JP5147056B2 - Method or apparatus for coil extraction and molding - Google Patents

Description

  The present invention relates to a method or apparatus relating to coil extraction and molding, and more particularly to a method or apparatus relating to coil extraction and molding suitable for manufacturing track-shaped (oval) or rectangular bobbinless coils.

In the case of winding (winding) a track-shaped or rectangular bobbinless coil, conventionally, a track-shaped or rectangular core having the same shape as the finished shape of the coil is used. A wire rod is wound around this to obtain a bobbinless coil having a target shape (see, for example, Patent Document 1).
JP 2003-168618 A

However, these conventional methods have the following problems.
(1) Alignment In the conventional method, the wire entry position is in the vicinity of the connection portion between the linear portion of the coil and the R portion (deflection portion). This is a position where it is difficult to produce a cross point, and the wire rod is likely to be disturbed.
(2) Deformation of coil In the conventional method, the minor axis (short axis) direction of the coil swells. For this reason, coils often do not fit in the specified dimensions, and post-treatment such as reheating in a furnace was necessary. Further, especially with a high tension wire, the coil was easily warped and twisted.
(3) Tact time a) Because of the problems (1) and (2) above, the conventional method has to reduce the number of rotations to about one fifth when winding a circular coil. B) The bobbin-less coil does not have a bobbin as its name suggests. For this reason, the dimensions are likely to go wrong originally. Therefore, conventionally, even if molding is performed to correct the dimensions, it is once removed from the core and manually remounted on the molding jig or on the winding machine. Forming is performed with a kite wound around. In other words, the operations are alternately performed in series, such as winding and forming, and winding and forming. This further increases the tact time.

  An object of the present invention is to solve the above-described problems and to further improve the dimensional accuracy particularly with respect to a track-shaped and rectangular bobbinless coil winding. At the same time, it is to improve or shorten the coil alignment or tact time.

In order to solve the above-mentioned problem, in the coil take-out and molding apparatus according to claim 1 , the winding jig disposed opposite to the winding jig is slidably disposed on one side of the winding jig and is directed toward the other side of the winding jig. A biased core, a plurality of coil receiving pins for supporting the coil from the inside and extending the coil from the inside, a pressing member arranged to be movable in a direction crossing the extending direction, and control The control means causes the plurality of coil receiving pins to face the winding core , and at this time, a difference between the outsides of the plurality of coil receiving pins is slightly smaller than an outer diameter of the winding core. In this state, one of the winding jig and the plurality of coil receiving pins is brought close to each other or close to each other, and the winding core is moved into the winding jig by the approach. is moved, the coil which is wound on the winding core of said plurality By transition to yl receiving pin, the coil from the inner side is supported by a plurality of coils receiving pins, is separated a plurality of coils receiving pins that support the coil, is extended to the coil,該伸length simultaneously with or before and after Then, the pressing member is brought close to the coil, the coil is pressed, and the coil is formed.

Further, in the coil extraction molding apparatus according to claim 2 quoting Claim 1, the cross section of the winding core is circular or elliptical.
Also, in the coil extraction molding apparatus according to claim 3 or claim 1 quoting Claim 2, further comprising a width regulating member, wherein, during the forming, the width of the coil in the width regulating member To regulate.
Further, in the coil take-out and molding apparatus according to claim 4, which is cited in claim 1, claim 2 or claim 3, the control means further comprises means for incorporating a heater in the pressing member or supplying hot air during molding. In the molding, the coil is heated by the heater or hot air.

  Each method or apparatus of the present invention is a combination of the following components. That is, a wire is wound around a winding core having a circular or elliptical cross section that is slidably disposed on one of the winding jigs and is biased toward the other side of the winding jig. This winding core and a supporting member for supporting the coil from the inside are directly opposed, and one of the winding jig and the supporting member is brought close to each other or close to each other. Transfer the coil to the member. The coil support member is separated to extend the coil, and the coil is formed into a track shape or the like. Alternatively, the coil is formed into a track shape or the like by extending and pressing with a forming member. The following effects are exhibited by these combinations.

(1) Smooth coil removal In the present invention, the coil is smoothly transferred from the winding core to the support member. Therefore, the coil can be taken out without causing deformation or the like. In addition, the coil to be transferred has high alignment as described in (2) and (3) below. Combined with this, the coil is smoothly taken out without causing deformation or the like.
(2) Alignment is improved.
In the conventional method, since the lengths of the sides of the winding core are different, the drawing of the wire becomes pulsating. For this reason, disorder of the wire was easy to occur. However, in the present invention, the wire winding itself is performed with a circular or elliptical core. If this is the case, the wire will not be disturbed. Moreover, high speed rotation is possible. Nevertheless, alignment is maintained. Therefore, a stable fully aligned winding is possible.
(3) No deformation of the coil occurs.
In the conventional method, the short axis direction of the coil swelled. In particular, with a high tension wire, the coil is likely to warp and twist. However, in the present invention, winding is performed with a circular or elliptical core. Then mold. For this reason, warping and twisting hardly occur.
(4) Tact time In the conventional method, due to the problems (2) and (3) above, it is necessary to reduce the core rotation speed to about one fifth compared with the case of winding a circular coil. There wasn't. However, if it is this invention, it can wind by the same rotation speed as a normal circular coil.
Furthermore, in the conventional method, the work must be performed alternately, such as winding → molding → winding → molding, which further increases the tact time. However, if the winding method and the coil receiving method of the present invention are combined, the winding operation and the forming operation can be separated, and both can be performed in parallel. In this respect, the tact time is further shortened.

  The details of the present invention will be described below based on the embodiments shown in the drawings. FIG. 1 shows the front of a winding machine 50 with a forming mechanism according to an embodiment. Regarding the structure of the winding machine portion of the device 50, for example, Japanese Patent Application Laid-Open No. 2005-116657, Japanese Patent Application Laid-Open No. 2001-358029, Japanese Patent Application Laid-Open No. 10-304628, etc., which are filed by the present applicant. Are described in detail. Therefore, only the part understood as necessary for the description of the embodiment is shown here.

  FIG. 1 shows the front of an embodiment 50. Reference numeral 1 denotes a spindle block, which is installed on the cabinet 5, with a block left 2 (fixed side) on the left side and a block right 3 (movable side) on the right side. A spline shaft 4 having a square cross section is rotatably supported at the lower portion of the spindle block 1. A shaft left pulley 10 is attached to the shaft 4. A main motor (not shown) is also arranged on the spindle block 1, and a motor pulley 11 having two grooves is attached to the shaft. An inter-motor spline belt 8 is stretched between the motor pulley 11 and the shaft left pulley 10, and the spline shaft 4 is rotated by the main motor. The drive control of each component and member, including the drive control of the main motor, is executed by a control device (not shown) composed of a microcomputer.

A fixed spindle is rotatably supported on the block left 2 and a fixed pulley 9 is attached to the left side of the block. A fixed-side motor belt 12 is stretched between the fixed-side pulley 9 and the motor pulley 11, and the fixed-side spindle is also rotated by the main motor.
A trabass base 14 extending to the left side is attached to the block left 2. A sliding frame 16 is disposed on the trabus base 14. The sliding frame 16 is driven by a left traverse motor 17 to traverse the line guide 18.

A tail plate support shaft 19 is attached to the middle of the block right 3. The tail plate support shaft 19 extends rightward and is inserted through the center of the tail plate 23 to support the tail plate 23 slidably.
An upper slide shaft 27 is slidably supported above the block right 3. A lower slide shaft 26 is slidably held below the block right 3. The right ends of the sliding shafts 26 and 27 are attached to the tail plate 23.
A tail plate air cylinder 24 is connected to the right end of the tail plate support shaft 19. With the air supply / exhaust to the air cylinder 24, the tail plate 23 and the upper and lower sliding shafts 26 and 27 move to the left and right by the required amount.

A driven pulley 28 is rotatably attached to the lower portion of the tail plate 23. A female spline (not shown) is formed in the center of the driven pulley 28. The spline shaft 4 meshes with the female spline, and the driven pulley 28 rotates together with the spline shaft 4.
The spline shaft 4 is rotatably supported on the tail plate 23. The driven pulley 28 is also rotatably supported by the tail plate 23 and moves to the left and right together with the tail plate 23.

A movable spindle (not shown) is rotatably supported on the upper sliding shaft 27. A movable pulley 31 is attached to the right side of the movable spindle, and a spline movable side belt 32 is stretched between the movable pulley 31 and the driven pulley 28. Thereby, the rotation of the spline shaft 4 is transmitted to the movable spindle.
A movable winding jig (jig cap) 21 is attached to the left end of the movable spindle. The core 13 is slidably held at the center. A core advance / retreat air cylinder 29 is attached to the right end of the upper sliding shaft 27. A connecting rod (not shown) inserted through the movable side spindle connects the core 13 and the air cylinder 29, and the air core 29 is supplied with air to the air cylinder 29 to fix the core 13 to the fixed side winding jig 22. It is biased in the (positioning jig) direction. The fixed-side winding jig 22 is attached to the right end of the fixed-side spindle and faces the movable-side winding jig 21.

A horizontal guide 33 is disposed above the spindle block 1. The horizontal guide 33 is supported by a bracket (not shown) standing on the cabinet 5. Here, the bracket is not shown in order to make the drawing easy to see.
A horizontal moving body 34 is supported on the horizontal guide 33 so as to be slidable in the horizontal direction. A horizontal moving bolt 36 is screwed to the horizontal moving body 34. Both ends of the horizontal movement bolt 36 are rotatably supported by the horizontal guide 33.
A horizontal movement motor 37 is attached to the right end of the horizontal guide 33. A horizontal movement bolt 36 is connected to the horizontal movement body 34 to move it.

  A vertical bracket 38 is attached to the horizontal moving body 34. A vertical guide 39 is attached to this. A vertical moving body 41 is supported on the vertical guide 39 so as to be vertically movable. A vertical moving bolt 42 is screwed to the vertical moving body 41. A bearing body 43 is attached to the vertical bracket 38, and an upper portion of the vertical movement bolt 42 is rotatably supported by the bearing body 43. A vertical movement motor 44 is attached to the upper end of the vertical bracket 38, and a vertical movement bolt 42 is connected to the vertical bracket 38 to move the vertical movement body 41 up and down.

A coil handling member 46 is attached to the vertical moving body 41. The coil handling member 46 has two upper and lower coil receiving pins 47U and 47D protruding in the right side surface direction. A solenoid (not shown) is disposed inside the coil handling member 46, and when energized, the coil receiving pins 47U and 47D are retracted (stored) in the coil handling member 46 (FIG. 7 (14)). In the figure, it is expressed by a circled number. The same applies to other figures.) Above the coil handling member 46, a receiving pin up / down air cylinder 48 is arranged. The air cylinder 48 is attached to the vertical moving body 41 with a bracket (not shown). The air cylinder 48 is connected to the upper coil receiving pin 47U, and the upper coil receiving pin 47U is moved up and down by supplying and exhausting air. Instead of the air cylinder 48, a pulse motor may be used.
A shutter 49 is also supported on the vertical moving body 41. The vertical moving body 41 has a shutter up / down air cylinder 51 and a shutter lateral movement air cylinder (not shown) attached thereto. The shutter 49 is connected to these, and moves up and down and left and right.

  Reference numeral 52 denotes a press mechanism. This press mechanism 52 is also supported by a bracket (not shown). This bracket (not shown) is erected on the cabinet 5. The press mechanism 52 includes a pair of press jigs 53L and 53R. The press jigs 53L and 53R are arranged in a direction perpendicular to the paper surface so as to face each other. Its shape is shown in FIG. FIG. 6 shows the shapes of the press jigs 53L and 53R when the press jigs 53L and 53R are viewed from the right side of the winding machine 50 with a forming mechanism. As shown in the figure, these centers bulge in a bowl shape toward the other party. A press motor 54 is disposed in the press mechanism 52, and the press jigs 53 </ b> L and 53 </ b> R are moved toward and away from the press mechanism 52.

  A procedure for manufacturing the oval coil 57 according to the embodiment 50 will be described. Here, the wire rod is wound around the core 13 having an elliptical cross section. At this time, the inner circumferential length of the forming object coil 56 is set to be the same as the inner circumferential length of the desired oval coil 57, for example. As an example, if the inner short diameter of the oval coil 57 is 3 mm and the inner long diameter is 13 mm, the inner circumferential length of the elliptical coil 56 is 29.42 mm. If the core cross section is circular, the diameter is 9.37 mm.

When the winding of the wire ends, the movable side winding jig 21 is retracted (state shown in FIG. 1). Next, the horizontal moving body 34, that is, the coil handling member 46 is advanced toward the fixed-side winding jig 22 (FIG. 1 (1)).
Next, the coil handling member 46 is lowered, and the upper and lower coil receiving pins 47U and 47D are opposed to the core 13 (FIG. 2 (2)). At this time, the difference between the outer sides of the upper and lower coil receiving pins 47 </ b> U and 47, i.e., the major axis of the ellipse that circulates them, is made slightly smaller than the major axis of the core 13. Thus, the two coil receiving pins 47U and 47D are located slightly inside the inner periphery of the wound coil 56.

In this state, the movable-side winding jig 21 is advanced toward the coil receiving pins 47U and 47D (FIG. 2 (3)). The winding core 13 is urged by the air pressure of the air cylinder, but is pushed by the coil receiving pins 47U and 47D by the advance of the movable side winding jig 21 and retracts into the movable side winding jig 21.
As a result, the coil receiving pins 47U and 47D enter the inside of the forming object coil 56 wound around the winding core 13, and the forming object coil 56 moves to the coil receiving pins 47U and 47D and is externally fitted thereto. (Fig. 2 (3)).

Next, the movable-side winding jig 21 is retracted (FIG. 3 (4)). As a result, the core 13 comes out of the forming object coil 56.
Next, the coil handling member 46 is raised (FIG. 3 (5)). After that, it is moved backward (FIG. 4 (6)). Thus, the forming object coil 56 is positioned between the two pressing jigs 53L and 53R (FIG. 6 (9)).
Next, the shutter 49 is lowered and positioned on the side surface of the molding object coil 56 (FIG. 5 (7)).
At this time, the movable side winding jig 21 is moved forward to prepare for winding the next wire. This shortens the tact time.

  Next, the shutter 49 is advanced. The distance from the coil handling member 46 is made equal to the finished width of the oval coil 57 (FIG. 5 (8)). The winding jigs 21 and 22 start winding the next wire 58 (same as above). Next, the upper coil receiving pin 47U is raised until the inner diameter on the major axis side of the coil 56 to be formed coincides with a desired finished dimension (FIG. 6 (9) → (10)). The forming object coil 56 is extended in the long axis direction. At the same time, the pressing jigs 53L and 53R are advanced from both sides. Thus, the short axis direction of the molding object coil 56 is pressed and molded (FIG. 5 (11)). Thereby, the elliptical coil becomes an oval coil 57.

In FIG. 5, (10) and (11) are shown separately. However, it is preferable that the stretching in the major axis direction and the pressing in the minor axis direction are performed simultaneously. This is because if the minor axis direction is pressed while stretching in the major axis direction, the ellipse is smoothly deformed into an ellipse.
At this time, the width of the forming object coil 56 (direction perpendicular to the paper surface of FIG. 6) is regulated by the shutter 49 and the coil handling member 46 (FIG. 5 (8)). Therefore, this pressing does not increase the width of the forming object coil 56.

When the molding is finished, the pressing jigs 53L and 53R are retracted (FIG. 6 (12)). The shutter 49 is raised (FIG. 7 (13)), and the coil receiving pins 47U and 47D are retracted (stored) in the coil handling member 46 (FIG. 7 (14)). The coil 57 thus molded is discharged to a tray (not shown) or the like.
Thereafter, the coil handling member 46 is returned to the state shown in FIG. If the next coil winding is finished, the molding operation of the coil 56 is immediately started (FIG. 2 (2)). If not finished, the molding work is started after the end of winding.

Another embodiment will be described. Coil transition from the core 13 to the coil receiving pins 47U and 47D (FIG. 2 (3)) may be performed by moving the coil handling member 46 toward the movable winding jig 21 side. However, the moving method as in the embodiment can use the fixed-side winding jig 22 as a backup of the coil handling member 46, and the coil can be moved smoothly (FIGS. 2 (2) and 3 (4). )). The coil handling member 46 and the movable side winding jig 21 may be brought close to each other.
The pressing of the molding object coil 56 in the minor axis direction may be performed before and after the stretching. Further, if the molding object coil 56 has a desired shape only by its extension, that is, by raising the coil receiving pin 47U, the pressing of the molding object coil 56 in the minor axis direction may be omitted.

  The cross section of the winding core 13 may be oval. That way, the amount of deformation is reduced during subsequent molding, and the dimensional accuracy is improved. However, if the ratio of the short axis to the long axis is too small, the winding is likely to be disturbed. How small it can be made depends on the function of the tension device, the rigidity of the wire, etc. In this case, there is a hand that lowers the rotation speed to some extent. The extent to which the ratio is reduced and the extent to which the rotational speed is reduced are determined by trial several times using actual devices and wire rods. Specifically, the ratio and the rotation speed reduction range are determined within a range in which the alignment property, tact time, etc. are not inferior to those when a circular core is used. The ratio of the molding object coil 56 in FIG. 6 (9) is obtained in this way.

A heater may be incorporated in the press jigs 53L and 53R. When the coil 56 is pressed, the coil is heated and more effective molding can be performed. You may heat with a hot air. However, excessive heating, on the other hand, disturbs alignment and is counterproductive. Need attention.
The coil receiving pins 47U and 47D are not limited to a cylindrical shape and a circular cross section as in the embodiment. These are appropriately changed depending on the shape of the coil to be formed, which part of the coil is to be deformed, and the like. For example, in the case where the curved portion after molding is a saddle shape, the cross section is also a saddle shape like the coil receiving pins 47-1 and 47-2 in FIG. The number of coil receiving pins is not limited to two. FIG. 8B shows an example constituted by four coil receiving pins 47-3 to 47-6. These are used, for example, when forming a coil having a quadrangular shape and rounded corners. Here, the coil extends in the left-right direction as necessary, and is also pressed from above and below as needed (press jigs 53U, 53D).
The winding core 13 may be disposed toward the fixed-side winding jig 22. In this case, the core advance / retreat air cylinder 29 and the like are also arranged on the left side of the block. The direction of the coil handling member 46 is also reversed, and the coil receiving pins 47U and 47D are also directed toward the fixed-side winding jig 22.

The front view which shows the winding machine 50 with a shaping | molding mechanism of the embodiment of this invention (coil handling member 46 advance). The enlarged front view which takes out and shows the winding jigs 21 and 22, the coil handling member 46, etc. (the coil handling member 46 descends, the movable side winding jig 21 advances). Since the structure is the same, the reference numeral is attached only to the left figure (2). The same applies hereinafter. The enlarged front view which takes out and shows the winding jigs 21 and 22, the coil handling member 46, etc. (the movable side winding jig 21 retreats, the coil handling member 46 rises). The front view (coil handling member 46 retreat) which shows winding machine 50 with a forming mechanism of an example of an embodiment of the invention. For the reference numerals, see FIG. 1 having the same structure. The enlarged front view which takes out and shows the winding jigs 21 and 22, the coil handling member 46, etc. (shutter 49 descending, movable winding jig 21 advance, shutter 49 advance, and next winding start). The enlarged right view which takes out and shows the press jig | tool 53L, 53R part. Each process (9)-(12) of coil shaping | molding is shown. The enlarged front view which takes out and shows the winding jig | tool 21,22, the coil handling member 46, etc. (Shutter 49 raise, coil receiving pin 47U, 47D accommodation, coil 57 discharge | emission). Other embodiment examples of the coil receiving pin are shown, (A) shows the coil receiving pins 47-1 and 47-2 and the like having a saddle-shaped cross section, and (B) shows the coil receiving pins 43-3 to 47 having four configurations. The enlarged right view which shows -6 etc.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Spindle block 2 ... Block left 3 ... Block right 4 ... Spline shaft 5 ... Cabinet 8 ... Motor spline belt 9 ... Fixed side pulley 10 ... Shaft left pulley 11 ... Motor pulley 12 ... Fixed side motor belt 13 ... Core 14 ... Trabus base 16 ... Sliding frame 17 ... Trabus motor 18 ... Line guide 19 ... Tail plate support shaft 21 ... Moving side winding jig 22 ... Fixing side winding jig 23 ... Tail plate 24 ... Tail plate air cylinder 26 ... Lower part Slide shaft 27 ... Upper slide shaft 28 ... Follow pulley 29 ... Core cylinder advancing / retreating air cylinder 31 ... Movable pulley 32 ... Spline movable side belt 33 ... Horizontal guide 34 ... Horizontal moving body 36 ... Horizontal moving bolt 37 ... Horizontal movement motor 38 ... vertical bracket 39 ... vertical guide 41 ... vertical moving body 42 ... vertical Moving bolt 43 ... bearing body 44 ... vertical moving motor 46 ... coil handling member 47U, 47D ... coil receiving pin 47-1～47-6 ... coil receiving pin (form other exemplary)
48 ... Air cylinder for receiving pin up / down 49 ... Shutter 50 ... Winding machine with molding mechanism 51 ... Air cylinder for up / down shutter ... Press mechanism 53L, 53R ... Press jig 53U, 53D ... Press jig (other embodiments) Example)
54 ... Pressing motor 56 ... Molded coil 57 ... Oval coil 58 ... Wire

Claims (4)

Winding jigs arranged opposite to each other;
A winding core slidably disposed on one of the winding jigs and biased toward the other side of the winding jig;
A plurality of coil receiving pins for supporting the coil from the inside and extending the coil from the inside ;
A pressing member arranged to be movable in a direction crossing the extension direction;
Control means, the control means comprising:
Directly facing the plurality of coil receiving pins to the winding core,
At this time, the difference between the outer sides of the plurality of coil receiving pins is slightly smaller than the outer diameter of the core,
In this state, about one of the winding jig and the plurality of coil receiving pins , either one of them is brought close to the other or close to each other,
The winding is moved into the winding jig by the approach, the coil wound around the winding core is transferred to the plurality of coil receiving pins , and the coils are moved from the inside to the plurality of coil receiving pins. To support
Separating a plurality of coil receiving pins supporting the coil, extending the coil ,
Simultaneously with or before or after the extension, the pressing member approaches the coil, presses the coil, and forms the coil. The coil take-out and molding apparatus according to claim 1 , wherein a cross section of the winding core is circular or elliptical. Furthermore, a width regulating member is provided,
Wherein, during the molding, the coil extraction molding apparatus according to claim 1 or claim 2, characterized in that to regulate the width of the coil in the width regulating member.   Furthermore, the pressing member has a built-in heater or a means for supplying hot air during molding,
  The control means heats the coil with the heater or hot air during the molding.
The coil take-out and molding apparatus according to claim 1, 2, or 3.

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