JPH065453A - Manufacture of coil device using a plurality of windings - Google Patents

Abstract

PURPOSE:To simplify manufacturing steps and to facilitate manufacture of a coil device having a plurality of windings by winding first and second windings on a bobbin, then cutting the windings to obtain leads from the windings. CONSTITUTION:A bobbin 4 having a flange 4a is placed on a moving unit 10, and a first winding 1 is wound on the bobbin 4 by a first winding machine 7. Then, while the winding 1 remains connected to the machine 7, the unit 10 is driven to move the bobbin 4 to other position, and a second winding 2 is wound on the bobbin 4 by a second winding machine 8 disposed correspondingly to the other position. Thereafter, the windings 1, 2 wound on the bobbin 4 are fixed with adhesive 11 to each other, the windings 1, 2 are cut, and leads 1a, 2a are obtained from the windings 1, 2. Then, the leads 1a, 2a are inserted into a plurality of grooves 4d formed at the flange 4a of the bobbin 4.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a coil device such as a transformer and a reactor, and more particularly to a method for manufacturing a coil device having a plurality of windings.

[0002]

2. Description of the Related Art A coil device having a coil device bobbin having a cavity for inserting a core and a pair of flanges, and a plurality of windings having an insulating coating wound between a pair of flanges of the bobbin is known. Is. For example, the actual Kaihei 3-25
Japanese Patent No. 219 discloses a transformer in which a primary winding and a secondary winding are wound in layers. This transformer consists of a primary winding or 2
The secondary winding is formed and wound around the core. The primary winding and the secondary winding of this transformer are wound around the entire pair of flanges of the bobbin in the order of the primary winding, the secondary winding, and the auxiliary primary winding, and attached to the core. . The lead wire of each winding of the transformer is wound around the bobbin terminal through a groove formed in the flange of the bobbin, and is fixed by soldering or the like.

[0003]

By the way, in the conventional method for manufacturing the coil device, each winding is cut every time it is wound on the bobbin, and the lead wire is taken out from each winding, so that the number of manufacturing steps increases. There was a drawback that the work was complicated. For this reason, it is not suitable for mass production, which causes an increase in the manufacturing cost of the coil device.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a method of manufacturing a coil device having a plurality of windings which can be manufactured easily by simplifying the manufacturing process.

[0005]

A method of manufacturing a coil device having a plurality of windings according to the present invention comprises a step of mounting a bobbin having a flange on a moving device, and a step of mounting a bobbin on the bobbin by a first winding machine. A first winding step for winding the first winding, and moving the bobbin to another position by driving the moving device with the first winding attached to the first winding machine. Moving step, a second winding step of winding the second winding on the bobbin by a second winding machine arranged corresponding to the other position, and cutting the plurality of windings. And a cutting step of obtaining a lead wire from the plurality of windings, and a step of inserting the lead wire into a groove formed in the flange of the bobbin. In an embodiment of the present invention, after the second winding step, the moving device is driven to move the bobbin to another position while keeping the second winding attached to the second winding machine. The second moving step of moving the bobbin to the bobbin, and the third and subsequent winding steps of winding the third and subsequent windings on the bobbin, and the plurality of windings wound on the bobbin before the cutting step. The step of fixing the windings to each other is included. In another embodiment of the present invention, a step of mounting a bobbin having a flange on a moving device, and a winding for winding each of the plurality of windings on the bobbin with a predetermined number of turns in a multi-winding machine. A step of cutting each of the plurality of windings to obtain a leader wire from the plurality of windings; and inserting the leader wire into a groove formed in the flange of the bobbin, Before the cutting step, a step of fixing a plurality of windings wound around the bobbin to each other is included.

[0006]

After the bobbin is wound with the first winding machine by the first winding machine, the moving device is driven while the first winding machine is attached to the first winding machine to move the bobbin to another position. Move to position. Next, the bobbin is wound with the second winding by the second winding machine arranged corresponding to another position. In this way, the bobbin first
And winding the second winding, and then cutting the first and second windings to obtain a lead wire from the first and second windings, the manufacturing process is simplified, and a plurality of windings are formed. The coil device having the wire can be easily manufactured.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a method for manufacturing a coil device having a plurality of windings according to the present invention will be described below with reference to FIGS. First, as shown in FIG. 1, the cavity 4c of the bobbin 4 is inserted into the protrusion 6a having a rectangular cross section of the pallet jig 6 and the pallet jig 6 is placed on the chain 10a of the chain conveyor 10 as a moving device. To do. The chain 10a of the chain conveyor 10 can move in the longitudinal direction. Bobbin 4
Is provided with a pair of flanges 4a and 4b, and one flange 4a is provided with a plurality of grooves 4d and a bobbin terminal 5. Further, although not shown in the drawing, in this embodiment, a plurality of pallet jigs 6 having bobbins 4 inserted therein are prepared and placed at a predetermined interval in the longitudinal direction of the chain 10a of the chain conveyor 10. 2 to 6, for convenience of explanation,
These plurality of bobbins are replaced by the first to third bobbins 4A, 4
B and 4C.

Next, the first bobbin 4A is connected to the first winding machine 7
After being placed in a position corresponding to
The winding machine 7 is rotated in the direction of arrow A and moved in the direction of arrow B to wind the first winding 1 between the pair of flanges of the first bobbin 4A. As shown in FIGS. 1 and 2, the first winding machine 7 includes a pair of arm portions 7a and 7b and a tubular shape that is provided through a central hole (not shown) of the pair of arm portions 7a and 7b. It is provided with a shaft portion 7c and a hook metal fitting 7d provided at the tip of one arm portion 7a. As the conductive wire material 13 used as the first winding, a coated conductive wire, which is disclosed in Japanese Utility Model Laid-Open No. 3-25219, and in which a linear conductor is triple-insulated, is used. The insulating coating of the coated conductor may have a single layer structure or a multilayer structure other than triple layer structure. In addition, the conductor 13 is penetrated from the tubular shaft portion 7c of the first winding machine 7,
It is arranged between the pair of flanges of the first bobbin 4A via the hooking metal 7d.

After winding the first winding 1 around the first bobbin 4A, as shown in FIGS. 1 and 3, the first bobbin 4A is placed at a position where the first bobbin 4A can move in the direction of arrow D. The pair of arm portions 7a and 7b of the winding machine 7 are rotated. Subsequently, as shown in FIG. 3, the chain conveyor 10 is driven while the first winding 1 is attached to the hooking metal fitting 7d of the first winding machine 7 to move the first bobbin 4A to the second winding. It is moved to the position corresponding to the machine 8. At this time, the first winding machine 7 is moved in the direction of arrow C in synchronization with the movement of the first bobbin 4A in the direction of arrow D, and the second bobbin 4B (FIG. 4) is moved in the first winding direction. It is moved to the position corresponding to the line machine 7.

Thereafter, as shown in FIG. 4, the first and second
While rotating the winding machines 7 and 8 in the direction of arrow A while moving them in the direction of arrow B, the first and second windings 1 and 2 are mounted on the second and first bobbins 4B and 4A, respectively. To do. 1 and 4
As shown in FIG. 2, the second winding machine 8 includes a pair of arm portions 8a,
8b, a tubular shaft portion 8c, and a hook metal fitting 8d.
Further, as the conductive wire material 14 used as the second winding wire 2, the same material as the conductive wire material 13 described above is used.

After winding the first and second windings 1 and 2 on the second and first bobbins 4B and 4A, respectively, as shown in FIGS. 1 and 5, the first and second bobbins 4A and 4A are 4B, a pair of arm portions 7a, 7b of the first winding machine 7 and a pair of arm portions 8a of the second winding machine 8 at a position where the movement is possible in the direction of arrow D.
Rotate each 8b. Then, as shown in FIG.
And the second winding 1 and 2 are engaged with the hooking metal fittings 7d and 8d of the first and second winding machines 7 and 8, respectively, and the chain conveyor 10 is driven to drive the second and first bobbins 4B, 4A is moved to the positions corresponding to the second and third winding machines 8 and 9, respectively. At this time, in synchronization with the movement of the second and first bobbins 4B and 4A in the direction of arrow D, the first and second winding machines 7 and 8 are moved in the directions of arrow C, respectively, and the third The bobbin 4C (FIG. 6) is moved to a position corresponding to the first winding machine 7.

Thereafter, as shown in FIG. 6, the first, second and third winding machines 7, 8 and 9 are rotated in the direction of arrow A and moved in the direction of arrow B to move the third and third winding machines. The first, second and third windings 1, 2, 3 are wound around the second and first bobbins 4C, 4B, 4A, respectively. The third winding machine 9 includes a pair of arm portions 9a and 9b, a tubular shaft portion 9c, and a hook metal fitting 9d. Further, as the conductive wire material 15 used as the third winding wire 3, the same material as the above-described conductive wire materials 13 and 14 is used. As described above, by repeating the moving process and the winding process alternately, the first to third windings 1 to 3 are sequentially wound around the first to third bobbins 4A, 4B, and 4C.

As described above, the bobbin 4 has the first to third parts.
After winding the windings 1 to 3 of the bobbin 4, the adhesive 11 is applied to the first to third windings 1 to 3 of the bobbin 4 as shown in FIG. 1 to 3 are fixed to each other. Adhesive 11
Is made of a thermoplastic synthetic resin such as polyamide or polyester, and is constantly heated by the heating tank 12 shown in FIG. After the adhesive 11 is cured,
The first to third windings 1 to 3 are cut to obtain lead wires 1a, 2a and 3a of the respective windings.

Next, as shown in FIG. 8, each lead wire 1a,
2a and 3a are inserted into the plurality of grooves 4d of the flange 4a of the bobbin 4 and connected to the terminals 5 of the bobbin. Each lead wire 1a, 2a,
3a is connected to the terminal 5 of the bobbin by connecting each lead wire 1a, 2
a, 3a directly spot weld to the bobbin terminal 5 without peeling off the insulating coating, or each lead wire 1a, 2a, 3a
It is carried out by peeling off the insulating coating at the end of and winding around the terminal 5 of the bobbin.

As described above, in this embodiment, the bobbin 4 is wound with the first to third windings 1 to 3 and then the first to third windings are cut to cut the first to third windings. Each lead wire 1 from windings 1 to 3
Since a, 2a, and 3a are obtained, the manufacturing process is simplified and the coil device having a plurality of windings can be easily manufactured. In addition, the first to the plurality of bobbins 4A, 4B, 4C.
Since the third windings 1 to 3 are continuously wound, the coil device can be mass-produced and the manufacturing cost can be reduced.

The embodiment of the present invention is not limited to the above embodiment, and can be modified. For example, although the bobbin 4 has the example in which the first to third windings 1 to 3 are wound on the bobbin 4 in the above embodiment, the step of winding the fourth and subsequent windings may be further included. In the above embodiment, the adhesive 11 is applied on the first to third windings 1 to 3 of the bobbin 4 to form the first to third windings 1.
Although the example in which 3 to 3 are fixed to each other has been shown, a plurality of windings may be fixed by a resinous adhesive tape or the like instead of the adhesive. Also, instead of connecting the lead wires 1a, 2a, 3a by providing the bobbin terminal 5 on the flange 4a of the bobbin 4, the lead wire 1
The peeled portion of the insulating coating at the ends of a, 2a, and 3a may be used as it is as the terminal of the bobbin. Further, as shown in FIG. 9, a multi-wire winding machine having a plurality of arm portions 16 to 18 each having a different size and independently rotatable with the center of each arm portion 16 to 18 as the same rotation axis. After winding each of the plurality of windings 1 to 3 on the bobbin 4 with a predetermined number of turns using 19, the plurality of windings 1 to 3 may be cut.

[0017]

According to the present invention, the manufacturing process can be simplified, the coil device having a plurality of windings can be easily manufactured, and the coil device can be mass-produced efficiently.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a method for manufacturing a coil device having a plurality of windings according to the present invention.

FIG. 2 is a plan view showing a state in which the first winding is wound around the first bobbin by the first winding machine.

FIG. 3 is a plan view showing a state in which the bobbin of FIG. 2 is moved to a position corresponding to a second winding machine while the first winding is attached to the first winding machine.

FIG. 4 is a plan view showing a state in which the first and second winding machines wind the first and second windings around the second bobbin and the bobbin of FIG. 3, respectively.

FIG. 5 is a plan view showing a state in which the bobbin of FIG. 4 is moved to a position corresponding to each of the second and third winding machines.

FIG. 6 is a plan view showing a state in which the first to third winding machines wind the first to third windings on the third, second and first bobbins, respectively.

FIG. 7 is a plan view showing a state in which a plurality of windings wound around a bobbin are fixed with an adhesive and then the plurality of windings are cut.

8 is a plan view showing a state in which the lead wire of the winding wire of FIG. 7 is inserted into a groove of a flange of a bobbin.

FIG. 9 is a plan view showing another embodiment of the present invention.

[Explanation of symbols]

1. ． First winding, 2. ． Second winding, 3. ． Third winding, 4. ． Bobbins, 4a, 4b. ． A pair of flanges, 4
c. ． Cavity, 4d. ． Multiple grooves, 5. ． Bobbin terminal,
6. ． Pallet jig, 6a. ． Protrusion, 7. ． First winding machine, 8. ． Second winding machine, 9. ． Third winding machine, 1
0. ． Chain conveyor (moving device), 10a. ． Chain, 11. ． Adhesive, 12. ． Heating tank, 13-1
5. ． Conductor wire, 19. ． Double track winding machine

Claims (5)

[Claims] 1. A step of placing a bobbin having a flange on a moving device, and a first winding machine winding the first winding on the bobbin.
Winding step of moving the bobbin to another position by driving the moving device with the first winding attached to the first winding machine. A second winding step of winding the second winding around the bobbin with a correspondingly arranged second winding machine; and cutting the plurality of windings to form a lead wire from the plurality of windings. And a step of inserting the lead wire into a groove formed in the flange of the bobbin, the method for manufacturing a coil device having a plurality of windings. 2. After the second winding step, the moving device is driven to move the bobbin to another position while the second winding is attached to the second winding machine. A method of manufacturing a coil device having a plurality of windings according to claim 1, which includes a second moving step and a third winding step for winding a third winding on the bobbin. . 3. The plurality of windings according to claim 1 or 2, including a step of fixing a plurality of windings wound around the bobbin to each other before the cutting step. A method for manufacturing a coil device having the same. 4. A step of placing a bobbin having a flange on a moving device, a step of winding a plurality of windings on the bobbin with a multi-winding machine at a predetermined number of turns, respectively. A cutting step of cutting each of the winding wires to obtain a leader wire from the plurality of winding wires; and a step of inserting the leader wire into a groove formed in a flange of the bobbin. A method for manufacturing a coil device having a winding. 5. The method for manufacturing a coil device having a plurality of windings according to claim 4, including a step of fixing a plurality of windings wound around the bobbin to each other before the cutting step. .