JP5109827B2 - Coil winder - Google Patents

Description

  The present invention relates to a coil winding device for winding a wire around a core bar and forming it into a coil shape.

Conventionally, the coil winding device described in Patent Document 1 is known.
This coil winding device is a device for winding a linear wire (for example, a flat wire) into a coil shape, and as shown in FIG. 7, a substantially rectangular cross section in which four corner portions are provided with R shapes. The core metal 100 is provided. The core metal 100 is formed into a coil shape by rotating the core metal 100 by a motor while winding the wire rod around the core metal 100 a predetermined number of times while guiding the wire rod with a roller. The molded coil body is used for a field coil of a starter motor, for example.
JP 2006-290479 A

However, after the coil body wound up using the core metal 100 is removed from the core metal 100, as shown in FIG. 8, due to the residual stress (spring back) of the wire 200 wound into a coil shape, For example, a twist angle θ = 3 to 4 degrees occurs every turn. For this reason, the coil body removed from the cored bar 100 requires a shaping process for correcting torsion before being assembled to the stator core of the motor, resulting in an increase in cost.
Further, since the wire rod 200 wound around the core metal 100 is wound and squeezed by the spring back, a large load is required to remove it from the core metal 100, and the removal is difficult.
The present invention has been made on the basis of the above circumstances, and its purpose is a coil that does not require a shaping process after the winding process and can easily remove the wire wound around the core bar from the core bar. It is to provide a winding device.

(Invention of Claim 1)
The present invention has cores having a substantially rectangular cross section each having an R shape at each of the four corners, and winding the wire around the cores N times (N is an integer of 2 or more) to form a coil. A coil winding apparatus for molding, wherein the core has an N-stage winding track for winding a wire, and the N-stage winding track is formed from the first stage to the N-stage every round. In addition, the four corners are sequentially shifted in the circumferential direction to form a spiral shape, and the cored bar is divided into a substantially rectangular longitudinal direction and a transverse direction, and each of the four cored bars includes a corner part. The four cored bar pieces are configured to be movable in a contracting direction in which the distance from each other radially approaches the center of the cored bar and in an expanding direction in which the distance from each other increases. .

The coil winding device of the present invention presses the wire against the side surface (winding track) of the core metal, winds the wire around the core metal while rotating the core metal, and forms the coil. The core metal used in this coil winding device has a winding track for winding a wire rod, and the four corners are sequentially shifted in the circumferential direction from the first stage to the N stage and spiral. It is configured. That is, the cored bar of the present invention has a shape twisted in advance in a spiral shape in anticipation of a springback of the wire wound in a coil shape. For this reason, since the wire wound around the metal core is formed into a coil shape in a helically twisted state, the wire is removed from the core metal and then the spring is twisted in advance by the amount twisted in a helical shape. By returning by the back, as a result, it can be formed into a coil shape without twisting.
Further, the four cored bar pieces constituting the cored bar are configured to be movable in a reduction direction in which the distance from each other radially approaches the center of the cored bar and in an expansion direction in which the distance from each other increases. After the wire is wound, the four cored bar pieces are moved in the shrinking direction, so that the wire wound in a coil shape can be easily removed from the four cored bar pieces.

(Invention of Claim 2)
2. The coil winding apparatus according to claim 1, wherein two cored bar pieces adjacent to each other in the longitudinal direction of the cored bar have an R shape when a common tangent line A is assumed in the R shape forming the corner portion of each other. The outer shape line from the contact point to the end of the corner portion is inward from the tangent line A.
According to said structure, since it can wind up, pressing a wire to the inner side of the tangent line A between the metal core piece adjacent to the longitudinal direction of a metal core, and a metal core piece, a wire is the outer side of the tangent A Swelling like a drum can be suppressed. As a result, the space between the corners in the longitudinal direction of the coil can be linearly formed.

(Invention of Claim 3)
The coil winding apparatus according to claim 2, wherein two cored bar pieces adjacent to each other in the short direction of the cored bar are assumed to have a tangent line B common to the R shape forming each other's corner portion. The outer shape line from the shape contact point to the end of the corner portion is inward from the tangent line B.
As in the case of claim 2, the wire rod can be wound while pressing the wire rod inside the tangent line B between the mandrel piece and the mandrel piece adjacent to each other in the short direction of the mandrel. It is possible to suppress a drum-like swell toward the outside of B. As a result, between the corners in the short direction of the coil can be linearly formed, and the overall shape of the coil can be approximated to a quadrangle (rectangle).

(Invention of Claim 4)
The coil winding apparatus according to any one of claims 1 to 3, wherein the wire is a rectangular wire having a rectangular cross section, and the rectangular wire is wound around the core metal in an edgewise direction to be formed into a coil shape. Features.

  The best mode for carrying out the present invention will be described in detail with reference to the following examples.

1 is a perspective view of a winding head 7 used in the coil winding device 1. FIG. 2A is a plan view of the winding head 7. FIG. 1B is a side view of the winding head 7. FIG. Is a three-sided view of the coil winding device 1, and FIG. 4 is a cross-sectional view of a first winding jig 4 used in the coil winding device 1.
The coil winding device 1 according to the present embodiment is a device for winding a linear wire 2 (see FIG. 3) from both ends around a core bar (described later) in a coil shape. This coil can be used for a field coil of a starter motor, for example.
As shown in FIG. 3, the coil winding device 1 includes two slide guides 3 installed in parallel, and a first winding jig 4 fixed to one end side of the two slide guides 3. In order to apply tension to the second winding jig 5 movably mounted on the two slide guides 3 and the wire 2 set on the first and second winding jigs 4 and 5. Tension cylinder 6 or the like.

The first winding jig 4 drives a winding head 7 (see FIGS. 1 and 2) for winding the wire 2 around the core and a main shaft 8 (see FIG. 4) provided on the winding head 7 as a belt drive. A servo motor 9 for performing the above operation, a pressing roller 10 for guiding the wire 2 with respect to the metal core, a servo motor 11 for driving the pressing roller 10 and the like.
As shown in FIGS. 1 and 2, the winding head 7 includes a cored bar composed of four cored bar pieces 12, a hook (not shown) for setting the end of the wire 2, and 4 A cam mechanism (described later) for moving the individual cored bar pieces 12 in the reduction direction and the enlargement direction (the arrow direction shown in FIG. 2A) is provided.
Note that the second winding jig 5 includes a winding head 7, a servo motor 9, a pressing roller 10, a servo motor 11, and the like, like the first winding jig 4. However, since each structure and function are the same as the 1st winding jig | tool 4, the description is abbreviate | omitted.

The four cored bar pieces 12 are each divided so as to include the corners of the cored bar. In other words, a cored bar having four corners is divided into four cored bar pieces 12, and each cored bar piece 12 includes one corner. Moreover, the corner | angular part of the metal core piece 12 is R chamfering, and the corner | angular part which has this R chamfering is called a corner part in the following description.
As shown in FIG. 1, the cored bar made up of four cored bar pieces 12 has an N-stage (N is an integer of 2 or more) winding track 12 a (side surface of the cored bar piece 12) for winding the wire 2. The N-stage winding track 12a is formed in a spiral shape with four corners sequentially shifted in the circumferential direction every round from the first stage to the N-th stage.
In addition, as shown in FIG. 5, two cored bar pieces 12 adjacent to each other in the longitudinal direction (the vertical direction in the figure) of the cored bar are assumed when a common tangent line A is formed in an R shape that forms a corner part of each other. The outer shape line from the R-shaped contact point a to the end of the corner portion is formed so as to enter inward from the tangent line A.

  The cam mechanism includes a cam plate 13 indicated by a broken line in FIG. 2A, an operation lever 14 for rotating the cam plate 13, and four cam followers 15 that contact the cam plate 13 (FIG. 2B). The cored bar pieces 12 are fixed to the four cam followers 15, respectively. In this cam mechanism, when the cam plate 13 is rotated by the operation lever 14, the cam follower 15 moves in the arrow direction shown in FIG. 2A along the uneven shape (cam profile) of the cam plate 13. The four cored bar pieces 12 fixed to 15 can move in a contracting direction in which the distance from each other radially approaches the center of the cored bar and in an expanding direction in which the distance from each other increases.

Next, the operation of the coil winding device 1 (see FIG. 3) will be described.
a) First, both ends of the linear wire 2 are set on hooks provided on the winding heads 7 of the first and second winding jigs 4 and 5, respectively. The wire 2 used is a rectangular wire having a rectangular cross section, and the rectangular wire is set in the edgewise direction with respect to the cored bar. However, it goes without saying that the coil winding device 1 of the present embodiment can also be used for wires other than rectangular wires, for example, wires having a circular cross section, an elliptical cross section, a polygonal cross section, and the like.
b) Subsequently, air is supplied to the tension cylinder 6 and the second winding jig 5 is biased in the counter-winding direction [rightward in FIG. The wire 2 is kept in a tensioned state.

c) The pressing roller 10 is advanced by the servo motor 11 and pressed against the wire 2.
d) The main shaft 8 of the winding head 7 is rotated by the servo motor 9. The winding head 7 is rotated by the rotation of the main shaft 8, and the wire 2 is wound around the core bar. As shown in FIG. 4, a screw shaft 16 having a trapezoidal screw is attached to the lower end portion of the main shaft 8, and the screw shaft 16 is screwed to the flange nut 17. The flange nut 17 is fixed to the support column 19 via a stay 18. Due to the screw connection between the screw shaft 16 and the flange nut 17, the winding head 7 descends at a fixed pitch each time the main shaft 8 rotates.
Further, since the first winding jig 4 is fixed at a fixed position and the second winding jig 5 is mounted on the slide guide 3, the first and second winding jigs 4 are used. When both the winding heads 7 and 5 are rotated to wind the wire 2 around the core metal, the second winding jig 5 moves on the slide guide 3 to move the first winding jig 4. Approaching.

e) The wire 2 is wound around the four cored bar pieces 12 a predetermined number of times (for example, three times), and the winding process is completed.
f) Stop the supply of air to the tension cylinder 6 and loosen the tension.
g) The cam plate 13 is rotated by the operating lever 14 to move the four cored bar pieces 12 in the reduction direction, and the coiled wire 2 wound up is removed from the cored bar piece 12.
The wire 2 removed from the cored bar piece 12 is formed with two continuous coil portions 20 as shown in FIG. 6 (a), and then formed into the final shape shown in FIG. 6 (b). And finished as a product.

(Effect of this embodiment)
The core bar used in the coil winding device 1 has a winding track 12a for winding the wire 2 in which the four corners are sequentially shifted in the circumferential direction every round from the first stage to the N stage. It is configured in a spiral. That is, the cored bar composed of the four cored bar pieces 12 has a shape twisted in advance in a spiral shape in anticipation of the spring back of the wire 2 wound in a coil shape (see FIG. 1). . For this reason, since the wire 2 wound around the metal core is formed into a coil shape in a spirally twisted state, after the wire 2 is removed from the metal core, the wire material 2 is previously twisted in a spiral shape. By returning by spring back, it can be formed into a coil shape without twisting. As a result, after the winding process, a shaping process for correcting the twist of the coil caused by the springback is unnecessary, which can contribute to cost reduction.

In addition, the four core metal pieces 12 are attached to the winding head 7 via a cam mechanism, and by operating the cam mechanism, a reduction direction in which the distance from each other radially approaches the core bar, It is configured to be movable in the enlargement direction in which the distance is increased. Thereby, after winding up the wire 2, the wire 2 wound in a coil shape can be easily detached from the four core bars 12 by moving the four core bars 12 in the reduction direction. .
Further, the two cored bar pieces 12 adjacent to each other in the longitudinal direction of the cored bar are formed such that the outer shape line from the R-shaped contact point a to the end of the corner portion enters inward from the tangent line A, as shown in FIG. Has been. As a result, the wire 2 can be wound while being pressed by the pressing roller 10 to the inside of the tangent line A between the metal core piece 12 and the metal core piece 12 adjacent to each other in the longitudinal direction of the metal core. It is possible to prevent the drum from swelling outside the tangent line A. As a result, the space between the corners in the longitudinal direction of the coil can be linearly formed.

  Further, not only in the longitudinal direction of the cored bar but also in the lateral direction, a common tangent line B (see FIG. 5) common to the R shape forming each other's corner portion is virtually assumed and the corner portion is connected to the corner portion from the R shape contact b. The outer shape line up to the end may be formed so as to enter the inside of the tangent line B. Thereby, it can suppress that the wire 2 shape | molded by the coil shape swells in the drum shape to the outer side of the tangent B, and can shape | mold between the corner | angular parts in the transversal direction of a coil linearly.

It is a perspective view of the winding head which has a metal core. (A) The top view of a winding head, (b) The side view of a winding head. (A) Top view of coil winding device, (b) Front view of coil winding device, (c) Side view of coil winding device. It is sectional drawing which shows the detailed structure of a winding jig | tool. It is a top view showing the shape of four cored bar pieces. (A) The top view of the coil-shaped wire removed from the metal core, (b) The top view which shows the final shape of a coil. (A) Top view of the metal core which concerns on a prior art, (b) Cross-sectional view of a metal core, (c) It is a bottom view of a metal core. It is a top view of the coil twisted by the springback (prior art).

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coil winding device 2 Wire material 12 Core metal piece (core metal)
12a Take-up truck

Claims (4)

Coil winding that has cores with a substantially rectangular cross-section each having an R shape at each of the four corners, and winding the wire around the cores N times (N is an integer of 2 or more) to form a coil shape Take-off device,
The core bar has an N-stage winding track for winding the wire, and the N-stage winding track has the four corner portions for each turn from the first stage to the N stage. The cored bar is sequentially shifted in the circumferential direction, and the cored bar is divided into a substantially rectangular long-side direction and a short-sided direction, and includes four cored bar pieces each including the corner portion. 4. A coil winding apparatus, wherein four cored bar pieces are configured to be movable in a reducing direction in which the distance from each other radially approaches the center of the cored bar and in an expanding direction in which the distance from each other increases. . In the coil winding device according to claim 1,
The two cored bar pieces adjacent to each other in the longitudinal direction of the cored bar, from the R-shaped contact point to the terminal end of the cornered part, when assuming a common tangent line A to the R-shaped form forming the corner part of each other The coil winding device is characterized in that the outer shape line enters the inner side from the tangent line A. In the coil winding device according to claim 2,
The two cored bar pieces adjacent to each other in the short direction of the cored bar assume the end of the corner part from the R-shaped contact point when a common tangent line B is formed to the R-shaped part that forms the corner part of each other. The coil winding device is characterized in that the outer contour line enters the inside from the tangent line B. In the coil winding device according to any one of claims 1 to 3,
The wire rod is a rectangular wire having a rectangular cross-section, and the rectangular wire is wound around the metal core in an edgewise direction to be formed into a coil shape.

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