mounting base 28 and along the flat wire introduction direction K in the above-described arrow S direction, as described above. This is a function capable of transferring the flat wire W by edge feeding.

When the second coil 12 is formed, the arrival detection sensor 31 detects that the completed first coil 11 has arrived at a predetermined position when moving to the winding head mechanism 25 side, and detects the detected information. It can be sent to the arithmetic control unit 35.
Then, when the first coil 11 moves to the winding head mechanism 25 side, the wire feed pulley 23 and the pulley flange 23A of the wire feed unit 21 are arranged so that the wire feed unit 21 does not get in the way. It is controlled by the arithmetic control unit 35 so as to move away from A in the Y-axis direction and retract.

The cutter unit 32 includes a mounting base 33 and a cutter body 34 provided on the mounting base 33 so as to be movable in the Y-axis direction.
The mounting base 33 includes two fixing portions 33A disposed at positions opposite to each other across the flat wire W, and two parallel guide portions 33B spanned between the fixing portions 33A. Has been.
The cutter body 34 is provided with a blade portion (cutter) (not shown). Therefore, the cutter main body 34 is slid in the Y-axis direction, and the fed rectangular wire W can be cut to a predetermined length by the cutter attached to the cutter main body 34.

  Further, in the vicinity of the winding head mechanism 25, the connecting portion 13 after the completion of the first coil 11 and before the final two turns (two turns of 90 degrees) of the second coil 12 immediately before the completion of the second coil 12. The parallel spacing between the corresponding coil sides of the coils 11 and 12 positioned in the direction orthogonal to the connecting portion 13 is measured as the connecting portion length, and this is sent to the arithmetic control unit 35. A connecting portion length measuring means 36 is provided (see FIG. 12).

  As shown in FIG. 12, the connecting part length measuring means 36 measures the distance from the reference position to the end face of the short side 12B of the second coil 12 at a position two turns before the final winding of the second coil 12. The distance to the end surface of the short side 11C of the first coil 11 that approaches the second coil 12 side as the winding of the second coil 12 advances at the same position as the second coil detection sensor 36B. It comprises a first coil detection sensor 36A to be measured.

The winding head mechanism 25 is provided with the arithmetic control unit 35 that variably controls the machining position setting operation of the head main body 27 at a predetermined timing based on externally input control information.
As shown in FIGS. 3 and 14, the arithmetic control unit 35 exchanges signals with the wire feed unit 21, the winding head mechanism 25, the cutter unit 32, and the like so that the mechanisms can be controlled. It has become.

  Commands based on various types of information are input from the input unit 37 to the arithmetic control unit 35. And based on the input command, between the calculation control unit 35 and the wire feeding unit 21, the feeding of the rectangular wire W on the processing line A by the wire feeding unit 21 is controlled, and if necessary, the wire Control such as retraction and return from the processing line A of the wire feed pulley 23 of the feed unit 21 is performed.

  Between the calculation control unit 35 and the winding head mechanism 25, based on a command from the input unit 37, the calculation control unit 35 controls the 90-degree bending process by the winding head unit 26, and the winding head mechanism 25. When the rectangular wire transfer function is activated and the rectangular wire W feeding action by the wire feeding unit 21 does not reach, the head body 27 in the winding head mechanism 25 is reciprocated in the direction of the arrow S, thereby Control for transferring W is performed.

  Between the calculation control unit 35 and the cutter unit 32, a predetermined rectangular wire W is generated by the calculation control unit 35 based on the command from the input unit 37 by the advancement of the cutter body 32 in the Y-axis direction of the cutter body 34. The cutting at the position, the return of the cutter body 34 to the initial position after cutting, and the like are controlled.

  The memory 38 stores various information necessary for control by the arithmetic control unit 35, for example, preset reference dimensions (set dimensions) between the first and second coils 11 and 12, the width and thickness of the rectangular wire W. Dimensions, the number of stacked layers to be wound into a rectangular rectangular tube, the long and short sides of the rectangular rectangular tube, the overall length of the rectangular wire W necessary to form the first and second coils 11 and 12, etc. Information is contained.

Further, the arithmetic control unit 35 includes the length of the connecting portion 13 before the last two turns in the second coil 12 immediately before the completion of the second coil 12 and is positioned in a direction orthogonal to the connecting portion 13. The connecting portion length measuring means 36 for measuring the parallel distance between the corresponding coil sides of the coils 11 and 12 as the connecting portion length and sending it to the calculation control unit 35 is connected.
Further, the calculation control unit 35 uses the second coil 12 for the arrangement interval of the coils 11 and 12 in which the measurement data of the connected part length measured by the connected part length measuring means 36 is specified (set) in advance. And a measurement data distribution function that distributes to the coil side including the rectangular wire adjustment set to the control, and the operation of the winding head mechanism 25 is controlled based on the distributed measurement data. An offset amount setting function for setting a predetermined offset amount F to one piece of the square winding portion and an arrangement interval setting control function for setting and controlling the arrangement interval between the coils 11 and 12 are provided.

Next, with reference to FIGS. 3 to 14, a method for forming a connection coil according to the first embodiment will be described based on the flowchart of FIG. 15.
In the flowchart of FIG. 15, the determination process at the time of moving to the next process (ST), that is, the determination of whether or not a desired condition is satisfied is yes in all processes, that is, The explanation will proceed on the assumption that. Moreover, the calculation control part 35 in the whole connection coil formation apparatus 20 is shown only in FIG. 3, and the display of the upstream and downstream of the flat wire introduction direction K is also shown only in FIG.

First, as a first step (ST1) shown in FIG. 15, a winding wire of the first coil 11 and the second coil 12, that is, a rectangular wire W having a length sufficient to form the connecting coil 10, is prepared. As shown in FIG. 3, the wire rod is fed from the wire bobbin and is fed onto the head main body 27 on the cutter unit 32, the wire feed unit 21, and the winding head mechanism 25 on the winding processing line A.
Here, the length of the flat wire W is determined based on the preset number of turns of the first coil 11 and the second coil 12, that is, the stacking dimensions of the coils 11 and 12, and the preset approximate offset portion 14. And the length of the connecting portion 13 including the information. The information is stored in the memory 38 of the arithmetic control unit 35. A flat wire W having a length longer than that is wound around the wire bobbin.

  Thereafter, the tip of the flat wire W is passed between the fixing jig 26A and the winding jig 26B of the head main body 27 in the winding head mechanism 25, and the tip is set at a reference position marked on the apparatus.

Next, the leading end of the rectangular wire W set at the reference position by driving the arithmetic control unit 35 based on a command from the input unit 37 is set to the length of the first winding side (long side or short side) set in advance. After moving to the first coil winding start position by the wire feed unit 21 by the length including the lead portion length, the winding head mechanism 25 is driven and controlled, and the leading end of the flat wire W is wound on the head main body 27. While being held between the jig 26B and the fixing jig 26A, the winding jig 26B is rotated 90 degrees from the initial position in the direction of arrow R shown in FIG. This 90-degree bending process is repeated, and the first coil 11 is completed by winding up to a predetermined number of turns.
When the first coil 11 is wound, the rectangular wire W is fed by edge feeding. In other words, the flat wire W is fed by the edge feed sequentially by the action of the wire bobbin and the wire feed unit 21, for example. This is called edge feeding.

The completion of the first coil 11 can be determined by, for example, counting the number of rotations of the winding jig 26B in the winding head mechanism 25. That is, the number of rotations of the winding jig 26B until the completion of the first coil 11 is set in advance, the number of rotations is stored in the memory 38, and when the set number of rotations is reached, the winding jig Control by the arithmetic control unit 35 is performed so that the line feed function of the line feed unit 21 is not driven so that the 26B does not rotate.
Therefore, when the above state is reached, it is determined that the first coil 11 is completed.

Subsequently, as a second step (ST2) shown in FIG. 15, the wire rod bobbin and the wire feed unit 21 are driven by the arithmetic control unit 35 based on a command from the input unit 37, as shown in FIG. 4. The completed rectangular wire W for the first coil 11 and the second coil 12 is sent out by lead wire feeding along the rectangular wire introduction direction K, the first coil 11 is pulled out from the winding head mechanism 25, and the rectangular wire introduction direction K Move to the downstream side.
At this time, the rectangular wire W for the first coil 11 and the second coil 12 drawn out from the winding head mechanism 25 is supported and moved by a transfer device having a transfer stand (not shown).

  Next, as a third step (ST3), as shown in FIG. 5, when the flat wire W is pulled out by lead wire feed to a position where a predetermined length for the second coil 12 is secured, calculation control is performed. The cutter body 32 of the cutter unit 32 is moved forward by the control of the section 35, and the rectangular wire W is formed at the end position (cutting position C1) of the lead wire 12A of the second coil 12 by the cutter provided in the cutter body 34. Disconnect.

  Thereafter, as a fourth step (ST4), as shown in FIG. 6, the completed first coil 11 and the rectangular wire W for the second coil 12 continuous thereto are further fed, and all of them are sent to the winding head mechanism. At the same time, it is pulled out from 25 and moved to a carrier stand (not shown) and moved to a position where the worker M is waiting.

Next, as a fifth step (ST5), the operator M holds the rectangular wire W for the first coil 11 and the second coil 12 continuous therewith as shown in FIG. The first coil 11 is carried to the initial position when forming, and as the second coil forming step, the leading end side of the flat wire W for the second coil 12 is placed on the wire feeding unit 21 and the winding head mechanism 25. Put.
Then, the wire feed unit 21 is driven by the arithmetic control unit 35 based on a command from the input unit 37, and the leading end of the flat wire W is set to the length of the first winding side of the second coil 11 and the lead portion 12B (FIG. 7 is indicated by an imaginary line), and the winding process of the second coil 12 is started by the side feed of the line feed unit 21.

  Thereafter, as the sixth step (ST6), as shown in FIG. 8, the line feed unit 21 is controlled by the operation of the arithmetic control unit 35 based on the command from the input unit 37 to feed the rectangular wire W side by side. However, as in the first step, the winding jig 26B of the winding head mechanism 25 is rotated 90 degrees at the other end of the rectangular wire W toward the completion of the second coil 12. The winding process of the second coil 12 is continued.

At this time, the completed first coil 11 is arranged on the left side of the winding processing line A toward the winding head mechanism 25, so that the orientation between the first coil 11 and the second coil 12 is changed. The connection coil 10 is formed in a parallel state.
Further, as the wire W of the second coil 12 is advanced as the flat wire W is fed side by side, the first coil 11 is connected to the wire feed unit 21 and the head main body 27 of the winding head mechanism 25 as shown in FIG. By the cooperative action of the fixing jig 26A and the winding jig 26B, it is pulled toward the winding head mechanism 25 and approaches the second coil 12 side.

Thereafter, as a seventh step (ST7), as shown in FIG. 9, the first coil 11 approaching the second coil 12 side is detected by the arrival detection sensor 31 arranged at a predetermined position, and the signal Is sent to the calculation control unit 35, and the line feed unit 21 is controlled by the calculation control unit 35.
At this time, the arithmetic control unit 35 opens the pair of wire feeding pulleys 23 vertically to prevent the wire feeding unit 21 from interfering with the movement of the first coil 11 based on the information from the arrival detection sensor 31. Control is performed so that W is opened, and the wire moves along the guide portion 22B of the mounting base 22 of the wire feeding unit 21 in the Y-axis direction and retracts from the flat wire W.

  Next, as the eighth step (ST8), as shown in FIG. 10, the winding control mechanism 35 controls the winding head mechanism 25 to operate the rectangular wire transfer mechanism of the winding head mechanism 25, and the arrow S The side feed along the direction is performed, and first, the offset adjustment of the connecting portion 13 between the first coil 11 and the second coil 12 is performed, and then the interval adjustment between the first coil 11 and the second coil 12 is performed. .

Then, as the ninth step (ST9), as shown in FIG. 11, the coupling coil 10 that has been adjusted for the offset between the first coil 11 and the second coil 12 and the interval is completed.
When the connecting coil 10 is completed, the connecting coil 10 is removed from the connecting coil forming device 20 and is transported to a predetermined storage place and stored therein. 10 formation is started.

Here, detailed operations of the offset adjustment and the interval adjustment in the eighth step (ST8) will be described with reference to FIGS.
That is, when the winding of the second coil 12 advances and the first coil 11 and the second coil 12 further approach each other, for example, two turns (twice by 90 degrees) are completed before the winding is completed. The distance from the measurement position serving as the reference position to the first coil 11 and the distance from the measurement position to the second coil 12 by the first coil position detection coil detection sensor 36A and the second coil position detection coil detection sensor 36B. Are measured, and the information is transmitted to the arithmetic control unit 35.

First, the first coil position detection coil detection sensor 36A measures the distance L1 to the side end face of the short side 11C of the first coil 11 approaching the first coil position detection coil 36A and the second coil position. The distance L2 to the side end face of the short side 12B of the second coil 12 two turns before is measured by the detection coil detection sensor 36B.
Then, the arithmetic control unit 35, based on the distance information from the first coil position detection coil detection sensor 36A and the second coil position detection coil detection sensor 36B, the short side 11C ahead of the moving direction of the first coil 11, and the short side A distance L3 between the short side 12C of the second coil 12 facing the side 11C is calculated.
The distance L3 between the opposite sides 11C and 12C of the coils 11 and 12 is the distance L2 from the distance L1 and the preset long side dimension of the second coil 12, that is, the dimension between the short sides 12B and 12C. It can be obtained by subtraction.

  Then, the distance L3 between the opposing short sides of the coils 11 and 12 obtained by calculation and the preset distance LL between the coils 11 and 12 as shown in FIG. When one turn is wound in the state of the distance L3 obtained by comparison and obtained from this measurement result, the sides of the coils 11 and 12 in the direction orthogonal to the set distance LL between the coils 11 and 12 are aligned with each other. Whether or not there is is calculated by the calculation control unit 35.

  As a result, when the distance L3 between the short sides of both the coils 11 and 12 (feed for the long side dimension) and two turns (turned 180 degrees), the distance between the coils 11 and 12 is the set distance. If it is determined that the sides of the coils 11 and 12 in the direction orthogonal to LL do not coincide with each other, it is necessary to adjust the deviation.

For this reason, the deviation is offset so that the deviation with respect to the sides of the two coils 11 and 12 in the direction orthogonal to the set distance LL is fed with a feed dimension added to the feed dimension corresponding to the normal long side dimension of the second coil 12. As F, that is, as an adjustment allowance. Then, a corrected feed dimension L4 obtained by adding an offset dimension F to a normal feed dimension (here, the long side dimension) is set.
And after sending the 1st coil 11 by this correction feed dimension L4, as shown in FIG.12 (B), when the said winding jig | tool 26B is rotated 90 degree | times and the flat wire W is bent, The long side dimension of the part of the second coil 12 appears as a dimension to which the offset dimension F is added.

Here, the distance between the coils 11 and 12 is, for example, the distance L3 between the centers of the opposite sides 11C and 12C of the first coil 11 and the second coil 12 shown in FIG. This is a distance that can be defined between the coils 11 and 12, such as the distance between the axis W1 of the first coil 11 and the axis W2 of the second coil 12 shown in FIG.
The detection coil detection sensors 36A and 36B may be any existing sensors that can measure the distance, for example, optical sensors and mechanical sensors. Further, after the visual measurement, the calculation of the forming apparatus 1 is performed. You may make it input a measured value into the control part 35 data.

  Then, based on the measured distance between the coils 11 and 12, the offset amount F is calculated as described above, and the rectangular wire W has the corrected feed dimension L4 obtained by adding the normal wire feed amount to the offset amount F. Sent out.

  As described above, by setting the distance between the axis W1 of the first coil 11 and the axis W2 of the second coil 12 of the connecting coil 10 as a preset (specific) set distance LL, the distance L3 When the coil 11 is wound for one turn, when the sides of the coils 11 and 12 in the direction orthogonal to the set distance LL between the coils 11 and 12 are aligned on a straight line, the substantially ring-shaped connecting core 2 is not used. These two straight portions can be inserted.

Next, as shown in FIG. 13 (A), in order to secure a preset gap dimension L5 between the coils 11 and 12 in FIG. 13 (B), the normal feed dimension, that is, the first coil 11 A second corrected feed dimension L6 added to the feed dimension for the length of the short side 11C is obtained, and the second corrected feed dimension L6 is fed, and at that position, as shown in FIG. The jig 26B is rotated 90 degrees, so that when the flat wire W is bent as the final square winding process, the gap L5 between the coils 11 and 12 is accurately ensured. It has become.
The gap dimension L5 is a dimension that is inevitably determined when the axial centers W1 and W2 of the coils 11 and 12 coincide with the set dimension LL.

  Here, when the wire feeding unit 21 is retracted from the processing line A and the feeding operation of the flat wire W by the wire feeding unit 21 is stopped, in particular, the second coil from the state before two turns to the final square winding. 12, the operation control unit 35 is driven by a command from the input unit 37, and the operation control unit 35 causes the head body 27 of the head mechanism 25 to move in the direction of introducing the rectangular wire as indicated by the arrow S. This is performed by reciprocating in a direction along K and rotating the winding jig 26B by 90 degrees with the fixing jig 26A as a base point at each position.

  That is, as shown in FIG. 12 (A), when the corrected feed dimension L4 between the coils 11 and 12 is set, the fixing jig 26A and the winding jig 26B indicated by the phantom lines at the position of S1 However, the head body 27 moves to the bending position S2 as described above. And 90 degree | times bending process is implemented as shown in FIG. 12 (B) in the position.

  Further, at the time of bending based on the second corrected feed dimension L6 between the coils 11 and 12, as shown in FIG. 13A, the fixing jig 26A and the winding jig indicated by the phantom line at the position of S2 are used. As described above, the tool 26B moves to the bending position S3 at the corrected feed dimension L6 by moving the head body 27 in the direction of arrow S by the side feed. Then, 90 ° bending is performed at that position as shown in FIG.

According to the first embodiment as described above, the following effects can be obtained.
(1) Since the processing position setting operation of the head main body 27 in the winding head mechanism 25 can be variably controlled by the arithmetic control unit 35, the arrangement interval between the first coil 11 and the second coil 12 is set in advance. When the coil is wound for one turn with the set dimension LL between the axial centers W1 and W2 of both the coils 11 and 12 and the distance L3, the coils 11 and 12 in the direction orthogonal to the set distance LL between the coils 11 and 12 When the sides coincide with each other on a straight line, a 90-degree bending process can be performed. As a result, the rectangular wire W can be bent and the distance between the first and second coils 11 and 12 formed in a rectangular tube shape and in parallel can be ensured with high accuracy, whereby the two coils of the reactor can be secured. For example, a substantially ring-shaped core can be easily inserted therein.

  (2) Since the connecting portion 13 that connects the first coil 11 and the second coil 12 is provided continuously to both the coils 11 and 12, the connecting portion 13 can be easily and without requiring welding or turning. Can be formed.

  (3) Since only one winding head mechanism 25 is required, the connected coil forming apparatus 20 can be reduced in size.

  (4) Since the winding head mechanism 25 has a rectangular wire transfer function for transferring the rectangular wire W by a necessary length, the wire feed unit 21 for transferring the rectangular wire W along the winding processing line A Even when the effect is not reached, it is possible to perform the final winding process. As a result, it is not necessary to provide a mechanism in place of the wire feeding unit 21 separately, and the apparatus can be simplified.

  (5) The measurement data of the connecting part length measured by the connecting part length measuring means 36 before the final turn 2 turns in the second coil 12 is set in the second coil 12 and for the arrangement interval of the coils 11 and 12. Since the offset amount F and the arrangement interval L5 between the coils 11 and 12 are set based on this data, the offset amount and the arrangement interval between the coils are set. It can be ensured accurately.

  (6) The connecting coil forming apparatus 20 is equipped with a cutter unit 32, and the cutter unit 32 is controlled by the arithmetic control unit 35. Accordingly, the flat wire W can be cut accurately and reliably at a necessary position.

Next, based on FIGS. 16-26, 2nd Embodiment of the formation apparatus of the connection coil of this invention which forms the said connection coil 10 is described.
In the second embodiment and the third embodiment and the fourth embodiment described below, the same reference numerals are assigned to the same and substantially the same components and members used in the first embodiment. Detailed description thereof will be omitted or simplified.

2nd Embodiment forms the said connection coil 10 using the connection coil formation apparatus 40 provided with two winding head mechanisms.
That is, the connecting coil forming device 40 includes two winding head mechanisms, a first winding head mechanism 45 and a second winding head mechanism 46, which are arranged linearly along the winding processing line A. Configured. Then, the rectangular wire W is used as a coil material, and one end portion thereof is sequentially square-wound by the first winding head mechanism 45 to form the first coil 11, and the other end portion is sequentially turned by the second winding head mechanism 46. The second coil 12 is formed by square winding, and the connecting coil 10 is formed by installing the first coil 11 and the second coil 12 in parallel with each other.

More specifically, as shown in FIG. 16 and the like, the connecting coil forming apparatus 40 includes the wire feeding unit 21, on the downstream side of the rectangular wire introduction direction K on the winding line A of the wire feeding unit 21. The first winding head mechanism 45 is disposed, and the second winding head mechanism 46 is disposed on the upstream side of the wire feeding unit 21 in the flat wire introduction direction.
The connecting coil forming device 40 includes a device main body 30A that supports the winding head mechanisms 45 and 46 and the wire feeding unit 21, and an arithmetic control unit 35A that controls the entire connecting coil forming device 40.
Further, the position detection sensor 31 is provided between the wire feeding unit 21 and the first winding head mechanism 45, and further, on the upstream side of the second winding head mechanism 46 in the rectangular wire introduction direction, the position detection sensor 31 is provided. A cutter unit 32 is arranged.

The first winding head mechanism 45 has a winding head portion 26 composed of the fixing jig 26A and the winding jig 26B, and a winding position of 90 ° bending with respect to the winding head portion 26. The head main body 47 which is a processing position setting unit variably set along the line processing line A is provided.
The head main body 47 of the second embodiment does not move along the rectangular wire introduction direction K, but can be rotated in the direction of arrow R about the fixing jig 26A by a known mechanism (not shown). ing.

On the other hand, the second winding head mechanism 46 has substantially the same structure as the winding head mechanism 25 of the first embodiment.
That is, the second winding head mechanism 46 includes the winding head portion 26, a mounting base 28, and the head main body 27 provided on the mounting base 28 so as to be slidable along the flat wire introduction direction K. The winding head portion 26 includes the fixing jig 26A and the winding jig 26B.

However, the arrangement of the fixing jig 26A and the winding jig 26B is different between the second winding head mechanism 46 of the present embodiment and the winding head mechanism 25 of the first embodiment.
In the second winding head mechanism 46, the fixing jig 26 </ b> A is arranged on the left side and the winding jig 26 </ b> B is arranged on the right side of the flat wire W arranged on the winding processing line A toward the front side in the flat wire introduction direction K. Has been. On the other hand, in the winding head mechanism 25 of the first embodiment, the fixing jig 26A on the right side of the flat wire W arranged in the winding processing line A toward the front side in the flat wire introduction direction K, A winding jig 26B is disposed on the left side.
In the first winding head mechanism 45 of the present embodiment, the winding jig 26B and the fixing jig 26A are arranged in the same direction as the winding head mechanism 25, respectively.

  Further, the second winding head mechanism 46 operates under the control of the arithmetic control unit 35A (see FIG. 25) when the rectangular wire W is square-wound and processed into a rectangular tube shape, and the rectangular wire is bent 90 degrees. Sometimes, along the winding processing line A, reciprocate in the direction of the arrow S as described above, and transport the rectangular wire W by a side feed that feeds the necessary length, that is, the long side or the short side. The flat wire transfer function is provided.

In the first winding head mechanism 45 and the second winding head mechanism 46 as described above, the respective machining position setting operations of the head main bodies 47 and 27 are performed at a predetermined timing based on control information input from the outside. An arithmetic control unit 35A for variable control is also provided.
As shown in FIGS. 16 and 25, the calculation control unit 35 of the first embodiment is configured to be able to control a set of winding head mechanisms 25, whereas the calculation control unit 35A of the present embodiment The only difference is that the first winding head mechanism 45 and the second winding head mechanism 46 can be controlled, and the other configurations are the same in both embodiments. Therefore, detailed description of the arithmetic control unit 35A is omitted.

Next, with reference to FIG. 16 to 24, with reference to the flowchart of FIG. 26, illustrating a method of forming a coupling coil 10 of the second embodiment.
In the flowchart of FIG. 26 , the determination process when moving to the next process (ST), that is, the determination of whether or not a desired condition is satisfied is YES in all the processes. The explanation should be recommended on the assumption that. Moreover, the calculation control part 35A in the whole connection coil formation apparatus 40 is shown only in FIG.

  First, as a first step (ST1) shown in FIG. 26, a length necessary for winding the first coil 11 and the second coil 12, that is, a flat angle long enough to form the connecting wire 10. The wire W is prepared, and the flat wire W is supplied to the winding line A from the wire bobbin, for example, in the material supply region B as shown in FIG. 32, the second winding head mechanism 46, the wire feeding unit 21, and the first winding head mechanism 45.

Further, the tip of the flat wire W is passed between the fixing jig 26A and the winding jig 26B of the first winding head mechanism 45, and the tip is set at a reference position marked on the apparatus.
Thereafter, the first winding head mechanism 45 is controlled by the arithmetic control unit 35 based on a command from the input unit 37, and the leading end of the flat wire W is fixed to the winding jig 26 </ b> B of the first winding head mechanism 45. Bending is performed by rotating 90 degrees in the direction of arrow R shown in FIG. Then, the feeding of a predetermined dimension of the rectangular wire W and the bending process are repeated, and the first coil 11 is completed by winding up to a preset number of turns.

Subsequently, as a second step (ST2) shown in FIG. 26, as shown in FIG. 17, the completed first coil 11 and the flat wire W continuous thereto are driven by driving the wire bobbin and the wire feeding unit 21. Feeding out, that is, pulling out the first coil 11 from the first winding head mechanism 45 and moving it to the downstream side in the flat wire introduction direction K.
At this time, the rectangular wire W for the first coil 11 and the second coil 12 drawn out from the first winding head mechanism 45 is supported and moved by a transfer device having a transfer stand (not shown).

  Thereafter, as a third step (ST3), as shown in FIG. 18, first, when the rectangular wire W is drawn to a position where the length for the second coil 12 is secured, the cutter body 34 of the cutter unit 32 is advanced. The rectangular wire W is cut at the end position of the lead wire 12A of the second coil 12, that is, at the cutting position C1. Then, the end portion of the cut rectangular wire W is controlled by the calculation control unit 35 based on a command from the input unit 37, and the lead length (lead portion) required for the second coil winding is controlled. 12A + long side or short side).

  Next, as a fourth step (ST4), as shown in FIG. 19, the opposite side of the first coil 11 in the rectangular wire W is the same as the winding of the first coil 11 by the first winding head mechanism 45 described above. Winding is performed from the end by the second winding head mechanism 46, and formation of the second coil 12 is started.

At this time, the winding jig 26B and the fixing jig 26A in the second winding head mechanism 46 are opposite to the arrangement of the winding jig 26B and the fixing jig 26A in the first winding head mechanism 45. Therefore, the winding jig 26B is rotated 90 ° clockwise from the left side of the flat wire W along the flat wire introduction direction K. That is, the second coil 12 is formed on the left side of the winding processing line A.
Further, as the second coil 12 is sequentially wound by the second winding head mechanism 46, the first coil 11 starts moving toward the second coil 12 by the upstream feeding action by the wire feeding unit 21. Therefore, the direction which leaves | separates from the flat wire W, for example by lowering | hanging the whole 1st winding head mechanism 45 or the winding head part 26 so that it may not interfere with the winding head part 26 at the time of the movement of the 1st coil 11. Evacuate.

  Next, as a fifth step (ST5), as shown in FIG. 20, the first coil 11 that moves to the second coil 12 side as the winding of the second coil 12 advances is arranged at a predetermined position. The arrival detection sensor 31 is detected. Simultaneously with the detection of the first coil 11 by the arrival detection sensor 31, as in the first embodiment, the wire feeding pulley 23 and the pulley flange 23A of the wire feeding unit 21 move in the Y-axis direction and the rectangular wire W Evacuate from the position.

Thereafter, as the sixth step (ST6), as shown in FIGS. 23 and 24 , in the same manner as described in the first embodiment with reference to FIGS. The offset adjustment is performed at the connecting portion 13 between the first coil 11 and the second coil 12, and the distance between the coils 11 and 12 is adjusted by the final winding.

And as a 7th process (ST7), as shown in FIG. 22, the connection coil 10 is completed.
When the connecting coil 10 is completed, the connecting coil 10 is removed from the connecting coil forming device 40, and is transported to a predetermined storage place and stored therein. 10 formation is started.

According to the second embodiment as described above, there are the following effects in addition to substantially the same effects as the above (1), (2), and (4) to (6).
(7) The first winding head mechanism 45, the second winding head mechanism 46, the first coil 11 and the second coil 12 are continuously formed, and the first completed by the operator as compared with the first embodiment. One end of the coil 11 is taken out from the device 20, carried to the position where the first coil 11 is formed, set again to form the second coil 12, and it is not necessary to start winding. Less. As a result, the working time can be shortened and the connecting coil 10 can be formed efficiently.

Next, a third embodiment of the present invention will be described based on FIGS.
3rd Embodiment forms the said connection coil 10 using the connection coil formation apparatus 50 provided with two winding processing lines in parallel.
That is, the connecting coil forming apparatus 50 is provided with a first winding processing line 54A and a second winding processing line 54B arranged in parallel with each other, and these two winding processing lines 54A, 54B. Then, the two winding head mechanisms of the first winding head mechanism 55 and the second winding head mechanism 58 are shared. That is, the first winding head mechanism 55 and the second winding head mechanism 58 are each in a direction (Y-axis direction) orthogonal to the first winding processing line 54A and the second winding processing line 54B. It can be reciprocated.

  In the first winding processing line 54A, the rectangular wire W is used as a coil material, and one end thereof is sequentially square-turned by the first winding head mechanism 55 to form the first coil 11, and the other end. The second coil 12 is formed by sequentially winding the portion by the second winding head mechanism 58, and the connecting coil 10 is formed by installing the first coil 11 and the second coil 12 in parallel with each other. To do.

  Further, in the second winding machining line 54B, the first winding head mechanism 55 or the second winding head mechanism 58 that is not used in the first winding machining line 54A is replaced with the second winding machining line 54B. In the same manner as described above, the first coil 11 is formed by sequentially winding one end of the flat wire W by the first winding head mechanism 55 to form the first coil 11 and the second winding head at the other end. The second coil 12 is formed by sequentially winding squarely by the mechanism 58, and the connecting coil 10 is formed by installing the first coil 11 and the second coil 12 in parallel with each other.

  As shown in FIG. 27 and the like, the connecting coil forming device 50 includes a wire feeding unit 51, and a rectangular wire introduction direction of the first winding machining line 54A and the second winding machining line 54B of the wire feeding unit 51. The first winding head mechanism 55 is disposed on the downstream side, and the second winding head mechanism 58 is disposed on the upstream side of the wire feeding unit 51 in the flat wire introduction direction.

The connected coil forming device 50 includes a device main body 30B that supports the winding head mechanisms 55 and 58, the wire feeding unit 51, and the like, and an arithmetic control unit 35B that controls the entire connected coil forming device 50.
Between the wire feed unit 51 and the first winding head mechanism 55, the arrival detection sensor 31 is provided outside the first winding processing line 54A and the second winding processing line 54B, respectively. A cutter unit 64, which is a cutter mechanism, is disposed upstream of the second winding head mechanism 58 in the flat wire introduction direction K.

  More specifically, the wire feeding unit 51 has a structure as if two wire feeding units 21 of the first embodiment are arranged, and the first winding machining line 54A and the second winding machining line. 54B and a mounting base 52 spanned between 54B, and supported by the mounting base 52, and formed so as to correspond to the respective winding processing lines 54A and 54B, and opposed to the vertical direction of the flat wire W. A pair of the wire feed pulley 23 and the pulley flange 23A are provided.

The mounting base 52 is provided between a fixed portion 52A disposed outside the first winding processing line 54A and the second winding processing line 54B, and between the fixed portions 52A. A guide portion 52B that can be engaged with the pulley 23 is provided.
The pair of wire feed pulleys 23 and the pulley flanges 23A described above are formed into a rectangular shape by opening the pair of wire feed pulleys 23 and the pulley flanges 23A vertically from the first winding line 54A and the second winding line 54B. After the line W is opened, it can be slid along the guide portion 52B of the wire feed unit 51 and slid in the Y-axis direction.

  As shown in FIG. 27 and the like, the first winding head mechanism 55 includes a head main body 56 provided with a winding head portion 26 composed of the fixing jig 26A and the winding jig 26B, and the head main body 56 as a first. And a mounting base 57 that supports the winding processing line 54A and the second winding processing line 54B so as to be reciprocally movable in a direction orthogonal thereto.

  The mounting base 57 is spanned between a fixing portion 57A disposed on the outer side of each of the first winding processing line 54A and the second winding processing line 54B, and between the fixing portions 57A. And a guide portion 57B that engages. Therefore, the head main body 56 is guided by the guide portion 57B and can reciprocate only in the Y axis direction between both the lines 54A and 54B, and cannot move along the flat wire introduction direction K. Yes.

  Further, the bending process of the flat wire W by the fixing jig 26A and the winding jig 26B is, for example, a configuration in which the head main body 56 can be rotated around the fixing jig 26A while being separated from the guide portion 57B. In this case, the head main body 56 may be rotated by a motor, a pulley, or the like (not shown), or may be rotated by a configuration in which only the winding jig 26B can be rotated.

  The second winding head mechanism 58 includes a head main body 59 provided with the winding head portion 26 composed of the fixing jig 26A and the winding jig 26B, and the head main body 59 is slidable along the flat wire introduction direction. A first mounting base 60 for supporting, a moving base 61 for supporting the first mounting base 60, and a second mounting base 62 for slidably supporting the moving base 61 in the Y-axis direction are configured. .

  The first mounting base 60 is fixed on both sides of the head main body 59 along the flat wire introduction direction K, and spans between the fixed parts 60A and engages with the head main body 59. And a guide portion 60B. Therefore, the head main body 59 is guided by the guide part 60B and can reciprocate between the fixed part 60A along the flat wire introduction direction K.

  The second mounting base 62 is spanned between the fixed portion 62A disposed on the outer side of each of the first winding processing line 54A and the second winding processing line 54B, and between the fixing portions 62A, and the movement described above. It is comprised by the guide part 62B engaged with the stand 61. FIG. Accordingly, the movable table 61 is guided by the guide portion 62B of the second mounting table 62, and can reciprocate between both lines 54A and 54B along the Y-axis direction.

As a result, the head body 59 of the second winding head mechanism 58 can reciprocate along the rectangular wire introduction direction K, and also between the first winding processing line 54A and the second winding processing line 54B. You can move back and forth.
As described above, the first winding head mechanism 55 and the second winding head mechanism 58 are shared by the first winding processing line 54A and the second winding processing line 54B, respectively. become.

The cutter unit 64 includes the cutter main body 34, and the cutter main body 34 is provided on a mounting base 65 disposed across the first winding processing line 54A and the second winding processing line 54B.
The mounting base 65 includes a fixed portion 65A disposed outside each of the winding processing lines 54A and 54B, and a guide portion 65B that is spanned between the fixed portions 65A and engages with the cutter body 34. ing. Therefore, the cutter main body 34 can reciprocate in the Y-axis direction orthogonal to the respective winding processing lines 54A and 54B, and the rectangular wire W can be cut in the respective winding processing lines 54A and 54B.

In the first winding head mechanism 55 and the second winding head mechanism 58 as described above, as shown in FIG. And an arithmetic control unit 35B that performs variable control at a predetermined timing based on the above.
Whereas the calculation control unit 35 of the first embodiment is configured to control a set of winding head mechanisms 25, the calculation control unit 35B of the present embodiment has a configuration as shown in FIGS. The only difference is that the first winding head mechanism 55 and the second winding head mechanism 58 in each winding processing line 54A, 54B can be controlled, and the other configurations are the same in both embodiments. is there. Therefore, detailed description of the arithmetic control unit 35A is omitted.

  In addition, in the arithmetic control unit 35A of the present embodiment, in addition to the above functions, the second set of winding head mechanisms 58 for forming the second coil 12 is provided on the one winding processing line 54A. A first crossover control function for driving and controlling the coils is provided. When the second coil 12 of the other set is formed on one winding processing line 54A, the winding head mechanism 58 of the other set is moved to the other winding processing line 54B, and the other set After the first coil 11 is formed on the winding processing line 54B, the first coil 11 is operated as a winding head mechanism for forming the second coil on the other winding processing line 54B, and at the same time, the first coil on the other winding processing line 54B. 11 is provided with a second crossover control function for returning one winding head mechanism 55 to the one winding processing line 54A side and driving and controlling it for forming the first coil 11 in the one winding processing line 54A. ing.

Next, a method of forming the coupling coil 10 using the coupling coil forming apparatus 50 of the third embodiment will be described based on the flowchart of FIG. 38 with reference to FIGS.
In the flowchart of FIG. 38, the determination step when the process proceeds to the next step (ST), that is, the determination whether or not a desired condition is satisfied is YES in all steps, that is, The explanation will proceed on the assumption that. Moreover, the calculation control part 35B in the whole connection coil formation apparatus 50 is shown only in FIG. 27, and the display of the upstream and downstream of the flat wire introduction direction K is also shown only in FIG.

  First, as a first step (ST1) shown in FIG. 38, a rectangular wire W having a sufficient length is prepared for the winding of the first coil 11 and the second coil 12, and the material is supplied as shown in FIG. In the region B, for example, the wire bobbin supplies the first winding line 54A and the second winding line 54B to the first winding line 54B and the rectangular wire W from the second winding head mechanism 58 side on the downstream side to the downstream side. Send to the first winding head mechanism 55 side.

  At this time, the second winding head mechanism 58 and the first winding head mechanism 55 are disposed so as to correspond to the first winding processing line 54A, and accordingly, in the first winding processing line 54A. Passes the tip of the rectangular wire W for the first coil 11 between the fixing jig 26A and the winding jig 26B of the winding head mechanisms 55, 58, and puts the tip at the reference position marked on the apparatus. set.

In the second winding processing line 54B, the rectangular wire W is placed on the wire feeding unit 21 so that the tip is located at the same position as the protruding portion of the rectangular wire W in the first winding processing line 54A. Further, it is placed on the mounting bases 62 and 57 in the second winding head mechanism 58 and the first winding head mechanism 55, respectively.
From the above state, the winding jig 26B is viewed from the initial position while the rectangular wire W is sandwiched between the winding jig 26B and the fixing jig 26A of the first winding head mechanism 55 in the first winding processing line 54A. Bending is executed by turning 90 degrees in the direction of arrow R shown in FIG. This bending operation is repeated to complete the first coil 11 by winding up to a predetermined number of turns of the first coil 11.

  Subsequently, as a second step (ST2) shown in FIG. 38, as shown in FIG. 28, the rectangular wire W is drawn out by driving the wire bobbin and the wire feeding unit 21 in the first winding processing line 54A. The first coil 11 is moved to the downstream side of the flat wire introduction direction in the direction away from the first winding head mechanism 55.

Thereafter, as a third step (ST3), as shown in FIG. 29, when the rectangular wire W is drawn to the position where the length for the second coil 12 is secured in the first winding processing line 54A, the calculation is performed. The driving cutter unit 64 is controlled by the control unit 35B, the cutter body 34 is advanced, and the flat wire W is cut.
Then, the end of the cut rectangular wire W is moved to the winding start position of the second coil 12, that is, from the position of the fixing jig 26A and the winding jig 26B of the second winding head mechanism 58 to the cutter unit 64 side. Is moved by the wire feeding unit 21 to a position protruding by a predetermined dimension.
At this time, no operation is performed in the second winding processing line 54B.

Thereafter, as a fourth step (ST4), as shown in FIG. 30, in the first winding processing line 54A, the fixing jig 26A and the winding jig 26B of the second winding head mechanism 58 Winding processing of the second coil 12 using the two-winding head mechanism 58 is started. At this time, the second coil 12 is wound so that the direction is opposite to that of the first coil 11, and the second coil 12 is formed by repeating the bending operation of the flat wire W. Further, as the formation of the second coil 12 proceeds, the first coil 11 moves to the second winding head mechanism 58 side with the bending operation.
Simultaneously with the formation of the second coil 12, in the second winding machining line 54B, the first winding head mechanism 55 has been slid and moved from the first winding machining line 54A to the second winding machining line 54B. After the rectangular wire W is placed on the first coil 11, the first coil 11 is formed on the second winding line 54B by the same procedure as the formation of the first coil 11 on the first winding line 54A. Be started.

Next, as a fifth step (ST5), as shown in FIG. 31, along the second coil 12 continuously wound on the first winding processing line 54A, The first coil 11 that approaches is detected by the arrival detection sensor 31. Simultaneously with the detection of the first coil 11, the wire feed pulley 23 corresponding to the first wire winding line 54 </ b> A of the wire feed unit 51 moves along the guide portion 52 </ b> B of the mounting base 52. Move to the line 54B side and retreat from the flat wire W.
At this time, the winding of the first coil 11 is repeated by the first winding head mechanism 55 in the second winding processing line 54B.

Thereafter, as a sixth step (ST6), as shown in FIGS. 32 to 36 , in the same manner as described in the first embodiment with reference to FIGS. 2, the distance between the first coil 11 and the second coil 12 is adjusted 2 turns before the final winding of the second coil 12, and the adjusted amount is added and sent 1 turn before the first coil 11. After determining the gap between the opposing side surfaces of the adjacent rectangular wire W with the second coil 12, that is, between the two rectangular tube-shaped side surfaces, final folding is performed to complete the connecting coil 10 as shown in FIG. Let

  On the other hand, in the second winding line 54B in the sixth step (ST6), the wire bobbin and the wire feed unit 21 are driven in the same manner as the second step in the first winding line 54A. Then, the rectangular wire W is pulled out, and the first coil 11 is moved by the set lead length to the downstream side of the rectangular wire introduction direction K in the direction away from the first winding head mechanism 55.

Next, as a seventh step (ST7), as shown in FIG. 33, in the first winding processing line 54A, after the connection coil 10 including the first coil 11 and the second coil 12 is completed, The connecting coil 10 is removed from the second winding head mechanism 58 and transferred to, for example, another storage location.
On the other hand, in the second winding processing line 54B, as in the third step, when the flat wire W is drawn to a position where the length for the second coil 12 is secured, the cutter body 34 of the cutter unit 64 is used. Is moved forward to cut the rectangular wire W. Then, the cutter unit 64 extends from the end of the cut rectangular wire W to the winding start position C2 of the second coil 12, that is, from the positions of the fixing jig 26A and the winding jig 26B of the second winding head mechanism 58. It is moved by the wire feed unit 21 to a position that protrudes to the side by a predetermined dimension.

Thereafter, as an eighth step (ST8), as shown in FIG. 34, in the first winding machining line 54A, the first winding head mechanism 55 located on the second winding machining line 54B side. Is moved to the first winding processing line 54A, and a new winding of the first coil 11 is started by the same means as in the first step.
On the other hand, in the second winding machining line 54B, the second winding head mechanism 58 located on the first winding machining line 54A side is moved to the second winding machining line 54B and the first winding machining line 54B is moved to the second winding machining line 54B. The rectangular wire W is placed at a predetermined position of the two-winding head mechanism 58, and the second winding head mechanism 58 starts winding the second coil 12 on the second winding processing line 54B.

  Thereafter, in the first winding line 54A, the third step (ST3) to the seventh step (ST7) in the first winding line 54A are repeated, and in the second winding line 54B, The fourth step (ST4) to the seventh step (ST7) in the first winding processing line 54A are repeated to produce a predetermined number of linked coils 10.

According to the third embodiment as described above, there are the following effects in addition to the same effects as the above (1), (2), and (4) to (6).
(8) The connecting coil forming apparatus 50 includes the first winding processing line 54A and the second winding processing line 54B, and the connecting coil 10 can be continuously formed by the respective lines 54A and 52. . At this time, in the middle of forming the connecting coil 10 on the first winding processing line 54A, the formation of the connecting coil 10 can be started also on the second winding processing line 54B. As a result, the coupling coil 10 can be formed alternately by the two lines 54A and 54B, so that the production efficiency can be further improved.

  (9) The connecting coil forming apparatus 50 includes a first winding processing line 54A and a second winding processing line 54B, and includes a first winding head mechanism 55, a second winding head mechanism 58, and a cutter unit. 64 can reciprocate between the first winding processing line 54A and the second winding processing line 54B and operate at the respective positions, so that a dedicated first winding is provided for each of the lines 54A and 54B. It is not necessary to provide a head mechanism, a second winding head mechanism, and a cutter unit. As a result, member saving can be achieved.

Next, based on FIGS. 39-48, 4th Embodiment of this invention is described.
4th Embodiment forms the said connection coil 10 using the connection coil formation apparatus 70 which can form the 1st coil 11 and the 2nd coil 12 simultaneously from the both ends of one flat wire W. FIG.

  That is, the connecting coil forming device 70 starts winding simultaneously from both ends of one flat wire W by the first winding head mechanism 75 and the second winding head mechanism 78, The first coil 11 is formed by the winding head mechanism 75, and the second coil 12 is formed by the second winding head mechanism 78 on the other end side of the flat wire W, thereby forming the connecting coil 10. is there.

  Here, the difference in the winding operation between the first to third embodiments and the fourth embodiment is that, in the first to third embodiments, the fixing jig 26A and the winding jig 26B arranged to face each other are different. Whereas the winding operation is performed after the flat wire W having a length corresponding to the long side or the short side of the coil to be formed is passed by the wire feeding unit 21 or the like, in the fourth embodiment, the flat wire is used. The winding head mechanism 75 mounted with the fixing jig 26A and the winding jig 26B is moved along the sliding guide 76B that engages with the winding head by a combination of a motor, a ball screw, etc. (not shown) without moving W. The winding operation is performed at a position moved by a distance corresponding to the long side or the short side of the coil. The other winding head mechanism 78 performs a series of winding operations in the same manner.

  The connecting coil forming device 70 includes the wire feeding unit 21 disposed in the center along the winding processing line A. The first winding head mechanism 75 is disposed on one side of the wire feeding unit 21 along the flat wire introduction direction K, that is, on the downstream side, and the second winding head is disposed on the other side, that is, on the upstream side. A mechanism 78 is arranged.

The connected coil forming device 70 includes a device main body 30C that supports the winding head mechanisms 75 and 78 and the wire feeding unit 21, and an arithmetic control unit 35C that controls the entire connected coil forming device 70.
The position detection sensor 31 is provided between the wire feeding unit 21 and the second winding head mechanism 78, and the cutter unit 32 is disposed upstream of the second winding head mechanism 78 in the flat wire introduction direction. Has been placed.

  More specifically, the first winding head mechanism 75 includes a head main body 27 provided with the winding head portion 26, and the head main body 27 along the flat wire introduction direction K on the second winding head mechanism 78 side. The winding head portion 26 is composed of the fixing jig 26A and the winding jig 26B.

  The mounting base 76 has a fixed portion 76A disposed at a predetermined interval on the downstream side and the upstream side along the flat wire introduction direction, and is spanned between the fixed portions 76A, and the head main body 27. And two first sliding guides 76B that can be engaged.

  Further, the bending process of the flat wire W by the fixing jig 26A and the winding jig 26B in the first winding head mechanism 75 is performed by, for example, a winding jig 26B fixed to the attachment member 29 by a motor or a pulley (not shown). May be rotated around the fixing jig 26A.

  The length of the first sliding guide 76B is formed to be longer than at least the rectangular wire W having a length capable of forming the first coil 11. In the first winding head mechanism 75, the head main body 27 is moved in the first sliding manner every time the rectangular wire W is bent by the cooperative operation of the fixing jig 26A and the winding jig 26B in the head main body 27. It moves along the guide 76B and approaches the second winding head mechanism 78 side. Further, by repeating the bending operation, the first winding head mechanism 75 can complete the first coil 11 having a preset number of turns.

The second winding head mechanism 78 reciprocates the head main body 27 provided with the winding head portion 26 and the head main body 27 back to the first winding head mechanism 75 side along the rectangular wire introduction direction. And a mounting base 79 to be moved.
In the second winding head mechanism 78, the bending of the rectangular wire W by the fixing jig 26A and the winding jig 26B is performed by, for example, a motor or a pulley (not shown) as in the first winding head mechanism 75 described above. The winding jig 26B fixed to the attachment member 29 may be rotated around the fixing jig 26A.

  The mounting base 79 includes a fixed portion 79A disposed at a predetermined interval on the downstream side and the upstream side along the flat wire introduction direction, and spans between the fixed portions 79A. And two parallel second sliding guides 79B that can be engaged. The length of the second sliding guide 79B is formed to be substantially the same as the length of the flat wire W that can form the second coil 12.

In the second winding head mechanism 78, the head main body 27 is moved to the second sliding guide 79B every time the flat wire W is bent by the cooperative operation of the fixing jig 26A and the winding jig 26B in the head main body 27. And moves closer to the first winding head mechanism 75 side. Further, by repeating the bending operation, the second winding head mechanism 78 can complete the second coil 12 having a preset number of turns.
In the first winding head mechanism 75 and the second winding head mechanism 78, the arrangement positions of the fixing jig 26A and the winding jig 26B provided in the head main body 27 are different.

  39 and the like, the length of the first sliding guide 76B in the mounting base 76 of the first winding head mechanism 75 and the length of the second sliding guide 79B in the mounting base 79 of the second winding head mechanism 78 is the same. Although the comparison is difficult, in practice, the length of the first sliding guide 76B is longer than the length of the second sliding guide 79B.

This is because when the first coil 11 and the second coil 12 are formed simultaneously from both ends of the rectangular wire W, the second turn just before the final winding is in the middle of the formation of the second coil 12 by the second winding head mechanism 78. Because it will be done in, it has been adjusted to balance with it.
That is, the first coil 11 winds the entire turn on the sliding guide 76B, whereas the final winding portion including the final two turns of the second coil 12 is a region between the winding head mechanisms 75 and 78. It is because it is done in.
Further, the fixing jig 26A and the winding jig 26B of the first winding head mechanism 75 can be lowered (not shown), so that, for example, when the first coil 11 is moved as shown in FIG. It has a configuration that does not interfere.

In the first winding head mechanism 75 and the second winding head mechanism 78 as described above, the machining position setting operation of each of the head main bodies 27 and 27 is performed at a predetermined timing based on control information input from the outside. An arithmetic control unit 35C that is variably controlled is provided together.
The calculation control unit 35 of the first embodiment is configured to be able to control a set of winding head mechanisms 25, whereas the calculation control unit 35C of the present embodiment is configured as shown in FIGS. The only difference is that it has a simultaneous machining control function capable of simultaneously controlling the first winding head mechanism 75 and the second winding head mechanism 78 in the winding machining line A, and the other configurations are the same in both embodiments. It is. Therefore, detailed description of the calculation control unit 35C is omitted.

Next, a method for forming the connection coil 10 of the fourth embodiment will be described based on the flowchart of FIG. 49 with reference to FIGS.
In the flowchart of FIG. 49, the determination process when moving to the next process (ST), that is, the determination of whether or not a desired condition is satisfied is YES in all processes, that is, The explanation will proceed on the assumption that. Further, the connection between the calculation control unit 35C and other mechanisms and the like in the entire connecting coil forming apparatus 70 is shown only in FIG. 39, and the display of the upstream side and the downstream side in the flat wire introduction direction K is also shown only in FIG.

  First, as a first step (ST1) shown in FIG. 49, as shown in FIG. 39, a rectangular wire W having a sufficient length for the windings of the first coil 11 and the second coil 12 is prepared. The wire W is supplied from, for example, a wire bobbin in the material supply region B, and is sent from the upstream side to the first winding head mechanism 75 side, and the fixing jig 26A of the winding head mechanism 75 and the winding are wound. Set it between the jig 26B.

  Subsequently, as a second step (ST2) shown in FIG. 49, as shown in FIG. 40, when the rectangular wire W is drawn to a position where the length for the second coil 12 is secured, the command of the input unit 37 is used. Then, the cutter unit 32 is driven and controlled by the arithmetic control unit 35C, the cutter body 34 of the cutter unit 32 is advanced, and the rectangular wire W is cut at the cutting position C1. Then, the other end of the flat wire W cut is set at the winding start possible position C 2 in the second winding head mechanism 78.

Subsequently, as a third step (ST3) shown in FIG. 49, as shown in FIG. 41, the first coil 11 and the second coil 12 are respectively obtained by the first winding head mechanism 75 and the second winding head mechanism 78. And start winding simultaneously.
At this time, the wire feeding unit 21 is in a state of moving away from the first coil 11 and the second coil 12 in a direction away from the rectangular wire W at a substantially intermediate position.
Further, the first coil 11 and the second coil 12 are wound in a state where the winding directions are different from each other. That is, for example, as shown in FIG. 41, the first coil 11 and the second coil 12 are wound in opposite directions across the rectangular wire W on the winding processing line A.
When the windings of the first coil 11 and the second coil 12 are continued in the winding head mechanisms 75 and 78, respectively, the head main body 27 of the winding head mechanisms 75 and 78 has the first winding as the winding advances. Slide along the first sliding guide portion 76B and the second sliding guide portion 79B in the direction in which they approach each other.

  Next, as a fourth step (ST4), as shown in FIG. 42, the winding by each of the winding head mechanisms 75 and 78 proceeds, and the second winding head mechanism 78 first starts the end of the second sliding guide portion 78B. At that time, the winding by the second winding head mechanism 78 is stopped. At this time, the first winding head mechanism 75 is in the middle of the first sliding guide portion 75B, and the winding of the first coil 11 is being executed at that position.

  Thereafter, as a fifth step (ST5), as shown in FIG. 43, the winding of the first coil 11 by the first winding head mechanism 75 is completed. When the completion of winding of the first coil 11 is detected, the fixing jig 26A and the winding jig 26B of the first winding head mechanism 75 are retracted from the first coil 11, for example, by lowering.

  Thereafter, as a sixth step (ST6), the winding of the second coil 12 is resumed by the second winding head mechanism 78 as shown in FIG. Then, along with this, the first coil 11 moves away from the first winding head mechanism 75 and approaches the second winding head mechanism 78 side.

  Thereafter, as a seventh step (ST6), as shown in FIGS. 45 to 47, the distance between the first coil 11 and the second coil 12 is adjusted two turns before the final winding of the second coil 12, The feed including the adjustment amount, that is, the feed including the offset amount is performed, and the side surfaces of the adjacent rectangular wires W of the first coil 11 and the second coil 12 facing each other one turn before the final winding of the second coil 12. A gap between two sides, that is, two side surfaces of the rectangular tube shape is determined.

Then, as the eighth step (ST8), as shown in FIG. 45, the connecting coil 10 is completed by final bending.
When the connecting coil 10 is completed, the connecting coil 10 is removed from the connecting coil forming device 70, and is transported to a predetermined storage place and stored therein. 10 formation is started.

According to the fourth embodiment as described above, there are the following effects in addition to the same effects as the above (1), (2), and (4) to (6).
(10) Winding of the first coil 11 by the first winding head mechanism 75, winding of the second coil 12 by the second winding head mechanism 78, and the head body 27 at the downstream side and upstream side in the flat wire introduction direction. Therefore, the first coil 11 and the second coil 12 can be formed at the same time. As a result, the connecting coil 10 can be formed in a short time, and the production efficiency can be improved.

The present invention is not limited to the above-described embodiments, and modifications, improvements, and the like within the scope that can achieve the object of the present invention are included in the present invention.
For example, in each said embodiment, as shown in FIG.12, FIG.23, FIG.35, FIG.46, the length of a connection part is located in the direction orthogonal to the said connection part by the connection site | part length measurement means 36. Although the parallel interval between the corresponding coil sides 11C and 12C of the first coil 11 and the second coil 12 is measured as the connection portion length L3, the measurement method is not limited to this and may be a measurement method as shown in FIG.
That is, the connection part length measuring means 36 is based on the reference point S set on the apparatus main body 30, 30A, etc., and the reference point of the coil sides 11C, 12C corresponding to the first coil 11 and the second coil 12 is determined. The distance from S to the side end face of the coil side 12C is measured.
Here, the distance L3-2 from the reference point S to the side end face of the coil side 11C on the distal end side in the moving direction of the first coil 11 is a stationary dimension, and this distance L3-2 and the above L3-1 Thus, the length L3-4 of the connecting portion is obtained.

  The present invention can be widely used as a coil for other electronic components such as a transformer as well as a coil for a reactor, for example.

It is the whole reactor perspective view which accommodated the connection coil formed by the connection coil formation apparatus which concerns on this invention. It is a whole perspective view which shows the connection coil formed by the connection coil formation apparatus which concerns on this invention. It is 1st Embodiment of the connection coil formation apparatus which concerns on this invention, and is a figure which also shows the 1st process of a connection coil formation method. It is a figure which shows the 2nd process of the connection coil formation method in the said 1st Embodiment. It is a figure which shows the 3rd process of the connection coil formation method in the said 1st Embodiment. It is a figure which shows the 4th process of the connection coil formation method in the said 1st Embodiment. It is a figure which shows the 5th process of the connection coil formation method in the said 1st Embodiment. It is a figure which shows the 6th process of the connection coil formation method in the said 1st Embodiment. It is a figure which shows the 7th process of the connection coil formation method in the said 1st Embodiment. It is a figure which shows the 8th process of the connection coil formation method in the said 1st Embodiment. It is a figure which shows the 9th process of the connection coil formation method in the said 1st Embodiment. It is an operation | movement figure which shows the offset adjustment method of the connection coil of the said 1st Embodiment. It is an operation | movement figure which shows the coil space | interval adjustment method of the connection coil of the said 1st Embodiment. It is a schematic block diagram which shows the main control part of the said 1st Embodiment. It is a flowchart of the connection coil formation method of the said 1st Embodiment. It is 2nd Embodiment of the connection coil formation apparatus which concerns on this invention, and is a figure which also shows the 1st process of a connection coil formation method. It is a figure which shows the 2nd process of the connection coil formation method in the said 2nd Embodiment. It is a figure which shows the 3rd process of the connection coil formation method in the said 2nd Embodiment. It is a figure which shows the 4th process of the connection coil formation method in the said 2nd Embodiment. It is a figure which shows the 5th process of the connection coil formation method in the said 2nd Embodiment. It is a figure which shows the 6th process of the connection coil formation method in the said 2nd Embodiment. It is a figure which shows the 7th process of the connection coil formation method in the said 2nd Embodiment. It is an operation | movement figure which shows the offset adjustment method of the connection coil of the said 2nd Embodiment. It is an operation | movement figure which shows the coil space | interval adjustment method of the connection coil of the said 2nd Embodiment. It is a schematic block diagram which shows the main control part of the said 2nd Embodiment. It is a flowchart of the connection coil formation method of the said 2nd Embodiment. It is 3rd Embodiment of the connection coil formation apparatus which concerns on this invention, and is a figure which also shows the 1st process of a connection coil formation method. It is a figure which shows the 2nd process of the connection coil formation method in the said 3rd Embodiment. It is a figure which shows the 3rd process of the connection coil formation method in the said 3rd Embodiment. It is a figure which shows the 4th process of the connection coil formation method in the said 3rd Embodiment. It is a figure which shows the 5th process of the connection coil formation method in the said 3rd Embodiment. It is a figure which shows the 6th process of the connection coil formation method in the said 3rd Embodiment. It is a figure which shows the 7th process of the connection coil formation method in the said 3rd Embodiment. It is a figure which shows the 2nd process of the connection coil formation method in the said 3rd Embodiment. It is an operation | movement figure which shows the offset adjustment method of the connection coil of the said 3rd Embodiment. It is an operation | movement figure which shows the coil interval adjustment method of the connection coil of the said 3rd Embodiment. It is a schematic block diagram which shows the main control part of the said 3rd Embodiment. It is a flowchart of the connection coil formation method of the said 3rd Embodiment. It is 4th Embodiment of the connection coil formation apparatus which concerns on this invention, and is a figure which also shows the 1st process of a connection coil formation method. It is a figure which shows the 2nd process of the connection coil formation method in the said 4th Embodiment. It is a figure which shows the 3rd process of the connection coil formation method in the said 4th Embodiment. It is a figure which shows the 4th process of the connection coil formation method in the said 4th Embodiment. It is a figure which shows the 5th process of the connection coil formation method in the said 4th Embodiment. It is a figure which shows the 6th process of the connection coil formation method in the said 4th Embodiment. It is a figure which shows the 7th process of the connection coil formation method in the said 4th Embodiment. It is an operation | movement figure which shows the offset adjustment method of the connection coil of the said 4th Embodiment. It is an operation | movement figure which shows the coil interval adjustment method of the connection coil of the said 4th Embodiment. It is a schematic block diagram which shows the main control part of the said 4th Embodiment. It is a flowchart of the connection coil formation method of the said 4th Embodiment. It is an operation | movement figure which shows the offset adjustment method of the connection coil of the deformation | transformation form of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Reactor 10 Connection coil 11 1st coil 12 2nd coil 13 Connection part 14 Offset part 20, 40, 50, 70 Connection coil formation apparatus 21, 51 Wire feed unit 25 Winding head mechanism 26 Winding head part 26A Fixing jig 26B Winding jig 27 Head body 30, 30A, 30B, 30C Apparatus body 32 Cutter unit which is a cutter mechanism 35 Main control unit 36 Connection portion length measuring means 45 First winding head mechanism 46 Second winding head mechanism 47 Head Main body 54A First winding processing line 54B Second winding processing line 55 First winding head mechanism 58 Second winding head mechanism 64 Cutter unit as a cutter mechanism 75 First winding head mechanism 78 Second winding Head mechanism

Claims (25)

The first coil and the second coil are formed in a state in which square winding portions formed by square winding a single rectangular wire from one end side and the other end side thereof are stacked in a rectangular tube shape, and each of these coils. A rectangular coil portion positioned between each other is a connecting portion for connecting the coils on the same plane, and the connecting coils are formed by arranging the coils in parallel with each other.
Forming a first coil from one end of the rectangular wire and forming a second coil from the other end;
In this coil forming step, the first coil is completed before the second coil is completed, and the length of the connection portion is measured after the first coil is completed and immediately before the second coil is completed. The length of the length measurement step and the length of the measured connection portion allocated to the coil spacing including the coil spacing including the two-coil arrangement interval specified in advance and the rectangular wire adjustment set in the second coil Corresponding to the divided length dimension, the connecting portion is formed on one piece of the last square winding portion of the second coil and connected on the same plane as the last square winding. connecting coil forming method characterized by comprising the final angle winding step, the setting the arrangement interval between and the coils provided an offset portion for adjusting the distance between the first coil and the second coil. In the connection coil formation method according to claim 1,
In the length distribution step, a length dimension for adjusting the rectangular wire including the length of the coil side two or more turns before the last set for the second coil is used for the arrangement interval between the two coils specified in advance. A connecting coil forming method, characterized in that the length is obtained by calculating from the length dimension of the above and the measured length dimension of the connecting portion. In the connection coil formation method according to claim 1 or 2,
The length measurement step for measuring the length of the connecting portion is performed in a state in which two or more turns immediately before the completion of winding in the step of forming the second coil are left,
In the final square winding step, an offset portion is provided in one piece of the final square winding portion of the second coil in the second turn immediately before the completion of winding of the second coil, and subsequently the winding of the second coil. A connected coil forming method, characterized in that a length dimension for the arrangement interval of the two coils is set in the first turn immediately before completion. In the connection coil formation method according to claim 1, 2, or 3,
In the coil forming step, a first coil is formed from one end of the flat wire, and a second coil is formed from the other end of the flat wire continuously after the first coil is formed. A second coil forming step,
In the second coil forming step, the length measuring step, the length distribution step, and the final square winding step are executed in the final winding step. In the connection coil formation method according to claim 4,
In the coil forming step, the first coil forming step and the second coil forming step are sequentially executed using a connected coil forming device having a set of winding head mechanisms for bending the rectangular wire by 90 degrees. The connection coil formation method characterized by comprising as follows. In the connection coil formation method according to claim 4,
In the coil forming step, a connected coil forming device including two sets of the winding head mechanisms is used, and the first coil forming step is executed by causing the one set of winding head mechanisms to function. A connected coil forming method, wherein the second coil forming step is performed by causing the other set of winding head mechanisms to function. In the connection coil formation method according to claim 6,
Between the first coil forming step and the second coil forming step, after the first coil is formed at one end, the rectangular wire is pulled out from the material supply region and the length of the rectangular wire is set to the second coil. A connecting coil forming method, characterized in that a second coil rectangular wire setting step for setting the length required for forming the second coil is provided. In the connection coil formation method according to claim 4,
In the coil forming step, a connected coil forming apparatus including two movable winding head mechanisms and two winding processing lines provided to share these winding head mechanisms is used.
The first coil forming step is performed by operating the one set of winding head mechanisms in the one winding processing line, and then the other set of windings in the one winding processing line. A head mechanism is operated to perform the second coil forming step;
In the other winding processing line, the one set of winding head mechanisms is moved from the one winding processing line to the other winding processing after the completion of the first coil forming step in the one winding processing line. And move to the line to perform the first coil forming step in the other winding processing line,
After completion of the second coil forming process in the one winding processing line, the second set of winding head mechanisms is moved to the other winding processing line, and the second coil in the other winding processing line is moved. A connected coil forming method, wherein the forming step is performed. In the connection coil formation method according to claim 8,
In the state where the first coil is formed at one end portion between the first coil forming step and the second coil forming step, respectively, in the one winding processing line and the other winding processing line. A connecting coil comprising a second coil rectangular wire setting step for pulling out the rectangular wire from the material supply area and setting the length of the rectangular wire to a length necessary for forming the second coil. Forming method. The first coil and the second coil are formed in a state in which square winding portions formed by square winding a single rectangular wire from one end side and the other end side thereof are stacked in a rectangular tube shape, and each of these coils. A rectangular coil portion positioned between each other is a connecting portion for connecting the coils on the same plane, and the connecting coils are formed by arranging the coils in parallel with each other.
In the coil forming step, a first coil forming step for forming the first coil from one end of the flat wire, and a second coil from the other end of the flat wire separately from the first coil forming step. A second coil forming step to be formed, and in the final winding step in the second coil forming step, the length measurement step, the length distribution step, and the final square winding step are executed,
In the coil forming step, one winding head mechanism mounted on each of one and the other in advance and one winding disposed on the same line while holding each winding head mechanism separately. Using a connected coil forming device having a processing line and the other winding processing line,
The first winding head mechanism is operated on the one winding processing line to execute the first coil forming step, and at the same time, the other winding head mechanism is operated on the other winding processing line. Then, the second coil forming step is configured to execute the second coil forming step. In the connection coil formation method according to claim 10,
The length measurement step, length distribution step, and final square winding step executed in the final winding step in the second coil forming step are performed between the one winding processing line and the other winding processing line. The first coil unit is configured to be executed in either the process of being transferred to the other winding processing line or the state after the transfer via a rectangular wire conveying unit interposed in advance. A connected coil forming method. In the connection coil formation method according to claim 10 or 11,
The rectangular wire having a length necessary for the connecting portion set between the first coil, the second coil, and the coils is drawn out from the material supply area and disposed on the one and other winding processing lines. A connecting coil forming method, characterized in that a rectangular wire arranging step is provided prior to the first and second coil forming steps. A first coil, which is a rectangular tube-shaped rectangular wire coil formed by sequentially winding one end of a rectangular wire as a coil material, is formed, and a second rectangular wire coil is similarly formed at the other end. In a connected coil forming apparatus having a parallel installation function of forming a coil, the first coil and the second coil being connected to each other by a connecting part that is continuous with both coils, and being installed in parallel with each other,
Corresponding to each coil that includes the length of the connecting portion that is two or more turns before the final completion of the second coil after completion of the first coil and that is located in a direction orthogonal to the connecting portion. Measuring the parallel interval between the coil sides as a connection part length, and having a connection part length measuring means for sending this to the main control unit,
When forming the first or second coil, the rectangular wire introduced from the material supply region is arranged linearly along the winding processing line and supports the wire feeding unit, and the winding processing line A winding head mechanism disposed on the downstream side of the wire feeding unit at the flat wire introduction direction on the upper side, and an apparatus main body for supporting the wire feeding unit and the winding head mechanism,
The winding head mechanism performs a 90-degree bending process on a rectangular wire that is the coil material, and a 90-degree bending process position on the winding head part is set on the winding processing line. And a machining position setting unit that is variably set along with the winding head unit when the rectangular wire having the first coil formed at the rear end is fed onto the winding machining line. A coil forming function for forming the second coil;
The machining position setting operation of the machining position setting unit is variably controlled at a predetermined timing based on control information input from the outside, and the arrangement interval between the first coil and the second coil is adjusted by adjusting the length of the coupling unit. A connected coil forming apparatus characterized in that a main control unit for setting a desired dimension to the desired dimension is provided in the winding head mechanism. The connected coil forming apparatus according to claim 13,
The winding head mechanism operates under the control of the main control unit when the rectangular wire that is the material of each of the first or second coil is square-wound and processed into a rectangular tube shape. A connecting coil forming apparatus comprising a rectangular wire transfer function for transferring the rectangular wire by a required length along the winding processing line during bending. In the connection coil formation device according to claim 13 or 14,
The main control unit is used for the arrangement interval of the two coils and the rectangular wire adjustment set in the second coil, which are specified in advance for the measurement data of the connection site length measured by the connection site length measuring means. A measurement data distribution function that distributes to the coil side to be included, and an operation of the machining position setting unit based on the distributed measurement data to control a predetermined offset amount to a piece of the last square winding portion of the second coil A connected coil forming apparatus, comprising: an offset amount setting function for setting an arrangement amount; and an arrangement interval setting control function for setting an arrangement interval between the two coils. A first coil, which is a rectangular tube-shaped rectangular wire coil formed by sequentially winding one end of a rectangular wire as a coil material, and a second coil that is also a rectangular wire coil is formed at the other end. In a connected coil forming apparatus having a parallel installation function of forming the
Corresponding to each coil that includes the length of the connecting portion that is two or more turns before the final completion of the second coil after completion of the first coil and that is located in a direction orthogonal to the connecting portion. Measuring the parallel interval between the coil sides as a connection part length, and having a connection part length measuring means for sending this to the main control unit,
When forming the first or second coil, the rectangular wire introduced from the material supply region is arranged linearly along the winding processing line and supports the wire feeding unit, and the winding processing line The first and second winding head mechanisms respectively disposed corresponding to the rectangular wire introduction direction and on the rectangular wire introduction side on the winding processing line, the wire feeding unit, and the windings An apparatus main body for supporting the head mechanism,
Each of the first and second winding head mechanisms changes the flat wire feed length by the winding head portion that sequentially executes 90 degree bending of the flat wire that is the coil material, and the flat wire feed length by the wire feed unit. And a machining position setting section for variably setting a machining position of the bending process along the winding machining line, and when the rectangular wire having a predetermined length is fed onto the winding machining line, the winding head A coil forming function for energizing the portion and the processing position setting portion to form a first coil from one end of the rectangular wire and a second coil from the other end,
A main control unit that drives and controls a machining position setting operation of the machining position setting unit at a predetermined timing based on externally input control information is provided in each of the first and second winding head mechanisms. Connected coil forming device. The connected coil forming apparatus according to claim 16, wherein
Corresponding to each coil that includes the length of the connecting portion that is two or more turns before the final completion of the second coil after completion of the first coil and that is located in a direction orthogonal to the connecting portion. Measuring the parallel interval between the coil sides as a connection part length, and having a connection part length measuring means for sending this to the main control unit,
The main control unit is used for the arrangement interval of the two coils and the rectangular wire adjustment set in the second coil, which are specified in advance for the measurement data of the connection site length measured by the connection site length measuring means. A measurement data distribution function that distributes to the coil side to be included, and controls the operation of each of the first and second winding head mechanisms based on the distributed measurement data to control the last square winding portion of the second coil. A connected coil forming apparatus comprising: an offset amount setting function for setting a predetermined offset amount in one piece; and an arrangement interval setting control function for setting and controlling the arrangement interval between the two coils. In the connection coil formation device according to claim 16 or 17,
The second winding head mechanism operates under the control of the main control unit when the rectangular wire that is the material of the corresponding first or second coil is square-wound and processed into a rectangular tube shape. The flat wire is provided with a flat wire transfer function for transferring the flat wire to each coil side by the length necessary for the square winding processing along the winding processing line when bending the flat wire by 90 degrees. Connecting coil forming device. In the connection coil formation device according to any one of claims 13 to 15 ,
Equipped with a cutter mechanism for cutting the rectangular wire in accordance with the command of the main control unit on the material introduction region side of the winding processing line,
After the main control unit completes the first coil at one end of the rectangular wire, the rectangular wire is a rectangular wire having a predetermined length necessary for forming the second coil and completing the connecting coil from the material supply region. A connecting coil forming apparatus, comprising: a rectangular wire cutting control function for instructing the cutter mechanism to perform a rectangular wire cutting operation when the wire is introduced. The connected coil forming apparatus according to claim 16, wherein
Each of the first and second winding head mechanisms is a movable winding head mechanism capable of reciprocating in a direction orthogonal to the winding processing line,
The winding processing line is two winding processing lines that share the respective winding head mechanisms, and the wire feed unit corresponds to the two winding processing lines and is individually separated from the winding processing line. The first and second wire feeding parts are configured to be retractable to,
The main control unit is provided with a linkage control function for cooperatively controlling each operation of the first and second winding head mechanisms and the wire feed unit according to a preset command. apparatus. The connected coil forming apparatus according to claim 20, wherein
The main control unit is
When the first coil is formed by driving and controlling the one set of winding head mechanisms in the one winding processing line, the one set of winding head mechanisms is used as the other winding processing line. At the same time as operating as a winding head mechanism for forming the first coil in the other winding processing line, the other set of winding heads for forming the second coil on the one winding processing line A first crossover control function for driving and controlling the mechanism for forming the second coil;
When the second coil of the other set is formed on the one winding processing line, the winding head mechanism of the other set is moved to the other winding processing line, After the first coil is formed, the one winding head is operated as the second coil forming winding head mechanism in the other winding processing line and at the same time, on the other winding processing line, the one winding head is formed after the first coil is formed. And a second crossing control function for returning the mechanism to the one winding line and driving and controlling the first coil in the one winding line. apparatus. In the connection coil formation device according to claim 20 or 21,
After each rectangular wire on each winding processing line is introduced and set for a required length, a cutter mechanism that is energized by the main control unit and cuts each winding processing line individually is provided in each winding processing line. A connected coil forming apparatus that is shared. The connected coil forming apparatus according to claim 16, wherein
Along the winding processing line, the wire feeding unit at the center, the first sliding guide for the first winding head mechanism on one side, and the second winding on the other side Equipped with a second sliding guide for the head mechanism,
The main control unit has a simultaneous machining control function for driving and controlling the first and second winding head mechanisms so as to execute the first and second coil machining operations in the same time zone. A connected coil forming apparatus. The connected coil forming apparatus according to claim 23,
The main control unit performs the first coil machining operation by the first winding head mechanism at least 1/2 turn (2 turns) or more before the completion of the second coil by the second winding head mechanism. Control to complete,
Corresponding coil of each coil positioned in the direction orthogonal to the length of the connecting portion before the final two turns or more in the second coil immediately after the completion of the first coil. A connecting part length measuring means for measuring a parallel interval between sides as a connecting part length and sending it to the main control unit is detachably disposed on the second sliding guide,
The main control unit is used for the arrangement interval of the two coils and the rectangular wire adjustment set in the second coil, which are specified in advance for the measurement data of the connection site length measured by the connection site length measuring means. A measurement data distribution function for distributing to the coil side including the second coil, and controlling the operation of the machining position setting unit based on the distributed measurement data to vary the flat wire feed amount of the wire feed unit. A connected coil forming apparatus comprising: an offset amount setting function for setting a predetermined offset amount in one piece of the last square winding portion of the coil; and an arrangement interval setting control function for setting an arrangement interval between the coils. . The connected coil forming apparatus according to claim 24, wherein:
The connection part length measuring means is configured to measure a parallel interval between corresponding coil sides of each coil as a connection part length based on a reference point set on the apparatus body,
The main control unit is used for the arrangement interval of the two coils and the rectangular wire adjustment set in the second coil, which are specified in advance for the measurement data of the connection site length measured by the connection site length measuring means. A measurement data distribution function for distributing to the coil side including the second coil, and controlling the operation of the machining position setting unit based on the distributed measurement data to vary the flat wire feed amount of the wire feed unit. A connected coil forming apparatus comprising: an offset amount setting function for setting a predetermined offset amount in one piece of the last square winding portion of the coil; and an arrangement interval setting control function for setting an arrangement interval between the coils. .

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