JP5244223B2 - Air-core coil and winding method thereof - Google Patents

Description

  The present invention relates to an air-core coil composed of a plurality of coil layers and a winding method thereof.

  Conventionally, as shown in FIG. 10, an air-core coil (200) is known in which unit coil portions (23) formed by winding a conducting wire (22) in a spiral shape are repeatedly arranged in the winding axis direction.

  As a winding method of such an air-core coil (200), as shown in FIG. 11 (a), a first unit winding portion (25) having different inner peripheral lengths is obtained by winding a conducting wire in a spiral shape. ), The second unit winding part (26) and the third unit winding part (27) are continuously formed in the winding axis direction, and a unit comprising the plurality of unit winding parts (25) (26) (27). After the coil portion is continuously formed in the winding axis direction to produce an intermediate product of the air-core coil, the intermediate product is compressed in the winding axis direction, as shown in FIG. Pushing at least part of the second unit winding part (26) inside the part (27) and pushing at least part of the first unit winding part (25) inside the second unit winding part (26). Thus, there is known a method for obtaining a finished product of an air-core coil composed of a plurality of coil layers (three layers in the illustrated example) (Patent Document 1).

  As a method for producing the intermediate product shown in FIG. 11 (a), a method using a stepped winding jig corresponding to the cavity shape of the intermediate product (Patent Document 1) or a winding process of each unit winding part There is known an automatic winding machine that winds a conductor around the core member while changing the form of the core member every time (Patent Document 2).

Japanese Patent Laid-Open No. 2003-86438 JP 2006-339407 A

In the conventional winding method of an air-core coil composed of a plurality of coil layers, the step of bending and deforming the conductive wire by about 90 degrees using the corner portion (30a) of the core piece (30) is repeated as shown in FIG. To form the bent portions (25c), (26c), and (27c) of the plurality of unit winding portions (25), (26), and (27) that constitute the air-core coil described above, but the corner portions of the same winding core piece (30) The plurality of bent portions (25c), (26c), and (27c) that are to be formed by (30a) have an arc shape with the same curvature radius, and therefore, between the bent portions of the inner and outer unit winding portions. A gap G is generated.
As a result, there has been a problem that the space factor of the conductive wire in the air-core coil is reduced.

In order to solve this problem, as shown in FIG. 9, at each corner (23c) of the air-core coil, the first unit winding (25), the second unit winding (26) and the third unit winding are provided. The bent portions (25c), (26c) and (27c) of (27) are formed in an arc shape having the same curvature center S and having a radius of curvature that increases by the diameter of the conducting wire from the inner peripheral side toward the outer peripheral side. Can be considered.
As a result, the bent portions of the unit winding portions on the inner peripheral side and the outer peripheral side are in close contact with each other, and the space factor of the conducting wire increases.

  However, in order to change the arc shape of the corner portion for each unit winding portion, in the winding process using the core piece (30) shown in FIG. 8, a plurality of types in which the radius of curvature of the outer peripheral surface of the corner portion (30a) is different. It is necessary to prepare the core piece (30) of this type and replace the core piece (30) for each unit winding part, and it is extremely difficult to automate such a winding process.

  SUMMARY OF THE INVENTION An object of the present invention is to provide an air core coil capable of increasing the space factor of a conductive wire as compared with the prior art, and a winding method capable of easily manufacturing such an air core coil.

In the air-core coil according to the present invention, unit coil portions formed by winding at least one conducting wire in a spiral shape are repeatedly arranged in the winding axis direction, and each unit coil portion has a different inner peripheral length. It is formed of a plurality of unit winding portions, and at least a part of the unit winding portion having a small inner peripheral length is pushed inside the unit winding portion having a large inner peripheral length.
Here, each of the plurality of unit winding portions forming each unit coil portion has a polygonal shape having a plurality of corner portions, and all of the corner portions of each unit winding portion are each a plurality of conductor wires bent at an obtuse angle. It is comprised from a bending part and the 1 or several connection part which connects adjacent bending parts.
In the corners of the plurality of unit winding portions constituting each unit coil, the plurality of bent portions that overlap each other at the same phase position are arranged on a single straight line extending from the inside to the outside of the unit coil portion.

  In the present invention, the air-core coil is not limited to a coil that does not have a core in the center space of the coil as a final product, but also a coil in a core that has a core in the center space of the coil (coil device) as a final product. It is a concept that includes.

  Specifically, in each corner portion, a straight line formed by a plurality of unit winding portions and overlapping a plurality of bent portions at the first phase position is formed, and a plurality of unit winding portions are formed by a plurality of unit winding portions. A single straight line in which a plurality of bent portions overlapping at two phase positions are arranged intersects at one point inside the unit coil portion.

An air-core coil winding method according to the present invention is the air-core coil winding method according to the present invention described above, and coincides with the number of corners of the polygonal shape around the rotating shaft serving as the winding shaft. A plurality of core mechanisms are arranged so as to be rotationally driven around the rotation axis, and each core mechanism is equipped with a plurality of core pieces that can be driven to reciprocate in a direction crossing the winding axis.
A first step of setting a plurality of core pieces of each core mechanism at a predetermined position;
A second step of winding a lead wire around the plurality of core pieces constituting the core mechanisms by rotating the plurality of core mechanisms in a state where the plurality of core pieces are set at predetermined positions; The plurality of unit winding parts constituting one unit coil part are repeated by changing the positions of the plurality of winding core pieces in a direction perpendicular to the rotation axis in a direction away from the rotation axis or in the opposite direction. Form.

  Specifically, in the formation of the continuous first and second unit winding portions, after the formation of the first unit winding portion, the unit winding portion is connected to a plurality of core pieces by a conductive wire that becomes the second unit winding portion. The second unit winding portion is formed by winding the conductive wire serving as the second unit winding portion around the outer peripheral surface of the plurality of core pieces while extruding from the outer peripheral surface.

  More specifically, after a plurality of unit coil portions are formed by repeating the first step and the second step, the unit coil portions are compressed in the winding axis direction so that a unit winding having a large inner peripheral length is obtained. At least a part of the unit winding part having a small inner peripheral length is pushed into the inside of the part to complete an air core coil composed of a plurality of coil layers.

  The air-core coil according to the present invention corresponds to an ideal structure in which each corner has a plurality of bent portions of a plurality of unit winding portions formed in an arc shape, and the arc shape is approximated by a polygonal shape (a broken line). Therefore, the gap between the bent portions at each corner becomes smaller than before, and the space factor of the conducting wire becomes large.

FIG. 1 is a front view of an air-core coil according to the present invention. FIG. 2 is a front view showing the main structure of an automatic winding machine for manufacturing an air core coil according to the present invention and the operation of a plurality of core pieces. FIG. 3 is a perspective view showing a main part of an automatic winding machine previously developed by the present inventor. FIG. 4 is a perspective view showing a state where a plurality of core shafts are moved and rotated from the state of FIG. 3 in the automatic winding machine. FIG. 5 is a front view showing a main part of the automatic winding machine. 6 is a cross-sectional view taken along line AA in FIG. FIG. 7 is a series of front views showing a winding process using the automatic winding machine. FIG. 8 is a diagram showing gaps formed between bent portions of a plurality of unit winding portions in a conventional air-core coil. FIG. 9 is a diagram showing a close state in an ideal structure in which bent portions of a plurality of unit winding portions are formed in a plurality of arcs having different radii of curvature. FIG. 10 is a perspective view of a conventional air-core coil. FIG. 11 is a diagram illustrating an air core coil compression process.

Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings. FIG. 1 shows an air-core coil (2) according to the present invention.
The air-core coil (2) according to the present invention has basically the same winding structure as the air-core coil (200) shown in FIG. 10, and a single conductor (22) is wound as shown in FIG. A unit coil portion (23) formed by spirally winding along a plane orthogonal to the axis is formed continuously in the direction of the winding axis, thereby forming an air-core coil composed of three coil layers. ing.

  As shown in FIG. 1, in the air-core coil (2) according to the present invention, each unit coil portion (23) has a substantially rectangular shape having four corner portions (23a) (23a) (23a) (23a) as a whole. The first unit winding portion (25) is pushed into the second unit winding portion (26) by the substantially entire length thereof, and the second unit winding portion (26) has a substantially entire length of the third unit. It is pushed inside the winding part (27).

  In each corner portion (23a) of the air-core coil (2), the first unit winding portion (25) has two bending portions (25a) (25a), and the second unit winding portion (26) has two bending portions. The third unit winding portion (27) has two bent portions (27a) and (27a), and the bent angle of each bent portion is set to 45 degrees.

  In each corner portion (23a), the two bent portions (25a) and (25a) of the first unit winding portion (25) are connected to each other by a linear connecting portion (25b), and the second unit winding portion (26) is connected. The two bent portions (26a) and (26a) are connected to each other by a linear connecting portion (26b), and the two bent portions (27a) and (27a) of the third unit winding portion (27) are linear connecting portions ( They are connected to each other by 27b).

  And in each corner | angular part (23a), the corresponding positional relationship of three unit winding parts (25) (26) (27), ie, the three bending parts (25a) (26a) (27a) of the same phase position, They are arranged in a line on a straight line extending from one point P.

  As a result, in each corner portion (23a), the lead wire of the first unit winding portion (25) and the lead wire of the second unit winding portion (26) are in contact with each other over substantially the entire length, and the second unit winding portion. The lead wire (26) and the lead wire of the third unit winding portion (27) are in contact with each other over substantially the entire length.

In other words, the corner portion (23a) of the air-core coil (2) according to the present invention includes the first unit winding portion (25), the second unit winding portion (26) and the third unit winding portion (shown in FIG. This corresponds to an approximation of the arc shape of the three bent portions (25c), (26c) and (27c) of (27) by two or more polygonal shapes (polygonal lines). As a result, the air-core coil (2) according to the present invention has an intermediate configuration between the conventional air-core coil (200) shown in FIG. 8 and the ideal air-core coil shown in FIG. The gap between the bends at the corners is smaller than in the prior art.
As a result, the air-core coil (2) according to the present invention has a larger space factor than the conventional air-core coil (200) shown in FIG.

  The air-core coil (2) according to the present invention can be easily manufactured using a modification of the automatic winding machine shown in FIGS. The automatic winding machine was previously developed by the present inventors. First, the automatic winding machine shown in FIGS. 3 to 6 will be described.

  The automatic winding machine has a central base shaft (20) that rotates counterclockwise as indicated by an arrow in FIG. 3 by a rotary drive mechanism (not shown) such as a motor. ) Are provided with four core shafts (31) (32) (33) (34) that rotate integrally with the central base shaft (20).

The core shafts (31), (32), (33), and (34) are arranged so as to be rotatable integrally with the central base shaft (20), and slide blocks (41) that slide toward and away from the central base shaft (20). ) (42) (43) (44).
More specifically, the core shaft (31) (32) (33) (34) is attached to the corner of the slide block (41) (42) (43) (44) on the central base shaft (20) side. The tip protrudes from the slide blocks (41) (42) (43) (44).
The core shafts (31), (32), (33), and (34) can be prisms with the central base shaft (20) side cut out, and as will be described later, slide blocks (41), (42), (43) ( The core shafts (31), (32), (33) and (34) can be moved toward and away from each other by sliding the shaft 44 in parallel with the central base shaft (20).

  The tip of the core shaft (31) (32) (33) (34) is slightly smaller than the diameter of the conductor (70) from the tip surface (45) of the slide block (41) (42) (43) (44). It protrudes to become longer. The protruding length of the core shaft (31) (32) (33) (34) is preferably 1 to 3 mm longer than the diameter of the conducting wire (70). Specifically, the protruding length is 2 to 2 mm. It is desirable to be about 5 mm.

  One or a plurality of press rollers (51), (52), and (53) are arranged on the outer periphery of the rotation transition path of the core shafts (31), (32), (33), and (34). In this embodiment, as shown in FIG. 5, three presser rollers (51), (52) and (53) are arranged at 90 ° on the upper and lower sides and on the left side of the central shaft (20). (Not shown) is biased by a biasing means such as a spring in a direction approaching the rotation transition path of the core shafts (31), (32), (33) and (34).

  More specifically, as shown in FIG. 6, the presser rollers (51), (52), and (53) are thin cylindrical presser body portions on the slide blocks (41), (42), (43), and (44) sides. (55) and a disc-shaped presser plate (56) formed on the front side of the presser body part (55) and having a diameter larger than that of the presser body part (55). It is desirable that the width of the presser body portion (55) is substantially the same as the protruding length of the core shafts (31), (32), (33), and (34).

  The presser body portion (55) and the presser plate (56) can be integrally formed, and the presser body portion (55) and the presser plate (56) are provided with a shaft hole (57) penetrating through the center. An urging means for urging the shaft hole (57) in a direction approaching the rotation transition path is connected to the shaft hole (57).

  A conducting wire (70) that forms an air-core coil is supplied between the upper pressing roller (51) and the rotation transition path of the core shaft (32) from the upstream side in the rotation direction of the core shaft (31). The conducting wire (70) can be supplied by a conducting wire supply mechanism (not shown), and the conducting wire supply mechanism passes the plurality of guide rollers (not shown) through the plurality of guide rollers (not shown), and the presser roller whose tip is on the upper side. A configuration in which a cylindrical guide (76) that opens between the shaft 51 (51) and the rotation transition path of the core shafts (31), (32), (33), and (34) is sequentially supplied can be exemplified.

  On the lower side than the opening of the guide (76), that is, on the upstream side in the rotation direction, the lead wire (70) wound around the core shaft (31) (32) (33) (34) is connected to the core shaft (31 ) (32), (33), and a pusher member (77) pushed out to the free end side of (34). The pusher member (77) is disposed in a non-rotating casing (not shown) of the automatic winding machine, and is disposed close to the rotation transition path of the core shafts (31) (32) (33) (34). . As with the presser rollers (51), (52), and (53), the urging means or the like urges the core shafts (31), (32), (33), and (34) to approach the rotation transition path. It is desirable to keep it.

  Further, as shown in FIG. 6, a winding auxiliary member (21) into which the unit winding portions pushed out by the pusher member (77) are sequentially inserted is detachably fitted to the central base shaft (20). The winding auxiliary member (21) can be exemplified by a resin, and the cross-sectional shape can be exemplified by a substantially cross-sectional rectangular shape to which the unit winding portion to be formed fits with a margin.

  The automatic winding machine configured as described above has a reciprocating mechanism constituted by a cam mechanism or the like, and rotates rotating slide blocks (41), (42), (43), and (44) as core axes (31), (32) ( 33) It can slide in the approach and separation directions within a plane perpendicular to the axis of (34).

Hereinafter, the winding process of the air-core coil using the automatic winding machine will be described.
First, as shown in FIG. 7 (a), a lead wire supply mechanism (not shown) is manually set by the user in a state where the core shafts (31), (32), (33), and (34) are positioned at the vertices of a rectangle in advance. The lead wire (70) is pulled out from the lead wire, and the tip of the lead wire (70) is bent into a U shape and hooked on the outer periphery of the core shaft (31) (32) (33) (34).

  At this time, as shown in FIG. 6, the conducting wire (70) is connected to the leading end surfaces of the core shafts (31), (32), (33), (34) and the slide blocks (41), (42), (43), (44). 45) and the presser body (55) and presser plate (56) of the presser rollers (51), (52) and (53) are surrounded by the presser rollers (51), (52) and (53) and will not fall off.

From this state, the rotary drive mechanism is operated and the reciprocating mechanism is operated to start winding of the conducting wire (70).
In this process, a certain amount of tension is applied to the lead wire (70).

  When the core shaft (31) (32) (33) (34) is rotated from the state shown in FIG. 7 (a) as shown in FIG. 7 (b), the core shaft (31) (32) (33) A conducting wire (70) is wound around (34). When the core shaft (31) (32) (33) (34) is further rotated, the conductor (70) is being pressed by the presser body (55) of the presser rollers (51) (52) (53) By bending, a rectangular unit winding portion having the shape of the core shaft (31) (32) (33) (34) is formed.

  When the winding core shaft (31) (32) (33) (34) is rotated by about 270 ° from the beginning of winding of the conducting wire (70), the conducting wire (70) is pushed into the pusher member (77) as shown in FIG. At this time, it is pushed out to the free end side of the core shafts (31) (32) (33) (34) and inserted into the winding auxiliary member (21) (see FIG. 6).

By rotating the core shafts (31), (32), (33) and (34) a predetermined number of times, for example, twice, the conducting wire (70) becomes a substantially rectangular two-turn unit winding part.
Next, by operating the reciprocating mechanism while operating the rotation drive mechanism, as shown in FIG. 7C, the core shaft (31) that matches the vertex of one of the long sides of the rectangle is set as the central base axis. The core shafts (31), (32), (33) and (34) are rotated while being moved away from (20).
Note that the core shafts (31), (32), (33), and (34) are moved at positions facing the guide (76) that supplies the lead wire (70). The reason is that if the core shaft around which the conducting wire (70) is wound is moved, the conducting wire (70) may be pulled and cut.

  After the above, by rotating the rotation drive mechanism, the lead wire (70) is also moved by the pusher member (77) for the core shaft (34) on the other long side as shown in FIG. 7 (d). Extruded and moved away from the central base axis (20). Similarly, the core shafts (32) and (33) at the vertices of the long sides of the other side of the rectangle, as shown in FIG. 7 (e), the core shafts (31), (32), (33), and (34). , While being rotated, is moved in a direction away from the central base shaft (20), although the distance is shorter than the core shaft (31) (34). The position of the core shaft (31) (32) (33) (34) at this time is referred to as an intermediate position.

  By rotating the winding core shafts (31), (32), (33), and (34) in this state, a unit winding portion having an inner circumferential length and an outer circumferential length slightly longer than the rectangle is formed.

  Further, while rotating the core shaft (31) (32) (33) (34), the core shaft (31) (32) (33) (34) is further away from the central base shaft (20) from the intermediate position. The core shaft (31) (32) (33) (34) is moved to the position that is the apex of the substantially trapezoidal shape while moving the core shaft (31) (32) (33) (34). As shown in FIG. 7F, for example, the lead wire (70) forms a substantially trapezoidal unit winding portion having an outer peripheral length and an inner peripheral length longer than the intermediate position. By rotating the core shafts (31), (32), (33), and (34) a predetermined number of times, for example, twice, the lead wire (70) becomes a substantially trapezoidal two-turn unit winding part.

  Next, the core shafts (31), (32), (33), and (34) are rotated while sequentially returning to the intermediate position, and the core shafts (31), (32), (33), (34) are further rotated as described above. ) Return the core shaft (31) (32) (33) (34) to a position where it becomes a substantially rectangular apex, and repeat the operation of rotating a predetermined number of times, so that the unit winding portion as shown in FIGS. The unit coil part having a continuous line is wound around the winding auxiliary member (21) to form an air-core coil.

Once an air core coil of a predetermined length is formed, the automatic winding machine is stopped once, and the lead wire (70) is cut on the winding auxiliary member (21) to obtain an air core coil as an intermediate product. it can. By operating the automatic winding machine again, the production of the air-core coil as an intermediate product is continued.
If an air core coil as an intermediate product is compressed in the winding axis direction, an air core coil as a finished product having a multilayer structure can be obtained.

  As shown in FIG. 8, the air-core coil manufactured using the above-described automatic winding machine is bent at the first unit winding part (25), the second unit winding part (26) and the third unit winding part (27). A gap G is generated between the parts.

Therefore, in the present invention, the core device (1) shown in FIG. 2 is adopted instead of the core device having the core shafts (31), (32), (33), and (34) shown in FIG.
The core device (1) is rotationally driven in a counterclockwise direction as indicated by an arrow in the figure by a motor (not shown), and has four core mechanisms (11), (12) at four corners. ) (13) (14) are deployed.

  These four core mechanisms (11), (12), (13), and (14) are similar to the four core shafts (31), (32), (33), and (34) shown in FIG. Reciprocation is possible in a direction away from the center and in a direction approaching the central base axis (20).

  As shown in FIGS. 2 (a) and 2 (b), the first core mechanism (11) is a first core piece that is reciprocated along a straight line A1 extending outward from one point S1 on the center base shaft (20) side. (61) and a second core piece (62) reciprocally driven along a straight line A2 extending outward from the one point S1, the first core piece (61) and the second core piece (62) are conventionally provided. The function corresponding to the first core axis (31) is exhibited.

  The second core mechanism (12) includes a first core piece (63) reciprocatingly driven along a straight line A3 extending outward from one point S2 on the central base shaft (20) side, and outward from the one point S2. A second core piece (64) reciprocally driven along the extending straight line A4, and the first core piece (63) and the second core piece (64) correspond to the conventional second core shaft (32). Demonstrate the function to do.

  The third core mechanism (13) includes a first core piece (65) reciprocally driven along a straight line A5 extending outward from one point S3 on the central base shaft (20) side, and outward from the one point S3. A second core piece (66) reciprocally driven along the extending straight line A6, and the first core piece (65) and the second core piece (66) correspond to the conventional third core shaft (33). Demonstrate the function to do.

  The fourth core mechanism (14) includes a first core piece (67) reciprocally driven along a straight line A7 extending outward from one point S4 on the central base shaft (20) side, and outward from the one point S3. A second core piece (68) reciprocally driven along the extending straight line A8, and the first core piece (67) and the second core piece (68) correspond to the conventional fourth core axis (34). Demonstrate the function to do.

  The eight core pieces (61) to (68) can be reciprocated by, for example, providing each core mechanism with a reciprocating drive mechanism such as a solenoid for each core piece.

  Each of the eight core pieces (61) to (68) has a chevron with a top angle of 135 degrees on the surface around which the conductive wire (22) is wound. Accordingly, when the conducting wire (22) is wound around two pairs of winding core pieces, two bends of the first unit winding portion (25) to form each corner of the air core coil (2) shown in FIG. Parts (25a) (25a), two bent parts (26a) (26a) of the second unit winding part (26), and two bent parts (27a) (27a) of the third unit winding part (27), Will be formed.

  As a result, the loop shape defined by the surfaces of the eight core pieces (61) to (68) is the loop of each unit winding part (25) (26) (27) of the air core coil (2) shown in FIG. It corresponds to the shape.

  The other configuration of the automatic winding machine of the air-core coil (2) according to the present invention is the same as that of the automatic winding machine shown in FIGS.

In the winding process of the air core coil by the automatic winding machine having the winding core device (1) shown in FIG. 2, the first unit winding part (25) is wound in the winding process of each unit coil part (23). When turning, as shown in FIG. 2A, all the core pieces (61) to (68) are fixed to the innermost peripheral position, and the core device (1) is rotated to rotate these core pieces (61). Wrap the lead wire (22) around)-(68).
The eight bent portions (26a) to (26a) of the second unit winding portion (26) are sequentially formed by sequentially winding the lead wire (22) around each surface of the eight core pieces (61) to (68). The bending angle of each bent portion is defined as 45 degrees.

Next, when winding the second unit winding part (26), move all the core pieces (61) to (68) to the outer circumference side by the wire diameter of the conducting wire (22) as shown in FIG. 2 (b). Then, by rotating the core device (1) in this state, the lead wire (22) is wound around the core pieces (61) to (68).
The eight bent portions (26a) to (26a) of the second unit winding portion (26) are sequentially formed by sequentially winding the lead wire (22) around each surface of the eight core pieces (61) to (68). The bending angle of each bent portion is defined as 45 degrees.

Thereafter, when winding the third unit winding portion (27), all the core pieces (61) to (68) are further moved to the outer peripheral side by the wire diameter of the conducting wire (22), and the core is in that state. The conductor (22) is wound around the core pieces (61) to (68) by rotating the device (1).
The eight bent portions (27a) to (27a) of the third unit winding portion (27) are sequentially formed by sequentially winding the lead wire (22) around each surface of the eight core pieces (61) to (68). The bending angle of each bent portion is defined as 45 degrees.

  In the winding process of the next unit coil portion (23), all the core pieces (61) to (68) are gradually moved to the inner peripheral side by the wire diameter of the conducting wire (22), while the core device (1 ) Is rotated to wind the lead wire (22) around the core pieces (61) to (68).

  In the formation of the two continuous unit winding portions, after the formation of the first unit winding portion, the conducting wire (22) of the unit winding portion is replaced by the conducting wire (22) serving as the second unit winding portion. While extruding from the outer peripheral surfaces of the eight core pieces (61) to (68), the conductor (22) serving as the second unit winding portion is wound around the outer peripheral surfaces of the eight core pieces (61) to (68), A second unit winding is formed.

  By repeating the above operation, an intermediate product of the air-core coil shown in FIG. 1 is obtained. Then, by compressing the intermediate product in the direction of the winding axis as shown in FIGS. 11 (a) and 11 (b), the second unit winding portion (26) is pushed inside the third unit winding portion (27), and the second The first unit winding part (25) is pushed into the inside of the two unit winding part (26) to obtain a finished product of the air-core coil (2) shown in FIG.

As shown in FIG. 1, the air-core coil (2) obtained in this way has a conductor of the first unit winding (25) and a conductor of the second unit winding (26) at each corner (23a). However, the conductors of the second unit winding part (26) and the conductors of the third unit winding part (27) are in contact with each other over substantially the entire length.
Accordingly, the air-core coil (2) has a larger space factor than the conventional air-core coil (200) shown in FIG.

In addition, each part structure of this invention is not restricted to the said embodiment, A various deformation | transformation is possible within the technical scope as described in a claim. For example, the number of bent portions of each unit winding portion at each corner of the air-core coil (2) is not limited to two, and may be three or more.
The conducting wire (22) is not limited to a round wire with a circular cross section, but may be a square wire with a rectangular cross section.

(1) Winding device
(11) Core mechanism
(12) Core mechanism
(13) Winding mechanism
(14) Winding mechanism
(61) Volume 1 core
(62) Second core piece
(63) Volume 1 core
(64) Volume 2 core piece
(65) Volume 1 core
(66) Volume 2 core piece
(67) Volume 1 core
(68) Volume 2 core piece
(2) Air core coil
(23) Unit coil section
(25) 1st unit winding part
(26) Second unit winding
(27) Third unit winding
(23a) Corner
(25a) Bend
(26a) Bend
(27a) Bend
(25b) Liaison Department
(26b) Liaison Department
(27b) Liaison Department

Claims (8)

Unit coil portions formed by spirally winding at least one conducting wire are repeatedly arranged in the winding axis direction, and each unit coil portion is formed from a plurality of unit winding portions having different inner circumferential lengths. In the air-core coil in which at least a part of the unit winding portion with a small inner peripheral length is pushed inside the unit winding portion with a large inner peripheral length,
Each of the plurality of unit winding portions forming each unit coil portion has a polygonal shape having a plurality of corner portions, and all the corner portions of each unit winding portion are each a plurality of bent portions obtained by bending the conducting wire to an obtuse angle. , Composed of one or a plurality of connecting portions connecting adjacent bent portions,
In the corners of the plurality of unit windings constituting each unit coil, the plurality of bent portions that overlap each other at the same phase position are aligned on a single straight line extending from the inside to the outside of the unit coil portion. Features an air-core coil.   At each corner, a straight line formed by a plurality of unit winding portions and overlapping a plurality of bent portions overlapping at the first phase position, and a plurality of unit winding portions formed at the second phase position at the second phase position. 2. The air-core coil according to claim 1, wherein the air-core coil intersects with one straight line in which a plurality of overlapping bent portions are arranged at one point inside the unit coil portion.   3. The air-core coil according to claim 2, wherein at each corner, each of the plurality of unit winding portions extends along a path approximating an arc centered on the one point by two or more polygonal shapes.   The air-core coil according to any one of claims 1 to 3, wherein the connecting portion is formed in a linear shape or an arc shape. Unit coil portions formed by spirally winding at least one conducting wire are repeatedly arranged in the winding axis direction, and each unit coil portion is formed from a plurality of unit winding portions having different inner circumferential lengths. At least a part of the unit winding portion having a small inner peripheral length is pushed inside the unit winding portion having a large inner peripheral length, and each of the plurality of unit winding portions forming each unit coil portion has a plurality of corner portions. In the winding method of the air-core coil presenting a polygonal shape,
A plurality of core mechanisms corresponding to the number of corners of the polygonal shape are arranged around the rotating shaft serving as the winding shaft so as to be rotatable around the rotating shaft. Equipped with multiple core pieces that can be driven back and forth in the direction crossing the shaft,
A first step of setting a plurality of core pieces of each core mechanism at a predetermined position;
A second step of winding a lead wire around the plurality of core pieces constituting the core mechanisms by rotating the plurality of core mechanisms in a state where the plurality of core pieces are set at predetermined positions; One unit coil by repeating the first step and the second step while changing the position of the plurality of core pieces in a direction perpendicular to the rotation axis in a direction away from the rotation axis or in the opposite direction. A method for winding an air-core coil, comprising forming a plurality of unit winding portions constituting the portion.   In the formation of the continuous first and second unit winding portions, after the formation of the first unit winding portion, the unit winding portion is separated from the outer peripheral surface of the plurality of core pieces by a conducting wire serving as the second unit winding portion. The winding method of the air core coil of Claim 5 which forms the 2nd unit winding part by winding the conducting wire used as a 2nd unit winding part around the outer peripheral surface of a some core piece, extruding.   After forming the plurality of unit coil portions by repeating the first step and the second step, by compressing these unit coil portions in the winding axis direction, the inner circumference is placed inside the unit winding portion having a large inner circumference length. The winding method of the air-core coil according to claim 5 or 6, wherein at least a part of the small unit winding portion is pushed in to complete an air-core coil composed of a plurality of coil layers.   The winding method of the air-core coil in any one of Claim 5 thru | or 7 with which the surface where the conducting wire of each winding core piece should be wound is formed in the mountain shape which has an obtuse apex angle.

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