JPH0745464A - Method and apparatus for manufacturing toroidal coil having core - Google Patents

Abstract

PURPOSE:To allow convenient automatic winding by entangling a spiral air core coil of conductor about a part of a toroidal soft magnetic body and then rotating the air core coil spirally. CONSTITUTION:A core 1 is made of manganese zinc ferrite into toroidal shape. An air core coil 5 formed of a conductor 4 into an anticlockwise coil is fixed, at one end thereof, to a chuck 3 secured to the rotary shaft of a motor 2 and entangled, at the other end thereof, to the core at the inner peripheral part thereof. When the motor 2 is rotated in a rotational direction 11, the air core coil 5 rotates through the chuck 3 thus advancing the conductor 4 in the winding direction around the core 1. The conductor 4 is further pressed sequentially against the periphery of the core 1 by means of a hand drum type roller 7 rotating in the rotational direction 12 and wound. This apparatus facilitates automatic winding of the core.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a toroidal coil having a magnetic core, and more particularly, a method and an apparatus for manufacturing a toroidal coil having a magnetic core having a simplified winding process of a conductor wire. Regarding

[0002]

2. Description of the Related Art In the conventional method of manufacturing a toroidal coil having a magnetic core, one end of a conductor wire which is generally straight or wound around a reel is magnetized so that the surface of the magnetic core having soft magnetism and having a toroidal shape is followed. It was manufactured by repeatedly performing winding work from the inner circumference side to the outer circumference side of the core, then from the outer circumference side to the inner circumference side, and further from the inner circumference side to the outer circumference side.

[0003]

In the conventional method of manufacturing a toroidal coil having a magnetic core, one end of a conductive wire is continuously passed alternately to the outer peripheral side and the inner peripheral side of the toroidal magnetic core. There is a drawback in that the mechanization is extremely difficult because the winding work is performed.

That is, in order to continuously wind a conductor wire around a magnetic core having an integral structure such as a toroidal shape, one end of the conductor wire inserted on the inner circumference side is again inserted on the inner circumference side via the outer circumference side. It is necessary to hold one end of the conductor wire, insert the conductor wire into the inner circumference of the magnetic core, and then re-hold the one end of the conductor wire from the side opposite to the insertion side. Since it is a repetitive process, not only is it difficult to replace the holding device for the wire, but the length of the wire connected to one end of the wire becomes shorter with the winding as the work of winding the magnetic core progresses. At the beginning of the wire work, the moving distance on the inner and outer circumferences of the magnetic core of the conducting wire is long, and the moving distance becomes shorter as the winding work progresses. Has the drawback of requiring changes,
It was difficult to mechanize, and it was a work that relied exclusively on human resources.

In response to the above-mentioned drawbacks, it has been considered that the winding work is mechanized by numerical control by applying an image processing technique which has been remarkably developed in recent years. However, not only a huge investment is required in terms of cost but also various types are required. In order to adapt to various specifications, a learning operation for a machine, generally called teaching, is required for each specification, and in practice there was a difficulty in introducing it.

Therefore, a technical object of the present invention is to provide a method and an apparatus for manufacturing a toroidal coil having a magnetic core which enables simple automatic winding and promotes labor saving.

[0007]

The inventor of the present invention has made earnest studies on the steps of the conventional method for manufacturing a toroidal coil having a magnetic core that relies on manpower and has accomplished the present invention.

According to the method of manufacturing a toroidal coil having a magnetic core of the present invention, one end of a spiral-shaped air-core coil made of a conductive wire prepared in advance is entangled with a part of the toroidal soft magnetic material. The air core coil is rotated in a spiral direction.

[0009]

That is, the present inventor has noticed that the winding portion formed by the conductor wire of the toroidal coil having the magnetic core is similar to the spiral cored air core coil, and further that the air core coil formed by the conductor wire is By having flexibility and toughness,
An object that has the property of returning to the coil shape again even if a slight elongation stress or tensile stress is applied to the conductor once formed into the coil shape, and that has a spiral shape is needless to mention bolts, screws, etc. The present invention is based on the fact that when a rotational motion is given to the spiral direction, a forward or backward motion is generated with respect to a surface in contact with an object having the spiral shape.

[0010]

Next, the present invention will be described in detail with reference to the drawings.

(Embodiment 1) FIG. 1 is a plan view illustrating a first embodiment of the present invention. In FIG. 1, the magnetic core 1 is made of manganese zinc ferrite and has an outer diameter of 36 mm and an inner diameter of 2
It has a toroidal shape in which the cross section of the magnetic path is 6 mm and the diameter is 5 mm.

One end of the magnetic core 1 is fixed to the chuck 3 fixed to the rotary shaft of the motor 2 according to JIS-C31.
02-compliant 1.2 mm diameter tin-plated annealed copper wire coated with tetrafluoroethylene resin (commonly known as PTFE) on the outer circumference of a 1.6 mm outer diameter conductor wire 4 with a 4.6 mm inner diameter coiled leftward After the other end of the air-core coil 5 processed into the above is entwined with the magnetic core, the motor 2 is rotated in the rotation direction 11 to rotate the air-core coil 5 via the chuck 3 and the conductor wire 4 to the magnetic core. 1 around the winding direction 1 in the winding direction 14. Further, the conducting wire 4 is pressed against the magnetic core 1 in sequence and wound by a roller 7 which is fixed to the rotating shaft of the motor 6 and which rotates in the direction of rotation 12 and has a drum shape. FIG. 1 shows a case where three sets of rollers 7 are arranged.

FIG. 2A is a plan view showing a state where the winding is completed according to the first embodiment of the present invention. FIG. 2B is a side view (the motor 6 and the roller 7 are omitted) showing a state where the winding is completed according to the first embodiment of the present invention.

In FIG. 2A, the conductor 4 is wound around the magnetic core 1 15 times by the rotational movement of the motor 2 and the motor 6. Then, as shown in FIG. 2B, the take-up roller 8 is rotated in the rotation directions 13a and 13b by a motor (not shown), so that the leading end of the lead wire 4 is pulled out from the magnetic core 1. Further, the motors 2 and 6 rotate in the direction opposite to the rotation directions 11 and 12, and the slack of the conductor wire 4 around the magnetic core 1 is corrected.

When the winding of 500 magnetic cores was performed in the above process, the average winding speed was 5.3 seconds / piece. For comparison, 5 skilled workers with 2 to 4 years of experience performed the winding work of 500 pieces using the same magnetic core and conducting wire, and the average winding speed per person was 20.3 seconds / piece. Met.

(Second Embodiment) FIG. 3 is a plan view illustrating a second embodiment of the present invention. In FIG. 3, the magnetic core 21 is
Made of nickel zinc ferrite, outer diameter 15 mm, inner diameter 1
It has a toroidal shape of 0 mm and a thickness of 3 mm, and has a depth of 0.55 mm and a width of 1.1 on the upper and lower surfaces formed by the outer diameter of φ15 and the inner diameter of φ10.
There are 20 grooves on each surface, each of which has a semicircle cross section of mm and is intermittently continuous.

A worm gear-shaped feed screw 23 having a left-handed screw structure, which is fixed to the rotating shaft of the motor 22, is attached to the JIS-
An air core coil 25 processed into a coil shape in the left-hand winding direction having an inner diameter of 3.6 mm is fitted with a conductor wire 24 made of a formal wire having a diameter of 1.0 mm and conforming to C3203, and one end of which is entwined with the inner peripheral portion of the magnetic core 21. After the rotation, the motor 22 is rotated in the rotation direction 31 to rotate the air-core coil 25 via the feed screw 23, and the conductive wire 24 advances around the magnetic core 21 in the winding direction 34.

Further, the conductors 24 are sequentially guided by the grooves of the magnetic core 21 by rollers 27a and 27b which are fixed to the rotary shafts of the motors 26a and 26b and rotate in the directions of rotation 32a and 32b. Is wound around.

FIG. 4A is a plan view showing a state where the winding is completed according to the second embodiment of the present invention. FIG. 4B is a side view showing a state where the winding is completed according to the second embodiment of the present invention (motors 26a, 26b and rollers 27a, 27b).
Omitted).

In FIG. 4A, the conductor 24 is moved to the magnetic core 21 by the rotational movement of the motor 22 and the motors 26a and 26b.
It is wound 20 times. Then, as shown in FIG. 4B, the take-up roller 28 is rotated in the rotation directions 33a and 33b by a motor (not shown), so that the tip of the lead wire 24 is pulled out from the magnetic core 21. Further, the motors 22, 2
6a and 26b are rotational directions 31, 32a and 32b
Rotate in the opposite direction to correct the slack of the conductor wire 24 around the magnetic core 21.

When 500 magnetic cores were wound in the above process, the average winding speed was 7.8 seconds / winding. For comparison, five skilled workers with 2 to 4 years of experience performed the winding work of 500 pieces using the same magnetic core and conducting wire, and the average winding speed per person was 31.5 seconds / piece. Met.

As the toroidal soft magnetic material applicable to the present invention, there are oxide soft magnetic materials such as nickel zinc ferrite and manganese zinc ferrite, and metal soft magnetic materials such as pure iron powder compact, and as the conductor wire. Can be, for example, a single copper wire or a stranded wire made of a plurality of copper wires, and a coated copper wire whose outer peripheral portion is coated with Teflon resin or the like, but it goes without saying that the present invention is not limited to these.

FIG. 5 shows, in a perspective view, the structure of an apparatus suitable for carrying out windings according to the winding method described above.

The magnetic core 1 taken out by the holder 45 from the magnetic core stocker 41 mounted on the pedestal 40 slides on the slide guide 43a of the magnetic core conveying path 42 to the position where the winding is carried out. On the other hand, the air-core coil 5 taken out from the air-core coil stocker 46 is fixed to the pedestal 40 by the chuck 3 at the tip of the motor 2 attached via the bearing 49, the shaft 48, and the bracket 47. The leading end of the conductor wire 4 forming the core coil 5 is entangled with the magnetic core 1. The shape of the air-core coil 5 and the type of the conductor wire 4 are preset according to the purpose. Subsequent steps are the same as those in the first embodiment described above. The magnetic core 1 whose winding is completed is held by the holder 45 on the inner peripheral side of the magnetic core 1 and the slide block 43b of the magnetic core conveying path is moved by the slide block 44. It is carried by sliding and taken out through the chute 51.

[0025]

As described above in detail, in the method and apparatus for manufacturing a toroidal coil having a magnetic core of the present invention, a conductor wire is preliminarily formed into an air-core coil shape, and then the principle of screw advancement due to rotational movement is advanced. Since it is possible to easily perform automatic winding on the magnetic core by utilizing, it is extremely useful in industry.

[Brief description of drawings]

FIG. 1 is a plan view illustrating a first embodiment of the present invention.

2A and 2B are diagrams illustrating a first embodiment of the present invention, FIG. 2A is a plan view and FIG. 2B is a side view.

FIG. 3 is a plan view illustrating a second embodiment of the present invention.

4A and 4B are diagrams illustrating a second embodiment of the present invention, FIG. 4A is a plan view and FIG. 4B is a side view.

FIG. 5 is an external perspective view of a manufacturing apparatus according to the present invention.

[Explanation of symbols]

 1, 21 Magnetic core 2, 22 Motor 3 Chuck 4, 24 Conductor 5, 25 Air core coil 6, 26a, 26b Motor 7, 27a, 27b Roller 8, 28 Take-up roller 11, 31 Rotational direction 12, 32a, 32b Rotational direction 13a, 13b, 33a, 33b Rotational direction 14, 34 Winding direction 23 Feed screw 40 Pedestal 41 Magnetic core stocker 42 Magnetic core carrier 43a, 43b Slide guide 44 Slide block 45 Holder 46 Air core coil stocker 47 Bracket 48 Shaft 49 Bearing 50 Slider 51 Shoot

Claims (2)

[Claims] 1. A magnetic pole characterized by winding one end of an air-core coil having a spiral shape made of a conductive wire around a toroidal soft magnetic material, and then spirally advancing the air-core coil for winding. A method for manufacturing a toroidal coil having a core. 2. A toroidal coil manufacturing apparatus for winding a spirally wound air-core coil made of a conductive wire along a magnetic core in a spiral manner, and including a mechanism for fixing the air-core coil. And a motor provided with a drum-shaped roller for guiding the progress of the winding along the magnetic core and correcting the slack of the winding, and the tip of the winding. An apparatus for manufacturing a toroidal coil, which comprises a motor having a roller for leading out a portion.