JPH097872A - Coil manufacturing method and device - Google Patents

Abstract

PURPOSE: To provide a coil manufacturing method and a device which make it possible to wind a thick conductor low in electrical resistance densely into a coil and to enhance in tension when it is wound so as to improve the coil in conductor space factor. CONSTITUTION: A first side plate and a second side plate possessed of a projection 26 are arranged confronting each other, and an insulating member 14 is twined around the projection 26. A conductor is wound on the insulating member 14, adhesive agent of thermoplastic resin is applied onto the conductor, an electrode 18 is connected to the conductor, and an electric current is made to flow through the conductor to make it release heat, whereby the adhesive agent is melted to penetrate into the coiled conductor. Compressed air is blown against the conductor through compressed air nozzles 20a and 20b to cool down it to harden the adhesive agent. The first side plate is dismounted from the projection 26, and the coiled conductor is taken off, whereby a coil can be obtained.

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 used in an electric motor and the like, and more particularly, to a coil jig having a plate-shaped insulating member wound around it. The present invention relates to a coil manufacturing method and apparatus for winding a conductor wire, fixing the coil by laminating and solidifying the wound conductor wire with an adhesive.

[0002]

2. Description of the Related Art Conventionally, coils used for electric motors are
It is manufactured by winding a conductor wire around a bobbin formed of a material such as a synthetic resin, and laminating and solidifying the wound conductor wire with an adhesive. This coil is mounted on an iron core of an electric motor or the like together with the bobbin.

In this case, since the magnetic force generated in the coil can be efficiently transmitted to the iron core if the gap between the coil and the iron core is narrowed, the bobbin is generally thin.

[0004]

However, in the above-described conventional coil manufacturing method, when a thickly formed conductive wire is wound around the bobbin in order to reduce electric resistance, a large tension must be applied to the conductive wire. Since the bobbin may be damaged if the bobbin is thin as described above, the thin conductive wire was wound as much as possible. However, it is clear that a thin conductor has a large electric resistance.

Even in the case of winding such a thin conductor, if the conductor is densely wound in order to improve the space factor of the conductor of the coil, that is, to increase the number of windings. Since it is necessary to increase the tension applied to the conductive wire when winding, there is a concern that the thin bobbin may be damaged as described above, and it is difficult to improve the space factor, which is the intended purpose. there were.

The present invention has been made to solve the above-mentioned problems, and a thick conductive wire can be wound around it.
An object of the present invention is to provide a method for manufacturing a coil and an apparatus for the same, which can increase the tension at the time of winding the conductive wire and improve the space occupied by the conductive wire of the coil.

[0007]

In order to achieve the above-mentioned object, a method of manufacturing a coil according to the present invention comprises a first side plate and a second side plate having an inwardly projecting protrusion. Facing each other; winding an insulating member around the protruding portion; winding a conductive wire around the insulating member while being regulated by the first and second side plates; and supplying an adhesive to the conductive wire. And a step of stacking and solidifying the conductive wire wound with the adhesive.

In this case, the adhesive is made of a thermoplastic resin, and in the step of laminating and solidifying the conductive wire, an electric current is passed through the wound conductive wire to heat the conductive wire, and the adhesive made of the thermoplastic resin is melted. It is preferable that this is a step of permeating the wound conductive wire.

Further, in this case, it is preferable to have a step of melting the adhesive layer made of a thermoplastic resin and then forcibly cooling the adhesive layer.

Further, in this case, it is preferable that a part of the insulating coating of the conductive wire is peeled off by a pair of electrodes before the conductive wire is heated to allow the adhesive made of a thermoplastic resin to penetrate into the conductive wire.

Further, the present invention is a coil manufacturing apparatus, wherein a first side plate, a second side plate having a protrusion projecting inward, and a plate-shaped insulating member mounted on the protrusion are provided. A member, and a hook portion for locking an end portion of a conductive wire wound around the insulating member is formed on either or both of the first side plate and the second side plate. To do.

In this case, the manufacturing apparatus further applies a coating means for applying an adhesive made of a thermoplastic resin to the conductive wire wound around the winding jig, and applies a current to the conductive wire to heat the conductive wire. And an electrode, and the electrode preferably has a peeling means for peeling the insulating coating.

[0013]

According to the present invention, the first side plate and the second side plate are arranged so as to face each other, and the insulating member is wound around the protrusion of the second side plate. When the conductive wire is wound around the insulating member, the side portion of the conductive wire wound by the first side plate and the second side plate is restricted. An adhesive made of a thermoplastic resin is applied to the wound conductive wire. After the winding process, the insulating coating on the end of the conductor is peeled off by the peeling means provided on the electrode, and when a power source is connected to the end of the conductor and a current is applied, the conductor heats up and the adhesive melts. Then
Penetrates between the wound conductors. When the wound conductor wire is cooled, the adhesive is solidified, the wound conductor wires are laminated and solidified, and the insulating member is fixed to the inner circumference of the wound conductor wire. A coil is obtained by removing the conducting wire wound from the protrusion.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A coil manufacturing method according to the present invention will be described in detail below with reference to the accompanying drawings, with reference to preferred embodiments in relation to an apparatus for carrying out the method.

In FIG. 1, reference numeral 10 indicates a coil manufacturing apparatus according to this embodiment. This manufacturing apparatus 10 is
Basically, the winding jig 12, the insulating member 14 mounted on the winding jig 12, and the winding jig 12 are provided so as to be close to and away from the winding jig 12, and an adhesive made of a thermoplastic resin is applied. Nozzle 16 for adhesives, an electrode 18 that energizes a wound conductor wire to generate heat, and nozzles 20a and 20b for compressed air that cool the heated conductor wire.

The winding jig 12 is made of a metallic material, and as shown in FIGS. 2a to 2d, a first side plate 24 defining a rectangular hole 22 and an inward projection. And a second side plate 28 having a protrusion 26. The first side plate 24 and the second side plate 28 are provided with inclined portions 30a and 30b, respectively, which are partially bent, so that the first side plate 24 and the second side plate 2 are provided.
One end side of 8 is formed to be gradually thin, and hook portions 32a and 32b with which the end portions of the conductive wires engage are formed near the end portions of the inclined portions 30a and 30b. The width W ₁ and the height H ₁ of the end portion 34 of the protrusion 26 are the width W _{2 of} the hole portion 22,
The size is the same as the height H ₂ or slightly smaller.
A winding portion 38 is formed via a step portion 36 directed from the end portion 34 toward the main body side of the second side plate 28. As is clear from the figure, the winding portion 38 is formed so as to be larger in width and height than the protrusion portion 26. In this case, the end portion 34 is inserted into the hole portion 22 of the first side plate 24. Then, the hole 2
The edge portion of the first side plate 2 engages with the step portion 36.
4 is detachably attached to the protrusion 26 (see FIG. 3).
The protrusion 26 is mounted on a jig (not shown) connected to the rotary drive source, and when the rotary drive source is biased, the protrusion 2
The winding jig 12 is configured to rotate as a whole around the center 6.

The insulating member 14 is a substantially rectangular plate-like body in which a thermoplastic resin film 42 and a PET film 44 are bonded together (see FIG. 4a). A protrusion 46 is formed at one end of the insulating member 14, and a hole 48 is formed at the other end for inserting the protrusion 46 (see FIG. 4B). Folding lines 50a and 50b are provided in parallel with the longitudinal direction of the insulating member 14, and the folding line 5 is further provided.
Folding curves 52a to 52c are provided at right angles to 0a and 50b. At this time, the space between the folding line 50a and the folding line 50b is formed to have the same size as the space between the first side plate 24 and the second side plate 28 of the winding jig 12. Further, along the folding lines 52a to 52c, the folding line 50a extends from the longitudinal edge of the insulating member 14,
The cut portions 54a to 54f are cut out by cutting up to the intersections of 50b and the folding curves 52a to 52c.

In the insulating member 14 thus formed,
The folding curves 52a to 52c are bent so that the surface of the thermoplastic resin film 42 is on the outside, and the protrusion 46 is inserted into the hole 48 (see FIG. 4c). Furthermore, the curve 5
0a and 50b are bent at right angles so that the surface of the thermoplastic resin film 42 faces inward, and the flange portions 56a and 56b.
Is formed.

The adhesive nozzle 16 is connected to an adhesive supply source (not shown) and can approach and separate from the winding jig 12. Further, the adhesive nozzle 16 extends in the longitudinal direction of the protrusion 26 of the winding jig 12. It is configured to be movable (see FIG. 1).

On the other hand, bent metal plates 60a and 60b are arranged on the electrode 18 with a predetermined gap therebetween, and a plate-shaped insulating plate 62 is sandwiched between the metal plates 60a and 60b (see FIG. 5a), electrical insulation between the metal plate 60a and the metal plate 60b is achieved. The metal plate 60a,
A power supply device (not shown) is connected to 60b. A blade portion 6 formed in a V shape at the tips of the metal plates 60a and 60b.
4a and 64b are provided (see FIGS. 5b and 5c).

The compressed air nozzles 20a and 20b are arranged so as to be able to approach and separate from the winding jig 12, and communicate with a compressed air supply source (not shown) (see FIG. 1).

The coil manufacturing apparatus 10 according to this embodiment is basically constructed as described above, and its operation will be described below in connection with the manufacturing method according to this embodiment.

First, when the end 34 of the protrusion 26 of the second side plate 28 is inserted into the hole 22 of the first side plate 24, the hole 2
The first side plate 24 is attached to the edge portion of the second side plate 24 by engaging the step portion 36, and the first side plate 24 and the second side plate 28 are arranged so as to be separated from each other by a predetermined distance and face each other (FIGS. 2d,
(See FIG. 3).

Next, the insulating member 14 is bent to surround the winding portion 38 of the protrusion 26, and the protruding portion 4 of the insulating member 14 is surrounded.
6 into the hole 48 to attach the insulating member 14 to the winding jig 1.
Wind around 2. In this case, the bending line 50a and the bending line 50b
Since the distance between the first side plate 24 and the second side plate 28 is substantially the same as the distance between the first side plate 24 and the second side plate 28, the flange portions 56a and 56b of the insulating member 14 contact the first side plate 24 and the second side plate 28. Become.

Next, one end of the conductive wire 70 is attached to the winding jig 1 described above.
2 is engaged with the hook portion 32b of the second side plate 28 (see FIG. 6).
reference). When the protrusion 26 is rotated by urging a rotating device (not shown), the winding jig 12 rotates in the direction of arrow A, and the conductor 7 is attached to the insulating member 14 wound around the protrusion 26.
0 is wound. At this time, since the winding jig 12 is made of a metallic material, the tension applied to the conductor wire 70 can be increased. Further, since the winding of the conductive wire 70 is restricted by the first side plate 24 and the second side plate 28, the conductive wire 70 is wound and laminated inside the flange portions 56a and 56b of the insulating member 14.

After the winding jig 12 has rotated a predetermined number of times, the rotating device is stopped and the other end of the conducting wire 70 is hooked with the hook portion 32.
a and the other end side of the conducting wire 70 is connected to the hook portion 3
Cut so as to project slightly outward from 2a (see FIG. 7).

Next, the adhesive nozzle 16 is attached to the winding jig 1.
2 and the rotating device (not shown) is operated to bring the tip of the adhesive nozzle 16 close to the corner portion of the wound conducting wire 70 (see FIG. 8). Adhesive nozzle 1
While moving 6 in the longitudinal direction of the protrusion 26, an adhesive supply source (not shown) is urged to apply a thermoplastic resin in the width direction of the wound conductor wire 70, preferably at the four corners of the protrusion 26. Apply an adhesive consisting of.

Next, the hook portions 32a, 3 of the winding jig 12
A rotating device (not shown) is slightly actuated so that 2b faces the electrode 18 to bring the electrode 18 close to the winding jig 12 (see FIG. 9).
reference). Then, the blade portions 64a and 64b of the electrode 18 are attached to both ends of the conducting wire 70 protruding outward from the hook portions 32a and 32b.
Are engaged with each other, and the insulating coating 71 of the conducting wire 70 causes the blade portions 64a, 6
4b, the metal plates 60a, 60b and the conductor 70 are separated.
And are in an electrically conductive state (see FIGS. 5b and 5c).

Then, when a power supply device (not shown) connected to the electrode 18 is energized, a current is passed through the wound conducting wire 70 and the conducting wire 70 generates heat. Due to this heat, the adhesive made of the thermoplastic resin is melted and penetrates into the gaps between the wound conductor wires 70. At the same time, the thermoplastic resin film 42 of the insulating member 14 is melted and the insulating member 14 and the wound conducting wire 70 are bonded. At this time, since the wound conductor wire 70 and the winding jig 12 are separated by the insulating member 14, the concern that the conductor wire 70 and the winding jig 12 are bonded to each other is eliminated.

The power supply is stopped and the compressed air nozzle 20
When a and 20b are brought close to the winding jig 12 and a compressed air supply source (not shown) is energized, compressed air is discharged to the heated conductor wire 70, the conductor wire 70 is cooled and the adhesive made of a thermoplastic resin is solidified. (See FIG. 10). Therefore, the wound conducting wire 70 is fixed by the adhesive.

The first side plate 24 is connected to the protrusion 26 of the second side plate 28.
When the conductor wire 70 wound around the insulating member 14 is taken out, the coil 72 is obtained (see FIG. 11).

The coil 72 manufactured in this way is
It is attached to an iron core 74 such as an electric motor (see FIG. 12). At this time, the iron core 74 comes into contact with the PET film 44, and the iron core 7
4 can be easily and smoothly inserted into the coil 72. Further, since the conductive wire 70 and the iron core 74 are separated by the insulating member 14, the insulating coating 71 of the conductive wire 70 is prevented from being damaged and the conductor being exposed when the iron core 74 is inserted into the coil 72.

In this embodiment, the first side plate 24 is mounted on the protruding portion 26 of the second side plate 28 and then the insulating member 14 is wound around the winding portion 38 of the protruding portion 26. However, as shown in FIG. ,
The insulating member 14 is bent and the winding portion 3 of the second side plate 28 is bent.
The first side plate 24 may be engaged with the protruding portion 26 after being mounted on the vehicle 8.

[0034]

The coil manufacturing method and apparatus according to the present invention have the following effects and advantages.

Since the conductor wire is wound around the winding jig formed of a relatively hard material such as metal, the conductor wire can be wound with a high tension. At this time, it is possible to form a coil by using a thick conductor having a low electric resistance or to improve the space factor of the conductor of the coil. Also, when the coil is mounted on the iron core, the inner circumference of the coil is covered with an insulating member and further solidified with a thermoplastic resin, so it can be easily inserted into the iron core, and when the coil is inserted, it is damaged by the iron core and the conductor is insulated. There is no concern that the coating will peel off.

[Brief description of drawings]

FIG. 1 is a perspective view showing a manufacturing apparatus according to an embodiment of the present invention.

FIG. 2a shows a first part of the manufacturing apparatus shown in FIG.
Side view of the side plate, FIG. 2b is a side view of the second side plate constituting the manufacturing apparatus, FIG. 2c is a plan view of the second side plate constituting the manufacturing apparatus, FIG. 2d is a side view of the second side plate constituting the manufacturing apparatus. It is a front view.

FIG. 3 is a plan view of a winding jig that constitutes a manufacturing apparatus.

FIG. 4a is a sectional view of an insulating member constituting the manufacturing apparatus, FIG. 4b is a plan view of an insulating member constituting the manufacturing apparatus,
FIG. 4c is a perspective view showing a method of using the insulating member constituting the manufacturing apparatus.

FIG. 5a is a perspective view of electrodes constituting a manufacturing apparatus,
FIG. 5b is a side view of the metal plate forming the electrode, and FIG.
It is sectional drawing of the metal plate which comprises an electrode.

FIG. 6 is a partial perspective view showing a method of using the manufacturing apparatus.

FIG. 7 is a partial perspective view showing how to use the manufacturing apparatus.

FIG. 8 is a partial perspective view showing a method of using the manufacturing apparatus.

FIG. 9 is a partial perspective view showing how to use the manufacturing apparatus.

FIG. 10 is a partial perspective view showing a method of using the manufacturing apparatus.

FIG. 11 is a perspective view showing a coil manufactured by a manufacturing method according to an embodiment of the present invention.

12 is a perspective view showing how to use the coil shown in FIG. 11. FIG.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10 ... Manufacturing apparatus 12 ... Winding jig 14 ... Insulation member 16 ... Adhesive nozzle 18 ... Electrodes 20a, 20b ... Compressed air nozzles 24, 28 ... Side plate 26 ... Protrusions 32a, 32b ... Hooks 64a, 64b ... Blade 70 ... Conductor 72 ... Coil

Claims (6)

[Claims] 1. A step of arranging a first side plate and a second side plate having a protrusion protruding inwardly in opposition to each other; a step of winding an insulating member around the protrusion; And a step of winding a conductive wire around the insulating member while being regulated by the second side plate, and a step of supplying an adhesive to the conductive wire and stacking and solidifying the conductive wire wound by the adhesive. Characteristic coil manufacturing method. 2. The coil manufacturing method according to claim 1, wherein the adhesive is made of a thermoplastic resin, and the step of laminating and solidifying the conductive wire is carried out by applying an electric current to the wound conductive wire. A method of manufacturing a coil, comprising a step of causing heat to be generated, melting an adhesive made of the thermoplastic resin, and permeating the adhesive into the wound conductive wire. 3. The coil manufacturing method according to claim 2, further comprising the step of forcibly cooling the adhesive layer after melting the adhesive layer made of a thermoplastic resin. Production method. 4. The method of manufacturing a coil according to claim 2, wherein the conductor is insulated by a set of electrodes before the step of causing the conductor to generate heat to penetrate the adhesive made of a thermoplastic resin into the conductor. A method for manufacturing a coil, which comprises peeling off a part of a coating film. 5. A coil manufacturing apparatus, comprising: a first side plate, a second side plate having a protrusion protruding inward, and a plate-shaped insulating member attached to the protrusion. Then, one of the first side plate and the second side plate,
Alternatively, a coil manufacturing device is characterized in that hook parts for locking the ends of the conductive wire wound around the insulating member are formed on both sides. 6. The coil manufacturing apparatus according to claim 5, wherein the manufacturing apparatus further comprises a coating means for coating an adhesive made of a thermoplastic resin on the conductive wire wound around the winding jig, and the conductive wire. A coil manufacturing apparatus, comprising: an electrode for supplying a current to the electrode to heat the conductive wire; and the electrode having a peeling means for peeling the insulating coating.