JPH09115757A - Manufacture and manufacturing equipment of coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a winding method and an equipment for putting the form of a coil in order determined in design. SOLUTION: A plurality of small-sized heaters 90 and temperature measuring sensors 91 are buried in a projected mold 2 and a recessed mold 3 around which a wire is wound. Each of the sensors 9 converts a metal mold temperature in the buried portion into an electric signal and outputs it to a temperature detection equipment 92, which receives the voltage output proportional to the metal mold temperature at each portion and calculates the mean value of the metal mold temperature. The mean value is compared with a previously set temperature, and the result is delivered to a temperature control equipment 93. According to the comparison result, the temperature control equipment 93 applies currents to the small-sized heaters 90 when the mean temperature of the metal mold is lower than the set temperature, and cuts off the currents of the small-sized heaters 90 when the mean temperature is higher than the set temperature. By the changeover like this, the temperature of the metal mold is controlled to be always equal to the set temperature. After the temperature of the metal mold becomes equal to the set temperature, the configuration of wire is put in order.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and apparatus for manufacturing a coil formed by winding a wire around a mold, particularly a deformed coil.

[0002]

2. Description of the Related Art Although various coils are currently used in electric appliances, saddle coils for deflection yokes are used in, for example, televisions and electron microscopes. The saddle coil for the deflection yoke is a coil for deflecting the electron beam so that the electron beam is applied to a predetermined position. Stator coils are used for induction motors and DC motors. These coils have shapes other than the usual cylindrical shape and prismatic shape, and are called deformed coils in particular.

As a method for manufacturing a deformed coil, a convex shape and a concave shape conforming to the coil shape are prepared, a space around which the wire is wound is formed by combining these, and the wire is sequentially wound into the space to manufacture the coil. The method is generally used, and is described in, for example, JP-A-4-47635. A molding method of press-molding a coil wound in a flat shape to obtain a predetermined shape is described in JP-A-56-28435.

In addition, since the space factor of each part of the coil cross section does not reach a predetermined value and the product performance cannot be satisfied only by winding on the die, the standard coil cross section is pressed to produce a metal. A method of pushing a wire into a mold to shape a coil has also been proposed (JP-A-63-94531, JP-A-63-119113, JP-A-63-150830).
No.). Further, in Japanese Patent Laid-Open No. 5-290731,
A method has been proposed in which each wire is integrated by using a thermoplastic adhesive layer.

[0005]

However, none of the conventional winding / shaping methods is decisive, and it is hard to say that the coil shape as designed is obtained. For example, in the manufacturing method described in JP-A-5-290731, it is considered that the bonding strength of the thermoplastic adhesive layer is not sufficient.

[0006] If the wire material varies and the desired shape and dimension cannot be obtained, the distribution of the generated magnetic field also varies.

In a color cathode-ray tube, usually R (red) G
The electron beams of three colors (green) and B (blue) pass through the shadow mask and irradiate the surface with the phosphors. However, if the magnetic field distribution varies as described above, each electron beam is designed. It will not pass the street orbit, causing color shift.

In order to correct the color misregistration and obtain the desired display performance, for example, it is necessary to attach a ferrite sheet or a small electromagnetic soft iron to the inner surface of the coil to partially correct the magnetic field. The working time increases geometrically as the size of the cathode ray tube increases and the pixel pitch decreases. The increase in working time causes a rise in production costs. Further, the above-mentioned correction work belongs to the skilled work because various cases must be dealt with, and this is also one of the causes of the cost increase.

Further, when a motor is taken as an example, variations in the magnetic flux density of each pole cause uneven rotation, which deteriorates the performance of the motor.

In view of the above problems, it is an object of the present invention to provide a coil manufacturing method and apparatus capable of obtaining a coil shaped as designed.

[0011]

According to a first aspect of the present invention for achieving the above object, a wire containing an insulating layer-covered conductor and a fusion-bonding layer as an outer cover is used. In the method for manufacturing a coil, after the temperature of the mold in which the coil formed of the wire is mounted is higher than room temperature, the conductor wire of the coil is heated to melt the fusion bonding layer, and the coil is predetermined. Provided is a method for manufacturing a coil, which is characterized by shaping into a shape.

According to a second aspect of the present invention for achieving the above object, in the first aspect, when heating the conductive wire, the temperature of the conductive wire is set to be equal to or lower than a heat resistant temperature of the insulating layer. A method for manufacturing a coil is provided.

According to a third aspect of the present invention for achieving the above object, in a method of manufacturing a coil using a wire rod including a conductive wire, the temperature of a mold in which the coil formed of the wire rod is mounted. After the temperature is higher than room temperature, the conductive wire of the coil is heated to shape the coil into a predetermined shape.

According to a fourth aspect of the present invention for achieving the above object, in a coil manufacturing method using a wire including an insulating layer-covered conductor and a fusion-bonding layer as an outer cover, After making the temperature of the mold in which the coil formed of the wire rod is mounted higher than room temperature, the conductive wire of the coil is heated to melt the fusion layer, and the fusion layer is solidified and then the coil is A method for manufacturing a coil is provided, which is characterized in that the coil is taken out from a mold.

According to a fifth aspect of the present invention for achieving the above object, in the first, second, third or fourth aspect, the mold is used when winding the wire. Provided is a method for manufacturing a coil, which is a mold.

According to a sixth aspect of the present invention for achieving the above object, in the first, second, third or fourth aspect, the coil formed of the wire rod is different from the mold. A method for manufacturing a coil is provided, which is manufactured by winding the wire rod in a different die for winding.

According to a seventh aspect of the present invention for achieving the above object, in the first, second, third, fourth, fifth or sixth aspect, the wire is lower than room temperature. There is provided a method for manufacturing a coil, which is characterized by being wound around a mold set to a temperature.

According to an eighth aspect of the present invention for achieving the above object, in the first, second, third, fourth, fifth, sixth or seventh aspect, the heating of the conductor wire is performed. A method for manufacturing a coil is provided, which is performed by passing an electric current through the conductive wire.

According to a ninth aspect of the present invention for achieving the above object, in a coil manufacturing apparatus using a wire covered with an insulating layer, and a wire material including a fusion layer as an outer cover, A mold for forming the coil, a mold around which the wire is wound, a heater for heating the mold, and a measurement for measuring the temperature of the mold. A device, a control device that adjusts the heater based on the measurement result of the measuring device, and sets the temperature of the mold to a predetermined value, a power supply for supplying an electric current to the lead wire of the coil, and the coil Is equipped with a shaping mechanism that starts shaping of the coil when the temperature of the mold mounted is set to a predetermined value by the control device and then the energization of the coil is finished. A coil winding device is provided.

A tenth aspect of the present invention for achieving the above object.
According to a ninth aspect, there is provided the coil winding device according to the ninth aspect, wherein the shaping mechanism presses a reference surface serving as an assembly reference of the coil to shape the coil.

In the present invention, since the temperature of the mold is set to a temperature higher than room temperature in advance as a preparation step for coil shaping, the temperature of the coil can be kept high during actual coil shaping. Since the higher the temperature of the coil is, the lower the yield stress of the wire of the wire is, it is possible according to the present invention to plastically deform the coil with a small shaping force. When the shaping force applied is small, the springback of the coil after shaping is reduced. Further, in the case of a wire having a fusion layer as an outer cover, shaping in a high temperature environment can enhance the bonding strength of the fusion layer. In addition, when a desired coil shape can be obtained only by winding, the fusion layer may be melted and re-solidified.

Further, when a die set at a temperature lower than room temperature is used at the time of winding, which is the former stage of coil shaping, friction between the die and the wire is reduced, and a more accurate aligned winding can be obtained. It will be possible.

[0023]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to the drawings.

FIG. 1A shows a winding shaping mold (convex mold 2, concave mold 3) used in the first embodiment of the present invention. FIG. 1B shows the structure of the winding shaping mold as seen from the AA ′ cross section of FIG. FIG. 1 (c)
[Fig. 2] is a perspective view of the winding shaping mold of Fig. 1 (a). FIG.
Shows a winding shaping device of this embodiment equipped with this winding shaping mold.

The convex mold 2 and the concave mold 3 are, as shown in FIG.
They are used as molds for deformed coils (saddle-type coils in this embodiment) in a state of being combined with each other. This saddle type coil constitutes a part of a deflection yoke used in a television. The saddle type coil is also used in an electron microscope and the like. Further, the present invention is not limited to the saddle type coil, but can be applied to manufacture of a stator coil such as an induction motor or a DC motor, for example.

A plurality of small heaters 90 and a plurality of temperature measuring sensors 91 are embedded in each of the convex mold 2 and the concave mold 3. It is desirable that these arrangements be determined so that the respective small heaters 90 can heat the entire mold and that the temperature measurement sensors 91 can grasp the temperature of the entire mold. Each temperature measurement sensor 91 converts the mold temperature of the embedded portion into an electric signal (specifically, voltage output) and outputs the electric signal to the temperature detection device 92. In this embodiment, the temperature measuring sensor 9
A thermocouple type sensor is used as 1. Small heater 9
Reference numeral 0 is a cartridge heater of a type in which a heating coil is built in a cartridge made of an iron-based material.

The temperature detector 92 receives a voltage output proportional to the mold temperature at each location and calculates the average value of these mold temperatures. Then, the average value is compared with the preset temperature, and the result is output to the temperature control device 93. Based on the comparison result, the temperature control device 93 switches the current to the small heater 90 when the average temperature of the mold is lower than the set temperature, and cuts off the current to the small heater 90 when the average temperature is higher than the set temperature. Then, the mold is controlled so as to always reach the set temperature.

In the winding shaping device of FIG. 5, the convex mold 2 is fixed to the fixed shaft 16 and the concave mold 3 is fixed to the block 60. The convex mold 2 and the concave mold 3 are the space 4 around which the wire 5 is wound.
Are abutted against each other at a predetermined distance so as to form a groove.

The wire 5 passes through a through hole 6 provided at the center of the flyer shaft 21 and is rotatable by rollers 7a, 7b, 7c,
It is guided by 7d and supplied toward the mold space 4. The flyer shaft 21 is a bearing 8 provided on the support 10.
It is rotatably held by a and 8b. The support 10 is
It is fixed to the base 9.

The gear 11 is fitted to the rear end of the flyer shaft 21. A pinion 12 meshes with the gear 11. The pinion 12 is mounted on the motor shaft of a servomotor 14 mounted on the support 10 by a bracket 13. The servo motor 14 has a built-in rotary encoder (not shown) for detecting the rotational phase of the flyer 1.

Bearings 15a and 15b are provided at the tip of the flyer shaft 21, and the above-mentioned fixed shaft 16 is provided.
Are rotatably held in these bearings.
That is, even when the flyer shaft 21 rotates during winding, the fixed shaft 16 remains stationary.
Is held.

A plurality of restriction pin insertion holes (not shown) extending in the direction parallel to the axial direction of the flyer shaft 21 are formed in the convex mold 2, and the concave mold 3 can be inserted into and removed from these restriction pin insertion holes. A plurality of regulation pins (not shown) are provided. The drive of each restriction pin is performed by an air cylinder (not shown) attached to the concave mold 3. When these restriction pins are inserted into the corresponding restriction pin insertion holes, mutual rotation of the convex mold 2 and the concave mold 3 is restricted.

The flyer shaft 21 has a spline portion 2
2 A hollow shaft 23 is fitted in the spline portion 22 so as to be movable in the axial direction. The hollow shaft 23 is provided with a flyer holding portion 23a, and the flyer 1 is rotatably attached to the flyer holding portion 23a via a pin 20. One end of a link 25 is rotatably attached to the flyer 1 via a pin 24. The other end of the link 25 is rotatably attached to the groove cam 27 via a pin 26. The groove cam 27 is slidably fitted to the hollow shaft 23. The cam follower 28 is slidably fitted in the groove cam 27 and moves the rotating groove cam 27 in the axial direction. The cam follower 28 is fixed to the table 29. A linear guide (not shown) having a guide direction parallel to the flyer shaft 21 is attached to the table 30. The table 29 moves relative to the table 30 via this linear guide. A nut 31 is fixed to the table 29, and the nut 31 is engaged with a ball screw 32. One end of the ball screw 32 is connected to the motor shaft of the servomotor 35 via a coupling 33. The servo motor 35 is attached to a bracket 34 fixed to the table 30. This servo motor 35
Rotates in synchronism with the flyer 1 according to a preset order based on the rotation phase angle of the flyer 1. This rotational movement is converted into a linear movement of the table 29 via the ball screw 32 and the nut 31, whereby the hollow shaft 23
The relative position of the groove cam 27 to the axis changes in the axial direction. The flyer 1 swings around the pin 20 according to the movement of the groove cam 27, and causes the wire 5 to enter the mold space 4 at an optimum penetration angle.

The cam follower 17 is slidably fitted in the hollow shaft 23. The cam follower 17 is fixed to the table 18. A linear guide (not shown) is attached to the table 29. The guide direction of this linear guide is the same as that of the aforementioned linear guide. The table 18 moves relative to the table 29 via this linear guide. Further, the table 18 is provided with a nut 36, and the nut 36 is engaged with the ball screw 37. One end of the ball screw 37 is connected to the motor shaft of a servomotor 40 via a coupling 38. The servomotor 40 is attached to a bracket 39 fixed to the base 9. Then, the servomotor 40 rotates in synchronization with the flyer 1 according to a preset order based on the rotation phase angle of the flyer 1. This rotational movement is converted into a linear movement of the table 18 via the ball screw 37 and the nut 36,
As a result, the hollow shaft 23 engaged with the cam follower 17 of the table 18 moves in the axial direction together with the groove cam 27.

Further, the concave mold 3 and the mechanism (for example, the regulating pin described above) provided therein are all supported by the block 60. The block 60 is fixed to the column 61,
The support column 61 is held by a block 63 fixed to a table 62. The table 62 is slidably attached to the base 9 by a slider 64. The table 62 is pressed in the two convex directions by an air cylinder (not shown).

The controller 300 includes servo motors 14, 3
5 and 40 are controlled. Specifically, inside the control device 300, the flyer 1 performed by the servo motor 14 is installed.
Memory for storing three programs for coordinating the three rotational operations, the swing motion of the flyer 1 performed by the servo motor 35, and the axial movement of the flyer 1 performed by the servo motor 40, and a program for executing this program. It has a built-in CPU that gives instructions to each motor. The three motors described above may be pulse motors, for example.

FIG. 2 shows a completed saddle coil 100. FIG. 3 is a cross-sectional view of the Braun tube when the two saddle type coils 100 are attached to the funnel portion 104 of the glass bulb to assemble the Braun tube.

In general, the saddle type coil including the ones targeted in this embodiment has a connecting portion 101 for electrically connecting the upper and lower fringe portions (fringe portions 102 and 103) as shown in FIG. The number of windings near the center is small, and the number of windings is large at the portion facing the other coil. Whether the magnetic field generated by the saddle type coil is good or bad is determined by the connection portion 101.
The degree of alignment of the windings has a great influence.

Therefore, the coil having such a shape is
Usually, after a winding process using a die, a shaping process is performed to complete the coil shape and the process is completed. Specifically, the part that bulges outward when the winding is completed (Fig. 4 (a)).
The reference coil is flattened by a shaping tool (for example, a shaping piece 79 as shown in FIG. 4B) to shape the entire coil to obtain the final coil shape. This flat portion 105 is
It serves as a reference plane for assembling the coil.

FIG. 6 shows a coil shaping mechanism 41 of this embodiment.
It is shown. The coil shaping mechanism 41 is preliminarily mounted on the winding shaping device and is moved to the position shown in FIG. At this time, the flyer 1 shown in FIG. 5 is in a state of being laid sideways so as not to get in the way of the coil shaping mechanism 41.

The coil shaping mechanism 41 has a column 70 arranged on the block 60 and a base 71 supported by the column 70. Linear guide 72 on the base 71
The shaping piece holding portion 77 is attached via. The shaping piece holding portion 77 has a built-in nut (not shown) engaged with the ball screw 76. The shaping piece 79 is attached to the lower end of the shaping piece holding portion 77. A gear 75b is attached to the ball screw 76, and the gear 75b meshes with a gear 75a of the motor shaft of the servomotor 73. The servo motor 73 is attached to a bracket 74 fixed to the base 71. When the servomotor 73 is driven, the shaping piece holding portion 77 moves left and right in the drawing according to the rotation of the ball screw 76. As a result, the shaping piece 79 is moved to the position shown in FIG.
Move to the position of (b).

Next, a winding shaping method using the winding shaping device of this embodiment will be described.

First, the winding shaping device is brought into the state shown in FIG. 5, and one end of the wire rod 5 supplied from the flyer 1 is temporarily fixed to a part of the concave mold 3 to prepare the winding.

Then, a drive command is input to the control device 300. As a result, the control device 300 starts drive control of each motor. Specifically, the flyer shaft 21 is rotated by the driving of the servomotor 14, and the wire 5 sent from the flyer 1 rotating around the convex mold 2 and the concave mold 3 is wound around the mold space 4. The angle of entry θ of the wire 5 into the mold space 4 is set by moving the flyer 1 in the axial direction while swinging the flyer 1. The swing motion of the flyer 1 is performed by moving the groove cam 27 by the servo motor 35, and the axial motion of the flyer 1 is performed by the servo motor 40.
It is realized by moving. The entry angle θ
Is sequentially set according to the rotation phase of the flyer 1 so that the wire 5 does not contact the mold surface when the wire 5 enters the mold space 4. If the wire 5 can be introduced into the mold space 4 without rubbing the surface of the mold, the winding can be advanced with the tension of the wire 5 kept constant, and the wire 5 can be moved to a predetermined position. Can be arranged in.

When the winding of the coil is completed, the flyer 1 is tilted sideways, and then the coil shaping mechanism 41 is moved to the position shown in FIG.

Next, using the temperature control device 93 described above, a current is passed through each small heater 90 to raise the temperature of the mold. When the mold reaches the target temperature, a current is passed through the saddle-shaped coil for a certain period of time to completely melt the nylon-based fusion bonding layer on the surface of the wire, and the coil shape is adjusted in this state. The target temperature of the mold is determined according to the type of wire used and the capacity of the mold. The electric current supplied to the saddle type coil is supplied from a power source (not shown).

The wire rod of this embodiment is formed by coating the surface of a linear conductor with an insulating layer and then coating a fusion-bonding layer as an outer coat. In this embodiment, copper is used for the conductor and polyesterimide is used for the insulating layer. Although the fusing layer is made of nylon, it has a softening temperature lower than that of the insulating layer and does not cause melting due to heat generation when the saddle coil is actually used. It is not particularly limited if it exists. Therefore, for example, an epoxy fusion bonding layer may be used. Also, the conductor may be aluminum.

FIG. 7 shows the temperature characteristics of the nylon-based fusion bonding layer of the wire 5. For reference, the same figure also shows the temperature characteristics of the two types of epoxy-based fusion bonding layers. As shown in the figure, in order to obtain high adhesive strength in this nylon-based fusion bonding layer, heating at 160 ° C. or higher is required.

Therefore, in this embodiment, the following shaping process was specifically performed.

First, the temperature of the mold was set to 80 ° C., and then a current of 80 A (ampere) was passed through the saddle type coil for 2 seconds to raise the temperature of the coil to 177 ° C. The shaping by the shaping piece 79 started at the same time when the coil was energized. Since the heat resistant temperature of the insulating layer of the wire is 180 ° C., the temperature of the mold was set within the range not exceeding this.

The temperature change of the coil from the time when the energization is started is as shown in FIG. 8 (a). As can be seen from the figure, the coil temperature is 160
It is kept near ℃. Since the shaping by the shaping piece 79 is completed during this period, in this example, the shaping operation is performed in the state where the nylon-based fusion bonding layer on the surface of the wire is completely melted at around 160 ° C. The melting of the nylon fusion layer is caused by Joule heat (= current ×
Current x wire resistance x time).

As described above, if the shaping operation can be performed on the fusion layer at the optimum temperature, sufficient bonding strength of the fusion layer can be obtained.

FIG. 8B shows the temperature change of the coil when the shaping operation is performed with the mold temperature kept at room temperature (20 ° C.) without heating by the small heater 90. In this case, the temperature difference between the coil and the mold was large, and the mold could not be set to the target temperature (80 ° C.). Further, for example, when focusing on 10 seconds from the time when the mold temperature drops to 140 ° C., in FIG. 8A, the mold temperature changes from 140 ° C. to 95 ° C.
In (b), there is a rapid change from 140 ° C to 60 ° C.
This is because even if the temperature of the coil can be set to the optimum temperature when the heating by the small heater 90 is not performed, the coil is kept at the optimum temperature during the coil shaping because the cooling rate is high. It means that you cannot do it.

After the shaping operation is completed, the electric current of the small heater 90 is cut and the mold and the coil are cooled. During this time, wire 5
The nylon fusion-bonding layer is solidified again. When the resolidification of the coil is completed, the servo motor 73 is used to move the shaping piece 79 to the position shown in FIG.
Move to the center right side and take out the coil.

The mold temperature is 20 ° C., 60 ° C., 80
FIG. 9 shows the result of the quality test for each saddle coil in the case where shaping is performed by sequentially setting the temperature to 90 ° C. and 90 ° C. Five saddle type coils to be tested were prepared for each mold temperature. In the quality test, as shown in FIG. 9B, a saddle-type coil to be tested is placed on a surface plate and each measurement point (a,
Reference plane for assembly in b, c) (flat portion 105 described above)
The degree of warp was measured. The measurement result is shown in FIG. In FIG. 9A, the obtained measurement result is
They are classified by mold temperature, and each of them is represented by the standard deviation at each measurement point. The total length of the saddle type coil is 80 mm. The measurement point a is the upper end surface,
The measurement points b and c were set at intervals of 5 mm and 10 mm from here.

As can be seen from FIG. 9A, in the mold temperature range of 20 ° C. to 90 ° C., the higher the value, the smaller the degree of warp of the assembly reference plane.

FIG. 10 shows the measurement results of the magnetic flux density of each saddle coil described above. Here, an electric current was actually passed through each saddle coil, and the magnetic field generated at that time was measured with a probe. The position of the probe with respect to the saddle coil is fixed during measurement.

As a result, the one in which the mold temperature was set to 80 ° C. had the least variation in the magnetic flux density. The variation of the magnetic flux density is represented by the standard deviation as described above.

As described above, according to this embodiment, since the shaping operation can be performed at the optimum temperature at which the strength of the fusion layer of the wire can be increased, the variation of the coil after shaping can be reduced. The deformation of the coil is reduced. The smaller the coil deformation, the smaller the variation in the magnetic flux density distribution. Further, if a homogeneous coil can be obtained from the beginning, the adjustment work of the cathode ray tube can be greatly shortened.

Next, a second embodiment of the present invention will be described.

FIG. 11A shows a stator used in an induction motor or the like. In FIG. 11B, one of the coils forming the stator is extracted and shown. FIG. 12 shows a winding bobbin used when winding the coil. FIG. 13A shows the state of the coil wound in a flat shape on the winding bobbin, and FIG.
3 (b) shows the state of the coil taken out from the winding bobbin. FIG. 14 shows how this coil is shaped into a shape as shown in FIG. 11B by using a convex mold 206 and a concave mold 207. A plurality of small heaters 90 and temperature measuring sensors (not shown) used in the first embodiment are embedded in the convex mold 206 and the concave mold 207. Although not shown in the drawing, each temperature measuring sensor is connected to a temperature detecting device as shown in FIG. 1, and each small heater 90 is temperature controlled by a temperature control device.

The above-mentioned stator is, specifically, the core 200.
And a plurality of stator coils 201, and the core 2
No. 00 has a structure in which each stator coil 201 is inserted into a slot groove. The stator coil 201 is
As shown in FIG. 11 (b), the slot portion 201a has a linear shape, and upper and lower fringe portions 201b connecting the linear portions have a deformed coil shape.

The stator coil 201 can be manufactured by the winding shaping device described in the first embodiment, but in this embodiment, the winding shaping method as described below is used.

First, a wire is wound around the bobbin 205 (see FIG. 12) using a flyer (not shown). The wire rod is the same as that of the first embodiment and has a conductor wire, an insulating layer, and a fusion layer. A state in which the winding is completed is shown in FIG. The flyer used may simply follow a circular orbit. After that, the coil 201 is taken out from the bobbin 205, and the coil 201 is temporarily fixed. Temporarily fixed the coil 2
This is performed by energizing 01 to melt the fusion layer as the outer cover. The coil 201 that has been temporarily fixed is shown in FIG. 13B, and the coil is finished in a flat shape. Hereinafter, this is called a flat coil.

Thereafter, the flat coil 201 is changed to the one shown in FIG.
A shaping force is applied by using the convex mold 206 and the concave mold 207 as shown in FIG. 3 to form the linear portion 201a and the fringe portion 201b on the flat coil 201. At this time, the mold temperature is raised by the same method as in the first embodiment. This can increase the strength of the fusion layer. The shaped coil 201 has a shape suitable for a motor stator coil, as shown in FIG. In this coil, since the bonding strength of the fusion bonding layer is high, the aligned state during winding is maintained even after shaping, and the density of the wire rod is high (see FIG. 15A).

Although a copper wire is used as the conductor of the wire 5, the temperature characteristics of copper are as shown in FIG. The figure shows changes in each of the yield point, tensile strength, reduction, and elongation with respect to temperature changes. Of these, the yield stress (δ
_{The value of y} ) decreases as the temperature increases.

Therefore, the force applied during shaping (shaping force)
When it is attempted to set the value above the yield stress (δ _y ) of the wire material, the shaping force can be reduced by raising the temperature of the die in advance and shaping the coil at a high temperature.
If the coil is shaped by applying a shaping force equal to or higher than the yield stress (δ _y ), the cross-sectional shape of the wire is plastically deformed, and a coil with higher density (see FIG. 15B) can be obtained. At the time of this deformation, the residual stress generated by the tension during winding is also removed. If shaping is performed with a low yield stress,
The springback amount of the coil after shaping is reduced. That is, the dimensional accuracy of the coil is improved, and the coil having the designed value can be obtained.

[0068]

As described above, according to the present invention, the coil can be shaped into the shape as designed.

[0069]

[Brief description of the drawings]

FIG. 1 is a structural diagram of a winding shaping mold according to a first embodiment of the present invention.

FIG. 2 is a perspective view of a saddle type coil manufactured by the winding shaping device according to the first embodiment of the present invention.

3 is a cross-sectional view of a Braun tube equipped with the saddle type coil of FIG.

FIG. 4 is an explanatory view showing a state at the time of shaping the saddle type coil of FIG.

FIG. 5 is a configuration diagram (part 1) of the winding shaping device according to the first embodiment of the present invention.

FIG. 6 is a configuration diagram (part 2) of the winding shaping device according to the first embodiment of the present invention.

FIG. 7 is a graph showing the temperature characteristics of the fusion layer of the wire used in the first and second examples of the present invention.

FIG. 8 is a graph showing a measurement result of a coil temperature when performing coil shaping using the winding shaping device of the first embodiment of the present invention.

FIG. 9 is an explanatory diagram regarding a quality test of a coil manufactured by the winding shaping device according to the first embodiment of the present invention.

FIG. 10 is a graph showing the results of quality tests of coils manufactured by the winding shaping device according to the first example of the present invention.

FIG. 11 is an explanatory diagram of a stator according to a second embodiment of the present invention.

FIG. 12 is a configuration diagram of a coil winding bobbin according to a second embodiment of the present invention.

FIG. 13 is an explanatory view of a coil winding bobbin according to a second embodiment of the present invention.

FIG. 14 is an explanatory view showing a state of coil shaping by the shaping die of the second embodiment of the present invention.

15 is an explanatory diagram showing a cross-sectional state of a coil shaped by the shaping die of FIG.

FIG. 16 is a graph showing the temperature characteristics of copper.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Flyer, 2 ... Convex type, 3 ... Recessed type, 4 ... Mold space, 5 ... Wire rod, 6 ... Through hole, 7a, 7b, 7c,
7d ... Roller, 8a, 8b, 15a, 15b ... Bearing, 9, 71 ... Base, 10 ... Supporting body, 11,
75a, 75b ... Gears, 12 ... Pinion, 13, 3
4, 39, 74 ... Bracket, 14, 35, 40, 7
3 ... Motor, 16 ... Fixed shaft, 20, 24, 26 ... Pin, 21 ... Flyer shaft, 22 ... Spline part, 2
3 ... Hollow shaft, 23a ... Flyer holding part, 25 ... Link, 27 ... Groove cam, 28, 17 ... Cam follower,
18, 29, 30, 62 ... Table, 31, 36 ... Nut, 32, 37, 76 ... Ball screw, 33, 38
... Coupling, 41 ... Coil shaping mechanism, 60, 6
3 ... Block, 61, 70 ... Struts, 64 ... Slider, 72 ... Linear guide, 77 ... Shaping piece holding part,
79 ... Shaping piece, 90 ... Small heater, 91 ... Temperature measurement sensor, 92 ... Temperature detection device, 93 ... Temperature control device, 100 ... Saddle coil, 101 ... Connection part, 10
2, 103 ... Fringe part, 104 ... Funnel part,
105 ... Reference plane, 200 ... Core, 201 ... Stator coil, 201a ... Slot section, 201b ... Fringe section, 205 ... Bobbin, 300 ... Control device

Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical display location H01J 9/236 H01J 9/236

Claims (10)

[Claims] 1. A method of manufacturing a coil using a wire covered with an insulating layer and a wire material including a fusion layer as an outer cover, wherein the temperature of a mold equipped with the coil formed of the wire material is controlled. A method for manufacturing a coil, which comprises heating the conductor wire of the coil to a temperature higher than room temperature to melt the fusion layer to shape the coil into a predetermined shape. 2. The method for manufacturing a coil according to claim 1, wherein, when heating the conductive wire, the temperature of the conductive wire is set to be equal to or lower than a heat resistant temperature of the insulating layer. 3. A method for manufacturing a coil using a wire rod containing a wire, wherein the temperature of a mold in which the coil made of the wire rod is mounted is higher than room temperature, and then the wire of the coil is heated,
A method of manufacturing a coil, which comprises shaping the coil into a predetermined shape. 4. A method of manufacturing a coil using a wire covered with an insulating layer and a wire including a fusion layer as an outer cover, wherein the temperature of a mold equipped with the coil formed of the wire is adjusted. A method for manufacturing a coil, which comprises heating the conductor wire of the coil to a temperature higher than room temperature to melt the fusion layer, and solidifying the fusion layer, and then taking out the coil from the mold. 5. The coil manufacturing method according to claim 1, 2, 3 or 4, wherein the mold is a mold used when winding the wire. 6. The coil according to claim 1, 2, 3 or 4, wherein the coil made of the wire is manufactured by winding the wire on a die for winding different from the die. A method of manufacturing a coil, characterized in that 7. The method for manufacturing a coil according to claim 1, 2, 3, 4, 5 or 6, wherein the wire is wound around a mold set at a temperature lower than room temperature. 8. The method for manufacturing a coil according to claim 1, wherein heating of the conductive wire is performed by passing an electric current through the conductive wire. 9. An apparatus for manufacturing a coil using a wire covered with an insulating layer and a wire material including a fusion-bonding layer as an outer cover, having a gap for forming the coil, and extending along the gap. A die around which the wire is wound, a heater for heating the die, a measuring instrument for measuring the temperature of the die, and adjusting the heater based on the measurement result of the measuring instrument. Then, a control device that sets the temperature of the mold to a predetermined value, a power supply for supplying an electric current to the conducting wire of the coil, and the temperature of the mold on which the coil is mounted are predetermined by the control device. A coil winding device, comprising: a shaping mechanism that starts shaping the coil when the energization of the coil ends after being set to a value. 10. The coil winding device according to claim 9, wherein the shaping mechanism presses a reference surface serving as an assembly reference of the coil to shape the coil.