JPH07201601A - Coil, method and machine for manufacturing coil - Google Patents

Abstract

PURPOSE:To prevent the strands from being lapped over by winding the strand spirally and to prevent the strand from tilting in the advancing direction of winding in the way of winding operation by previously tilting the strand in the opposite direction. CONSTITUTION:A strand 22 is extended to a coil former 25 and when the coil former 25 is rotated, the strand 22 is fed out from a wire drum 29 and wound around the former 25. Guide rollers 41g-41c are arranged movably a long the axial direction of the former 25 so that the strand 22 is guided to be wound regularly. In this regard, the guide rollers 41a-41c are arranged rotatably around the Za-axis so that the strand 22 is fed while inclining to the former 25. The guide rollers 41a-41c are also rotatable around the Ya-axis so that the strand 22 is tilted oppositely to the advancing direction of winding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil in which element wires having a rectangular cross section are wound in alignment along an axial direction, a coil manufacturing method, and a coil manufacturing apparatus.

[0002]

2. Description of the Related Art Conventionally, as shown in FIG. 12, a coil 1 used in a transformer or the like has a wire 2 having a rectangular cross section.
There is one wound in a line along the axial direction. In the case of this configuration, the winding angle θ of the wire 2 with respect to the axis α of the coil 1
1 is set to 90 degrees for both the first layer and the second layer (see FIG. 15). Also, the angle θ2 formed by the wire 2 and the axis α is set to 90 degrees for both the first and second layers,
As a result, the strand 2 is in the vertical state. 3a
And 3b are interlayer papers, and 3c to 3f are end tapes.

Next, a conventional structure of a coil manufacturing apparatus for manufacturing the coil 1 will be described with reference to FIGS. 13 and 14. First, in FIG. 13, a winding die 5 is rotatably provided on the base plate 4. The winding shaft 5a of the winding form 5 is connected to the winding form motor 6, and when the winding form motor 6 is driven, the winding form 5 is rotated.

A base plate 7 is provided on the left side of the base plate 4. The base plate 7 has rails 7 parallel to the winding shaft 5a.
a, 7a are provided, and a drum mounting portion 8 is provided on these rails 7a, 7a, as shown in FIG.
A wire drum 9 is attached to the drum mounting portion 8, and when the drum motor 9a is driven, the wire drum 9 moves along with the drum mounting portion 8 along the rails 7a, 7a.

The base plate 4 is provided with a support base 4a.
As shown in FIG. 13, rails 4b and 4b are provided on the support base 4a in parallel with the winding shaft 5a, and a base 10 is provided on the rails 4b and 4b. Also,
The base 10 is provided with a roller mounting portion 10a, and the roller mounting portion 10a is provided with three guide rollers 11. Then, when the X-axis motor 10b is driven,
Along with the base 10, three guide rollers 11 are provided on the rail 4
Move along b and 4b. The drum motor 9a and the X-axis motor 10b are connected to a control means (not shown) mainly composed of a microcomputer, and are drive-controlled by the control means.

Next, a method of manufacturing the coil 1 will be described. First, in FIG. 12, the interlayer paper 3 is formed on the outer peripheral surface of the winding form 5.
A is wound, and the end tape 3c is wound around the end portion in the opposite X direction. Next, as shown in FIG. 13, the tip of the wire 2 wound around the wire drum 9 is fixed to the winding form 5, and as shown in FIG. To be in contact with. Then, in FIG. 13, the winding form 5 is rotated,
By pulling out the wire 2 from the wire drum 9, the wire 2 is wound around the winding form 5.

In this case, the control means controls the drum motor 9a and the X-axis motor 10b each time the winding form 5 makes one revolution.
Is driven to intermittently move the wire drum 9 and the three guide rollers 11 in the mark X direction by the short side dimension S of the wire 2. As a result, the first layer wire 2 is aligned and closely wound around the winding form 5 at a winding angle θ1 (= 90 degrees).

After that, after winding the wire 2 for one layer, in FIG. 12, an end tape 3d is wound around the end of the winding die 5 in the X direction to form an interlayer on the wire 2 of the first layer. The paper 3b is wound, and the end tape 3e is wound on the interlayer paper 3b. Then, in FIG. 13, the winding drum 5 is rotated while intermittently moving the wire drum 9 and the three guide rollers 11 in the opposite arrow X direction to rotate the winding drum 5 in the same manner as the first-layer strand 2. And the second layer of wire 2 is wound vertically at a winding angle θ1 (= 90 degrees). Finally, as shown in FIG. 12, the end tape 3f is wound around the end of the second layer wire 2 in the opposite X direction.

[0009]

However, in the above-mentioned conventional structure, since the winding angle θ1 of the wire 2 is 90 degrees, the winding method of intermittently moving the guide roller 11 must be adopted. There wasn't. As a result, for example, when winding the strands 2 in the direction of the arrow X, as shown in FIG. 16, rows of the strands 2 from the first row a to the second row b, the second row b to the third row c, and the like. It is difficult to change the wire, and there is a fear that the wire 2 to be wound in the third row c may ride on the wire 2 in the second row b.

Moreover, since the wire 2 is in the vertical state, when winding the wire 2 in the direction of arrow X, for example,
May fall in the winding direction (arrow X direction), and this tendency is due to the ratio L / S between the long side L and the short side S of the wire 2.
Becomes noticeable as the size increases. Therefore, in the above-described conventional configuration, it is necessary to monitor the worker during operation, and moreover,
The workability was poor because the condition of winding up the wire 2 and correcting the collapse of the wire 2 continued.

Incidentally, in FIG. 13, the drum mounting portion 8 is provided with a tension detecting means 12. As shown in FIG. 14, the tension detecting means 12 is composed of three tension rollers 12a to 12c and a load converter 12d, and the control means controls the load acting on the central tension roller 12b. The tension of the wire 2 is detected by detecting the load converter 12d. Further, the wire drum 9 is provided with a drum brake 9b, and the control means adjusts the rotation resistance of the wire drum 9 by the drum brake 9b so that the detected value of the load converter 12d becomes equal to the set tension. A constant tension is applied to the wire 2.

However, in this case, since the strand 2 is pressed by the tension rollers 12a and 12c and a load is applied to the central tension roller 12b, the strand 2 is bent especially when the strand 2 is thick. There is a risk that the insulation paper around the outer circumference of the strand 2 may be displaced. As a result, the quality of the insulating paper becomes unreliable,
After winding the wire 2 around the winding form 5, the operator must always perform a visual check, and the workability was poor.

The present invention has been made in view of the above circumstances, and a first object of the present invention is to provide a coil, a coil manufacturing method, and a coil manufacturing apparatus capable of preventing the strand from rising and falling. A second object of the invention is to provide a coil manufacturing apparatus capable of preventing the bending of the wires and the displacement of the insulating paper.

[0014]

[Means for Solving the Problems] According to claim 1,
In a coil in which strands having a rectangular cross section are wound in an array along the axial direction, the strands are spirally wound, and moreover, the strands are inclined at a constant angle to the side opposite to the winding direction. It has a feature in that it exists.

According to a second aspect of the present invention, in the method for producing the coil according to the first aspect, when winding the wire in the winding form while moving the wire along the axial direction of the winding form,
It is characterized in that the wire is supplied in an inclined state with respect to the winding form while being held in a state in which the wire is tilted to the side opposite to the winding direction.

According to a third aspect of the present invention, in the apparatus for producing the coil according to the first aspect, a winding die, which is rotatably provided and around which the wire is wound with the rotation, and a winding die of the winding die. A guide roller that is provided so as to be movable along the axial direction and that guides the wire to a predetermined position of the winding form with the movement,
First rotating means for rotating the guide roller so that the wire is supplied in an inclined state with respect to the winding form, and the wire is inclined to the side opposite to the winding advancing direction. It is characterized in that it is provided with a second rotating means for rotating the guide roller.

According to a fourth aspect of the present invention, in the coil manufacturing apparatus according to the third aspect, a drum brake that adjusts a rotational resistance of a wire drum for supplying an element wire to the winding form and a torque of the winding form are detected. And a drum brake control means for controlling the drum brake based on the detection value of the torque sensor.

[0018]

According to the means described in claims 1 to 3, since the wire is spirally wound, it is easy to change the row of the wire, and as a result, it is possible to prevent the wire from climbing up. Moreover,
Since the wire is wound in a state in which it is tilted to the side opposite to the winding direction, it is possible to prevent the wire from falling in the winding direction during winding. According to the means described in claim 4, since the tension of the wire is indirectly detected from the winding torque,
It is possible to eliminate the structure in which the wire is pressed by the tension roller, and as a result, it is possible to prevent the wire from bending.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment of the present invention will be described below with reference to FIGS.
It will be described based on. First, referring to FIG.
Is obtained by winding the strands 22 having a rectangular cross section in an aligned manner along the axial direction. In this case, as shown in FIG.
The winding angle of the first-layer wire 22 is set to θ1 degree, which is smaller than 90 degrees. Further, as shown in FIG. 11, the second-layer wire 22 is inclined in the opposite direction to the first-layer wire 2,
The winding angle is set to θ1 degree, which is equal to the winding angle of the first-layer wire 22. Thereby, the wire 22 is spirally wound.

Moreover, as shown in FIG. 1, the first-layer wire 22 is tilted in the opposite arrow X direction, and the second-layer wire 22 is tilted in the arrow X direction. The inclination angle of the wire 22 and the inclination angle of the second-layer strand 22 are both set to θ3 degrees, which is a constant value out of 1 to 10 degrees. It should be noted that 23a to 23c are interlayer papers, 23d to 23g are end tapes, and the strands 22 are formed by covering the conductors 22a with insulating paper 22b as shown in FIG.

Next, the structure of the coil manufacturing apparatus for manufacturing the coil 21 will be described. First, in FIG.
Supports 24a and 24b are installed on the base plate 24, and a winding shaft 25a of a winding form 25 is pivotally supported on the supports 24a and 24b. In addition, the winding motor 2 is provided in the support base 24a.
6 is housed in the winding motor 26.
It is connected to the winding shaft 25a via 6a. As a result, when the winding motor 26 is driven, the winding mold 25 moves the winding shaft 25.
It rotates around a and the torque of the winding form 25 is detected by the torque sensor 26a. still,
The winding motor 26 and the torque sensor 26a are connected to a control means (not shown) mainly composed of a microcomputer, and this control means drives and controls the winding motor 26a and displays the measurement result of the torque sensor 26a. To detect.

A base plate 27 is provided on the left side of the base plate 24. Rails 27a, 27a and a feed screw 27b are provided on the base plate 27 in parallel with the winding shaft 25a.
In the former rails 27a, 27a, as shown in FIG.
The drum mounting portion 28 is fitted. The drum mounting portion 28 is screwed into the feed screw 27b, and when the drum motor 29a is driven, the feed screw 27b rotates and the drum mounting portion 28 moves along the rails 27a and 27a.

A wire drum 29 is rotatably attached to the drum mounting portion 28, and the wire 22 is wound around the wire drum 29. The tip of the wire 22 is fixed to the winding form 25, and when the winding form 25 rotates,
The wire drum 29 rotates, the wire 22 is drawn out, and the wire 22 is wound around the winding form 25. The drum motor 29a is connected to a control means, and the control means drives and controls the drum motor 29a so that the wire drum 29 continuously moves in synchronization with the rotation of the winding form 25.

The wire drum 29 has a drum brake 2
9b is provided, and the rotation resistance of the wire drum 29 is adjusted by the drum brake 29b. The drum brake 29b is connected to the control means that functions as a drum brake control means, and this control means compares the target torque stored in advance with the detection value of the torque sensor 26a, and this detection value is the target. The drum brake 29b is controlled so that it becomes equal to the torque. The target torque is the torque of the wire 22 according to the distance R between the winding center of the winding form 25 and the winding position of the wire 22.

The drum mounting portion 28 is provided with a plate 30 projecting toward the winding form 25 side.
A support base 31 extending upward is provided. As shown in FIG. 5, a forked portion 31a is provided at the tip of the support base 31, and rollers 31b, 3 are provided between the forked portions 31a.
1b is attached to the upper and lower two stages. And the wire 22
Is inserted between the rollers 31b and 31b, and the upper and lower and left and right side surfaces thereof are guided by the rollers 31b and 31b. The rollers 31b and 31b are movable and replaceable so as to match the long side L and the short side S of the various types of the wire 22.

As shown in FIG. 4, the base plate 24 is provided with a support base 32 extending upward. This support 32
As shown in FIG. 3, it has a form extending in a direction along the winding shaft 25a, and has rails 32a, 32a and an X-axis feed screw 32b on its upper surface in parallel to the winding shaft 25a.
Is provided. In addition, the former rails 32a, 32a
As shown in FIG. 4, a first base 33 is fitted in the. The first base 33 is the X-axis feed screw 32.
When the X-axis motor 33a is driven, the X-axis feed screw 32b rotates and the first base 33 moves along the rails 32a and 32a in the arrow X direction in FIG.

As shown in FIG. 7, a Y-axis feed screw 33b extending in the direction of the arrow Y and two rails 33c are provided on the upper surface of the first base 33, and the former Y-axis feed screw 3 is provided.
3b is rotated by a Y-axis motor 33d. Further, as shown in FIG. 6, two rails 33c are provided.
A second base 34 is fitted to the second base 34, and the second base 34 is screwed to the Y-axis feed screw 33b. This makes Y
When the shaft feed screw 33b rotates, the second base 34 moves in the arrow Y direction along the rail 33c. Further, a U-shaped roller mounting portion 35 is provided on the upper side of the second base 34. The roller mounting portion 35 is connected to the second base 34 via a Z-axis rotating actuator 36 that is a first rotating means.
When the shaft rotation actuator 36 operates, it rotates about the axis Za.

As shown in FIG. 8, a Z-axis feed screw 35a extending in the direction of arrow Z and two rails 35b are provided on the front surface of the roller mounting portion 35, and the former Z-axis feed screw 3 is provided.
As shown in FIG. 6, 5a is rotated by a Z-axis motor 35c. And two rails 3
The third base 37 is fitted to 5b, and the third base 3
7 is screwed into the Z-axis feed screw 35a, and when the Z-axis feed screw 35a rotates, the third base 37 moves the rail 35.
Move in the direction of arrow Z along b. Also, the third base 3
7, a bracket 38 is provided. The bracket 38 is connected to the third base 37 via a Y-axis rotating actuator 39 which is a second rotating means. When the Y-axis rotating actuator 39 operates, the bracket 38 is centered on the axis Ya. Rotate.

A roller 40 is attached to the first base 33, and the roller 40 moves only in the X direction together with the first base 33. Further, guide rollers 41a to 41c are attached to the bracket 38, and these guide rollers 41a to 41c move in the X direction with the movement of the first base 33, and with the movement of the second base 34. Move in the Y direction, and move in the Z direction with the movement of the third base 37. Moreover, the guide rollers 41a-4a
1c rotates about the axis Za with the operation of the Z-axis rotation actuator 36, and rotates about the axis Ya with the operation of the Y-axis rotation actuator 39.

Then, as shown in FIG. 4, the roller 31
The wire 22 inserted between b and 31b is guided from below by the roller 40 and then guided by the guide rollers 41a and 41b.
It is inserted between b and 41c, and its upper and lower and left and right side surfaces are guided by guide rollers 41a to 41c. Therefore, the winding angle of the wire 22 is determined by the guide roller 41.
It is adjusted to .theta.1 degree by rotating a to 41c about the axis Za. Further, the inclination angle of the wire 22 is adjusted to θ3 degrees based on the rotation of the guide rollers 41a to 41c about the axis Ya.

The rollers 41a to 41c are movable and replaceable so as to fit the long side L and the short side S of the various types of the wire 22. In addition, the X-axis motor 33
a, Y-axis motor 33d, Z-axis motor 35c, Z-axis rotation actuator 36, Y-axis rotation actuator 3
Reference numeral 9 is connected to control means, and the drive is controlled by this control means.

Next, a method of manufacturing the coil 21 will be described. First, in FIG. 9, the interlayer paper 2 is formed on the outer peripheral surface of the winding form 25.
3a is wound, and the end tape 23d is wound around the end portion in the opposite X direction. 3 and 4, the Y-axis motor 33d and the Z-axis motor 35c are driven to drive the winding form 2
The positions of the roller 40 and the guide rollers 41a to 41c are moved so as to correspond to the size of 5.

Along with this, the Y-axis rotation actuator 3
By operating 9 as shown by the solid line in FIG.
The guide rollers 41a to 41c are rotated about the axis Ya in the arrow A direction by θ3 degrees. Further, as shown by the solid line in FIG. 7, by operating the Z-axis rotation actuator 36, the guide rollers 41a to 41c are rotated about the axis Za in the direction of arrow B (90-.theta.1) degrees.

After the above operation is completed, as shown in FIG. 3, the tip end of the wire 22 wound around the wire drum 29 is fixed to the winding form 25, and the short side S of the wire 22 is wound around the winding form 25. To be in a state of facing. Next, the winding form 25 is rotated, and the strand 22 is pulled out from the wire drum 29 to wind the strand 22 around the winding form 25. In this case, the control means
The drum motor 29a and the X-axis motor 33a are continuously driven, and the drum mounting portion 28 and the first base 33 are moved in the arrow X direction in synchronization with the rotation of the winding form 25. Thereby, the guide rollers 31b, 40, 41a to 41c
Is continuously moved to take up the winding angle θ1 and the tilt angle θ3.
Then, it is wound around the winding form 25 in close alignment.

After that, after winding the wire 22 for one layer, in FIG. 9, an end tape 23e is wound around the end of the winding form 25 in the X direction to form an inter-layer on the wire 22 of the first layer. Paper 23b
And the end tape 23f is wound from above the interlayer paper 23b. Next, the Y-axis rotation actuator 39 is actuated to guide the guide roller 41a as shown by the chain double-dashed line in FIG.
It is assumed that .about.41c are rotated about the axis Ya in the direction of the opposite arrow A by .theta.3 degrees. Along with this, the Z-axis rotation actuator 36 is operated, and as shown by the chain double-dashed line in FIG.
It is assumed to be rotated about the axis Za in the direction of the counter arrow B by (90-.theta.1) degrees.

Then, the drum mounting portion 28 and the first base 33 are moved in the direction opposite to the arrow X in synchronism with the rotation of the winding form 25, and as shown in FIG.
The wire 22 is aligned and closely wound on the winding form 25 at a tilt angle of 1 and a tilt angle θ 3. After this, when the second layer wire 22 is wound around the winding form 25, an end tape 23g is wound around the end of the second layer wire 22 in the direction opposite to the X direction as shown in FIG. The interlayer paper 23c is wound from above the strand 22 of the layer to prevent the coil 21 from losing its shape.

Moreover, while the wire 22 is wound around the winding form 25, the control means detects the torque of the winding form motor 26 from the torque sensor 26a, and the drum is adjusted so that the detected value becomes equal to the target torque. Control the brake 29b, and wire 2
2 is given a constant tension.

According to the above-described embodiment, the winding angle of the wire 22 is set to θ1 degree smaller than 90 degrees, and the wire 22 is wound in a spiral shape. Therefore, the guide rollers 41a to 41c are connected to the wire 22. The winding method of intermittently moving by the short side dimension S can be eliminated. As a result, it becomes easier to change the columns of the wires 22, and it is possible to prevent the wires 22 from riding up. Moreover, the inclination angle of the wire 22 is set to θ3 degrees,
Since the wire is wound in a state of being tilted to the side opposite to the winding direction, it is possible to prevent the strand 22 from falling in the winding direction during winding. Therefore, the work of climbing up the wire 22 and the work of correcting the collapse are not required, and the workability is improved.

Further, since the tension of the wire 22 is indirectly detected from the torque of the winding form 25, the structure of pressing the wire 22 with the tension roller can be eliminated and the bending of the wire 22 can be prevented. Therefore, the reliability of the quality of the insulating paper 22b is improved, the visual check after winding the wire 22 on the winding form 25 can be eliminated, and the workability is further improved.

In the above embodiment, the coil 21 is exemplified by the wire 22 wound in two layers.
The number of layers may be one or three or more. In the case of a plurality of layers, the directions of the strands 22 of the odd layers and the even layers are opposite to each other.

[0041]

As is apparent from the above description, according to the coil according to claim 1, the coil manufacturing method according to claim 2 and the coil manufacturing apparatus according to claim 3, the wire is spirally wound. Therefore, it becomes easy to change the row of the wires, and it is possible to prevent the wires from climbing up. Moreover, since the wire is wound in a state in which it is tilted to the side opposite to the winding direction, it is possible to prevent the wire from falling in the winding direction during winding. As a result, the work of climbing up the wire and the work of correcting the collapse are unnecessary, and the workability is improved.

Further, according to the means described in claim 4, since it is possible to abolish the structure in which the wire is pressed by the tension roller,
Bending of the wire is prevented. As a result, it is possible to eliminate the visual check after winding the wire around the winding form and further improve the workability.

[Brief description of drawings]

FIG. 1 is a vertical sectional rear view of a coil showing an embodiment of the present invention.

FIG. 2 is a vertical sectional view of a wire.

FIG. 3 is a top view of a coil winding device.

FIG. 4 is a side view of the coil winding device.

FIG. 5 is a vertical sectional rear view showing a guide roller.

FIG. 6 is an enlarged side view near the roller mounting portion.

FIG. 7 is an enlarged top view near the roller mounting portion.

FIG. 8 is an enlarged front view near the roller mounting portion.

FIG. 9 is a view corresponding to FIG. 1 showing a winding state of a coil.

FIG. 10 is a top view showing a wound state of the first-layer wire.

FIG. 11 is a top view showing a winding state of the second-layer wire.

FIG. 12 is a view corresponding to FIG. 1 showing a conventional example.

FIG. 13 is a view corresponding to FIG.

FIG. 14 is a view corresponding to FIG.

FIG. 15 is a view corresponding to FIG. 11.

FIG. 16 is a diagram for explaining the riding and falling of the wire.

[Explanation of symbols]

21 is a coil, 22 is a wire, 25 is a winding die, 26 is a winding motor, 26a is a torque sensor, 29 is a wire drum, 2
9b is a drum brake, 36 is a Z-axis rotating actuator (first rotating means), 39 is a Y-axis rotating actuator (second rotating means), and 41a to 41c are guide rollers.

Claims (4)

[Claims] 1. A wire in which a wire having a rectangular cross section is wound in an array along an axial direction, the wire is wound in a spiral shape, and the wire is wound in a direction opposite to a winding direction. A coil characterized by falling at a constant angle. 2. The method for manufacturing a coil according to claim 1, wherein the wire is wound in a winding form while being moved along an axial direction of the winding form. The coil manufacturing method is characterized in that the coil is supplied in an inclined state with respect to the winding form while being held in a state of being tilted to the opposite side. 3. The apparatus for manufacturing a coil according to claim 1, wherein the winding die is rotatably provided, and the wire is wound with the rotation, and the winding die moves along an axial direction of the winding die. A guide roller that is movably provided and that guides the element wire to a predetermined position of the winding form with its movement; and the guide roller is rotated so that the element wire is supplied in an inclined state with respect to the winding form. A coil manufacturing apparatus comprising: a first rotating means; and a second rotating means for rotating the guide roller so that the strand of wire falls to the side opposite to the winding direction. 4. A drum brake for adjusting the rotation resistance of a wire drum for supplying a wire to a winding form, a torque sensor for detecting a torque of the winding form, and the drum based on a detection value of the torque sensor. 4. The coil manufacturing apparatus according to claim 3, further comprising a drum brake control unit that controls a brake.