JPH10284336A - Manufacture of multi-winding coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable continuous winding operation, by forwarding a tape supply section in a coiling forward direction of a coil conductor and properly repeating inversion in the axial direction to form an insulating layer of a predetermined insulation thickness on the inner side of the coil conductor. SOLUTION: A conductor supply section is reciprocated between one end a and the other end b in the axial direction synchronously with rotation of a coil former 1, thus continuously coiling a coil conductor 2 on an outer peripheral portion of the coil former 1 by each layer sequentially from the inner layer. At the same time as coiling of the n-th layer of the coil conductor 2, a tape supply section is moved in a movement pattern for forwarding in a coiling forward direction of the coil conductor 2 and properly repeating inversion in the axial direction, while the winding start position is made the same as the coil conductor 2. Then, a tape-like insulating material 4 is wound on the inner side of the n-th layer of the coil conductor 2, thus forming an insulating layer 3 having a predetermined thickness.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a multi-turn coil which is used for, for example, a transformer, a reactor and the like, and is formed by winding a coil conductor in a multilayer structure with an insulating layer interposed between layers in a cylindrical winding form. A method for producing the same.

[0002]

A multi-turn coil in which a coil conductor is wound in multiple layers with an insulating layer interposed between layers in a cylindrical winding form, the winding operation of the coil conductor is relatively easy. In recent years, transformers have been adopted for large-capacity transformers for electric power and the like. In this type of multi-turn coil, there is a situation where the potential between the layers becomes high, and in order to prevent a short circuit between the layers, it is necessary to form an insulating layer of a required thickness with a large amount of insulator interposed between the layers.

[0003] As a method of forming such an insulating layer,
Conventionally, there has been a method of wrapping a wide sheet-shaped insulator so as to be wound, and a method of winding a tape-shaped insulator in a spiral shape (so-called gaiter shape) while partially wrapping the insulator.
Among them, the former method using a sheet-shaped insulator has a disadvantage that the larger the coil, the larger the sheet-shaped insulator, which makes the winding operation by an operator difficult and makes automation difficult. Further, it was impossible to freely change the insulation thickness depending on the location.

On the other hand, in the latter method using a tape-shaped insulator, for example, Japanese Patent Publication No.
As shown in JP-A-6-34085, a certain degree of automation of the winding operation of the tape-shaped insulator, that is, the operation of forming the insulating layer can be achieved. Also, as shown in Japanese Patent Application Laid-Open No. 2-47817, which is also filed by the present applicant, it is possible to freely change the insulation thickness depending on the location.

However, in the prior art using the tape-like insulator as described above, after winding a coil conductor for one layer, the coil conductor is once cut off, and the tape-like insulator is wound around the outer periphery of the layer. The operation of turning and rejoining the separated coil conductors is repeated, and a cumbersome operation of separating and joining the coil conductors for each winding operation must be performed. There was room for further improvement. Accordingly, if the winding operation can be continuously performed without cutting the coil conductors one by one while using the tape-shaped insulator for forming the insulating layer, the workability can be greatly improved. is there.

Japanese Patent Publication No. 59-31969 filed by the applicant of the present invention discloses a technique in which a tape-shaped insulator is used to integrally form an insulator at the end of the coil. ing. However, in this technique, in order to form an end insulator corresponding to the type of the coil (thickness, width, coil length, number of turns of the coil conductor), the type of the coil (the size of the end insulator) is required. Etc.), the width and thickness of the tape-shaped insulator must be changed for each coil, and when manufacturing coils of various sizes, there is a problem that various types of tape-shaped insulators that are suitable for each are required. Was.

The present invention has been made in view of the above circumstances, and has as its object to perform continuous winding work without separating and joining coil conductors while using a tape-shaped insulator for forming an insulating layer. It is an object of the present invention to provide a method for manufacturing a multi-turn coil which can be performed.

[0008]

According to a first aspect of the present invention, there is provided a method for manufacturing a multi-turn coil, comprising winding a coil conductor in multiple layers on a cylindrical winding form with an insulating layer interposed between layers. A method for manufacturing a multi-turn coil, comprising: a rotation driving means for rotating the former in one direction; and a movable side between the one end and the other end in the axial direction on the side of the former. A conductor supply unit for sequentially supplying a long coil conductor to the winding form, and a part between the one end side and the other end side in the axial direction on the side of the winding form independently of the conductor supply unit. A tape supply unit that is movable and sequentially supplies a long tape-shaped insulator to the winding form, and the conductor supply unit is disposed between one end and the other end in the axial direction of the winding form. By rotating the former while reciprocating, the coil conductor is continuously layered on the outer periphery of the former one by one. Simultaneously with the winding of the n-th layer of the coil conductor, while setting the winding start position on one end side or the other end side in the axial direction to be the same as that of the coil conductor, and changing the tape supply section to the coil of the conductor supply section. The coil winding conductor is moved forward in the winding direction of the conductor, and the inversion is repeated in the axial direction as appropriate.
The present invention is characterized in that an insulating layer having a predetermined insulating thickness in which the winding thickness of the tape-shaped insulator changes in the axial direction is formed on the inner peripheral side of the layer.

According to this, the tape-shaped insulator supplied from the tape supply unit and the coil conductor supplied from the conductor supply unit are provided on the outer periphery of the winding form with the tape-shaped insulator on the inner periphery. It is wound so as to be overlapped and wound at the same time. At this time, the tape supply unit is arranged to repeat the inversion in the axial direction as appropriate in front of the winding progression direction of the coil conductor so that the tape-shaped insulator does not interfere with the winding of the coil conductor. It is possible to freely change the insulating thickness of the insulating layer formed by the tape-shaped insulator within the number of turns of one conductor, depending on the axial position.

[0010] Therefore, after one layer winding operation is completed, it is possible to proceed to the next layer winding operation without cutting the coil conductor. At this time, the size of the tape-shaped insulator used for the coil size is not strictly limited, and one kind of tape-shaped insulator is commonly used for many types of coils. And versatility can be improved.

According to a second aspect of the present invention, there is provided a method of manufacturing a multi-turn coil, comprising: a conductor supply section and a plurality of tape supply sections; While the winding start position at one end or the other end in the axial direction is the same as that of the coil conductor, the plurality of tape supply units are appropriately inverted in the axial direction in front of the winding direction of the coil conductor in the conductor supply unit. The feature is that an insulating layer having a predetermined insulating thickness in which the winding thickness of the tape-shaped insulator changes in the axial direction is formed on the inner peripheral side of the n-th layer of the coil conductor by being repeated. Have.

[0012] According to this, a plurality of tape-shaped insulators and coil conductors can be wound on the outer peripheral portion of the former so that the tape-shaped insulators are located on the inner peripheral side so as to be simultaneously overlapped and wound. . Further, similarly to the first aspect of the present invention, the insulating thickness of the insulating layer formed by the tape-shaped insulator can be freely changed depending on the position in the axial direction. An insulating layer having a larger thickness can be formed by the object. Furthermore, after the one-layer winding operation is completed, it is possible to proceed to the next-layer winding operation without cutting the coil conductor.

In this case, the respective tape-shaped insulators in the plurality of tape supply portions may be different in thickness, width and the like from each other (the invention of claim 3). Thereby, the insulating thickness of the insulating layer formed by the tape-shaped insulator can be more precisely adjusted, and the optimum insulating thickness can be obtained.

According to a fourth aspect of the present invention, in the method for manufacturing a multi-turn coil, the conductor is rotated while the conductor supplying portion is reciprocated between one end and the other end in the axial direction of the coil.
The coil conductor is continuously wound one layer at a time around the outer periphery of the former, and the tape supply unit is wound around the coil conductor of the conductor supply unit during the winding of the (n-1) th layer of the coil conductor. The first insulating layer is formed on the outer peripheral side of the (n-1) th layer of the coil conductor by appropriately repeating the inversion in the axial direction with a delay in the backward direction, and after the tape-shaped insulator is once cut off, When winding the n-th layer of the coil conductor, the tape supply portion is wound in the same direction as the coil conductor of the conductor supply portion while the winding start position at one end or the other end in the axial direction is the same as that of the coil conductor. The second insulating layer is formed on the inner peripheral side of the n-th layer of the coil conductor by leading in front and repeating the inversion in the axial direction as appropriate, and the n-th layer of the coil conductor is formed from the first insulating layer and the second insulating layer. The insulation layer of the specified insulation thickness on the inner peripheral side of the layer Characterized in was to be formed.

According to this, on the inner peripheral side of the n-th layer of the coil conductor, a tape-shaped insulator wound around the outer peripheral portion when the (n-1) -th layer of the coil conductor is wound up. An insulating layer is formed from the one insulating layer and the second insulating layer made of a tape-like insulator wound on the inner peripheral side when the n-th layer of the coil conductor is wound. At this time, the first insulating layer is formed on the front side in the winding progress direction of the n-th layer of the coil conductor, and the second insulating layer is also formed on the front side in the winding progress direction of the n-th layer of the coil conductor. Therefore, the tape-shaped insulator can be wound without interfering with the winding of the coil conductor, and the insulating thickness of the insulating layer formed by the tape-shaped insulator can be freely changed depending on the axial position. It becomes possible. In this case, also on the winding start side of the n-th layer, the first
By forming the insulating layer, a sufficiently thick insulating layer can be formed. Then, since the tape-shaped insulator is once separated, the number of windings for one insulating layer of the tape-shaped insulator can be freely adjusted with respect to the number of windings for one coil conductor. The limitation on the size of the tape-shaped insulator can be eased.

Further, in the above-described method for manufacturing each of the multiple winding coils, the tape supply unit may be configured to supply a plurality of tape-shaped insulators simultaneously (the invention of claim 5). In addition, the thickness of the insulating layer that can be formed with the same number of turns can be further increased. Furthermore, it is also possible to adopt a configuration in which the tape-shaped insulator is bent in accordance with the winding angle of the tape-shaped insulator and turned upside down when the tape supply section is inverted (the invention of claim 6). According to this, it is possible to prevent wrinkles from being generated in a portion where the tape-shaped insulator is inverted.

[0017]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Some embodiments of the present invention will be described below with reference to the drawings. (1) First and Second Embodiments First, a first embodiment (corresponding to claim 1) of the present invention will be described with reference to FIGS.

First, although not shown as a whole, the configuration of the multi-turn coil according to the present embodiment will be briefly described. This multi-turn coil is formed by winding a coil conductor 2 in a multilayer (only two layers are shown in FIG. 1 (e)) around an outer peripheral portion of a former 1 which is formed in a cylindrical shape from an insulator. .
The coil conductor 2 has, for example, a rectangular cross-section, and each layer coil is formed by placing the coil conductor 2 in a region between one end side a and the other end b in the axial direction of the outer periphery of the former 1 (see FIG. 1). Then, it is configured by tightly winding one by one in an aligned state. Then, as shown only in FIG. 1E, an insulating layer 3 is provided between each layer of the coil conductor 2.

The insulating layer 3 is formed by winding a tape-shaped insulator 4 around the outer periphery of the coil conductor 2 layer, as described later, so that the insulating layer 3 is insulated at a portion where the interlayer potential gradient is high. It is formed so that the thickness changes in the axial direction so that the thickness increases. In the present embodiment, as shown in FIG. 1, the width of the tape-shaped insulator 4 is
5 to 6 times (for example, several tens of mm). Further, a ring-shaped end insulator 5 (only a part is shown in FIG. 1) is provided at both ends in the axial direction of each layer coil of the coil conductor 2. Further, although not shown, the multi-turn coil is entirely molded with a resin to form a molded coil, and in this state, it is assembled to, for example, an iron core of a transformer.

Next, although not shown in detail, the schematic configuration of an apparatus (coil winding apparatus) for performing the manufacturing method according to the present embodiment for manufacturing the above-described multi-turn coil will be briefly described. . This coil winding device is roughly divided into a winding mechanism for performing a winding operation on the former 1, a conductor supply unit for supplying the coil conductor 2 to the former 1, and a former 1 A tape supply unit for supplying the tape-shaped insulator 4 to the control unit, and a control unit including a microcomputer for controlling the whole are provided.

The winding mechanism comprises a spindle on which the former 1 is set in a fixed state, and a motor for rotating this spindle and thus the former 1 in one direction in the direction of arrow A about the axis c shown in FIG. And a rotation drive mechanism as a rotation drive means. A conductor accommodating section provided on a side of the winding mechanism section (winding form 1), a drum accommodating section in which a drum around which a long coil conductor 2 is wound is rotatably set; And a guide for guiding the coil conductor 2 fed from the drum toward the outer peripheral portion of the former 1. The conductor linear moving mechanism is arranged along the axis c (in the directions indicated by arrows B and C in the figure). ) Can be freely moved.

The tape supply section is provided on a side of the winding mechanism section (winding form 1), for example, at a position above the conductor supply section so as not to interfere, and is a long tape-shaped insulator. And a guide 6 for guiding the tape-shaped insulating material 4 fed from the drum toward the outer peripheral portion of the former 1.
(See FIG. 2) so that the tape can be freely moved in a direction along the axis c (directions of arrows B and C in the figure) independently of the conductor supply section by a tape linear movement mechanism. Has become.

The control unit is configured to execute the rotation drive mechanism, the conductor linear movement mechanism, and the tape linear movement based on a control program (movement pattern of the tape supply unit) stored in advance and a switch operation of an operator. By controlling the mechanism and the like, the operation of winding the coil conductor 2 on the former 1 and the operation of winding the tape-shaped insulator 4 (the operation of forming the insulating layer 3) are performed.

At this time, as will be described in detail later, the control unit moves the conductor supply unit between the one end side a and the other end side b in the axial direction in synchronization with the rotation of the former 1 by the rotation driving mechanism. By reciprocating in the directions B and C, the coil conductors 2 are successively wound around the outer periphery of the former 2 one by one from the inner layer. At the same time with the winding of the n-th layer of the coil conductor 2, the tape supply unit is moved ahead of the coil conductor 2 in the winding traveling direction, and the winding start position is the same as that of the coil conductor 2. By moving the coil conductor 2 in a predetermined movement pattern that repeats reversal in the axial direction, the inner circumference side of the n-th layer ((n-
1) A tape-shaped insulator 4 is wound around an outer peripheral side of the layer to form an insulating layer 3 having a predetermined insulating thickness.

Now, a procedure for performing a coil winding operation by the above-described coil winding apparatus will be described. FIG. 1 (a)-
(E) shows a state in which the winding operation of the second layer coil 8 proceeds after the winding operation of the first layer coil 7 by the coil conductor 2 ends. FIG. 1F schematically shows a movement pattern P of the tape supply unit at that time. FIG. 2 shows a state in which the winding of the second layer coil 8 is started after the winding operation of the first layer coil 7 by the coil conductor 2 is finished.

Here, first, when forming the first layer coil 7, the winding form 1 is set on the spindle of the winding mechanism section, and as shown in FIG. An end insulator 5 is fixed to the side a). Then, the tip side portion of the coil conductor 2 drawn out from the conductor supply portion is fixed (temporarily fixed) so as to be in close contact with the inside of the end portion insulator 5,
From this state, the former 1 is rotated in the direction of arrow A, and the conductor supply part is synchronously moved from one end a to the other end b.
In the direction of arrow B. As a result, the coil conductor 2 is tightly wound in an aligned state on the outer peripheral surface of the former 1 so as to be wound, and the conductor supply portion reaches the other end b and has a predetermined number of turns (for example, 30 turns). Then, winding is stopped. By attaching the end insulator 5 on the other end b, the first layer coil 7 of the coil conductor 2 is formed.

Next, the process proceeds to the formation of the second-layer coil 8. Here, first, the second-layer end insulator 5 on the other end b is attached, and FIG. 1 (a) and FIG. As shown in the figure, a tape-shaped insulator pulled out from the tape supply unit is provided on the outer peripheral portion of the winding end position of the first layer coil 7 (the inner peripheral portion of the coil conductor 2 at the winding start position of the second layer coil 8). 4
Fix the tip of. Then, in this state, the winding form 1 is rotated in the direction of arrow A, and in synchronization with this, the conductor supply unit is moved in the direction of arrow C from the other end b to the one end a in synchronization with the tape supply unit. Is moved in a predetermined movement pattern P.

In this embodiment, as shown in FIG.
This movement pattern P is obtained by first setting the tape supply unit to the other end b
To one end side a in the direction of arrow C, and once it reaches one end side a, it is temporarily stopped and then turned in the direction of arrow B, and again in the axial middle part (position d) in the direction of arrow C again. When it reaches one end a, it is reversed again in the direction of arrow B, and when it has advanced a little (position e), it is reversed in the direction of arrow C and proceeds to one end a.
In addition, the moving speed of the tape supply unit at this time is set to a speed at which the winding position is shifted by half a pitch in the axial direction for each rotation of the winding die 2 (ie, the winding position is overlapped by half the width). Has become. Furthermore, the tape-shaped insulator 4 is cut when it reaches a predetermined number of turns (the number of turns of the coil conductor 2 or less).

Thus, as shown in FIGS. 1A to 1E, the outer peripheral portion of the former 1 (the outer peripheral surface of the first layer coil 7).
Then, the tape-shaped insulator 4 and the coil conductor 2 are simultaneously overlapped and wound with the tape-shaped insulator 4 on the inner peripheral side, so that the formation of the insulating layer 3 and the formation of the second layer coil 8 are performed once. Will be performed. At this time, the tape-like insulator 4 interferes with the winding of the coil conductor 2 by appropriately repeating the inversion in the axial direction ahead of the winding traveling direction of the coil conductor 2 (direction of arrow C). The insulating layer 3 having a predetermined insulation thickness is thinner at the other end b, which is the winding start side, and is thicker toward the one end a having a higher interlayer potential gradient.
Is formed.

When the winding operation of the coil conductor 2 is completed and the second layer coil 8 is formed, the end insulator 5 on one end side a is attached, and the process proceeds to the next third layer. In the third tier,
At the same time as attaching the third layer end insulator 5 on one end side a, the tape supply unit attaches to the outer peripheral portion at the winding end position of the second layer coil 8 (the inner peripheral portion at the winding start position of the third layer). The leading end of the tape-shaped insulator 4 to be pulled out is fixed, and the tape supply unit is moved in a predetermined movement pattern P while moving the conductor supply unit in the direction of arrow B. The coil of the layer and the insulating layer on the inner peripheral side thereof are simultaneously formed. By repeating this, a multi-turn coil is formed.

According to the present embodiment, the coil conductor 2 and the tape-shaped insulator 4 are simultaneously wound and overlapped to form the second coil 8 and the insulating layer 3 on the inner peripheral side thereof. Are formed at a time, and such operations are successively performed one by one, whereby a multi-turn coil can be formed. In this case, unlike the conventional one, it is no longer necessary to cut and join the coil conductor 2 every time each layer is formed while using the tape-shaped insulator 2 for forming the insulating layer 3.

Therefore, the operation of winding the coil conductor 2 and the operation of forming the insulating layer 3 can be performed at the same time, resulting in excellent work efficiency. In addition, the coil conductor 2 can be continuously cut without being cut one by one. Since the winding work can be performed in a targeted manner, the workability can be improved. In addition, the insulating layer 3 whose insulating thickness is freely changed in the axial direction as required can be easily formed. Furthermore, since the tape-shaped insulator 4 and the end insulator 5 are provided separately, the size of the tape-shaped insulator 4 to be used is not strictly limited with respect to the size of the coil. The insulator 4 can be used in common for various types of coils, and the versatility can be improved.

FIG. 3 shows a second embodiment (also corresponding to claim 1) of the present invention. This embodiment differs from the first embodiment in the shape of the insulating layer 10 formed on the inner peripheral side of the second layer coil 9. It is formed so as to gradually increase in thickness in the axial direction from b to one end side a. In this case, the movement pattern P of the tape supply unit when the conductor supply unit is moved in the direction of arrow C from the other end b to the one end a is set as shown in FIG.

That is, the tape supply unit is first moved in the direction of arrow C from the other end b to one end a, and when it reaches about one-third of the whole (position f), this time the arrow B Arrow C
Flip in the direction. Then, one end side a further than the position f
At a certain position (position h), the position is reversed again in the direction of arrow B, and when the position is advanced slightly beyond position f toward the other end b (position i), the position is reversed in the direction of arrow C. Subsequently, the reversal is repeated at the positions j and k, and when it reaches the one end side a, it is reversed again, and when it has advanced a little (position l), it is reversed and proceeds to the one end side a.

In this embodiment, as in the first embodiment, the operation of winding the coil conductor 2 and the operation of forming the insulating layer 3 can be performed at the same time. As a result, the winding operation can be performed continuously without cutting the coil conductor 2 for each layer, so that the workability can be improved. Moreover, the insulating layer 3 in which the insulating thickness is freely changed in the axial direction as required can be easily formed. Further, one kind of the tape-shaped insulator 4 is commonly used for many kinds of coils. It can be used for various purposes.

(2) Third Embodiment Next, a third embodiment (corresponding to claim 2) of the present invention will be described with reference to FIGS. In order to avoid repetition of the description of the embodiments described below, new descriptions of the same parts as those of the first embodiment, such as the mechanical configuration of the coil winding device, are omitted, and the same reference numerals are used. It will be used and different points will be mainly described.

In this embodiment, a plurality of tape supply units for supplying the tape-shaped insulator 4 to the former 1 are provided in this case, and two of them are provided independently of each other in the directions of arrows B and C. It can be moved freely. At the same time as the winding of the nth layer of the coil conductor 2, the winding start position in one (the right side in the case of the second layer shown in FIGS. b)
While the winding start position in the other tape supply unit is set to the opposite one end side a, the two tape supply units are moved in a predetermined moving pattern P1, P2 in the winding direction of the coil conductor 2 (direction of arrow C). By repeating the inversion in the axial direction, the insulating layer 11 having a predetermined insulation thickness in which the winding thickness of the tape-shaped insulator 4 changes in the axial direction is formed.

FIGS. 5A to 5E show the progress of the winding operation of the second layer coil 12 after the winding operation of the first layer coil 7 by the coil conductor 2 is completed. Is shown. FIG. 5F schematically shows the movement patterns P1 and P2 of the two tape supply units at that time.

In this case, as shown in FIG. 4, when the first layer coil 7 is formed, it is pulled out from one of the tape supply portions to the other end b of the outer peripheral portion of the first layer coil 7. The tip of the tape-shaped insulator 4 is fixed, and the first layer coil 7 is fixed.
The front end of the tape-shaped insulator 4 drawn out from the other tape supply unit is fixed to the portion a on one end side of the outer periphery of the tape-shaped insulator. Then, in this state, the winding form 1 is rotated in the direction of arrow A, and in synchronization therewith, the conductor supply section is moved in the direction of arrow C from the other end b to the one end a, and two tapes are supplied. The parts are moved in predetermined movement patterns P1 and P2, respectively.

As shown in FIG. 5 (f), the movement pattern P1 of one tape supply unit is such that the tape supply unit is first moved in the direction of arrow C from the other end b, and is moved to a position m substantially in the axial direction. To be reversed in the direction of arrow B, to be reversed in the direction of arrow C at a position slightly advanced (position n), to be reversed again at a position slightly advanced beyond position m (position o), and to be reversed again at position m. . At the position p near the one end a, it is again reversed in the direction of the arrow B. When it has advanced slightly beyond the position o toward the other end b (position q), it is reversed in the direction of the arrow C at the position q. a. On the other hand, the movement pattern P2 of the other tape supply unit starts from one end side a, goes to position m, returns to one end side a, goes to position o, returns to one end side a, and goes to position p. The pattern returns to one end side a.

Thus, as shown in FIGS. 5A to 5E, the outer peripheral portion of the former 1 (the outer peripheral surface of the first layer coil 7).
Then, the two tape-shaped insulators 4 and the coil conductor 2 are simultaneously wound with the tape-shaped insulator 4 on the inner peripheral side, so that the insulating layer 11 and the second layer coil 12 are formed. And will be performed at once. Also in this embodiment, as in the first embodiment, the operation of winding the coil conductor 2 and the operation of forming the insulating layer 11 can be performed at the same time, and the work efficiency is excellent. Conductor 2
Can be continuously wound without cutting each layer, so that the workability can be improved.

At this time, as in the case of the first embodiment, the insulating thickness of the insulating layer 11 formed by the tape-shaped insulator 4 can be freely changed depending on the axial position. The insulating layer 11 having a predetermined insulating thickness is formed to be thinner at one end b and to be thicker toward the one end a having a higher interlayer potential gradient. At this time, two tape-shaped insulators 4 are formed. Insulating layer 11 having a greater thickness
Can be formed.

In the above-described third embodiment, the tape-type insulators 4 supplied from the two tape supply units are of the same type. In this case, though not shown, a plurality of tape supply units are provided. Each of the tape-shaped insulators in the section may have different types such as thickness and width (corresponding to claim 3). Thereby, the insulating thickness of the insulating layer formed by the tape-shaped insulator can be more finely adjusted, and a more appropriate insulating thickness can be obtained.

(3) Fourth Embodiment Next, FIG. 6 shows a fourth embodiment (corresponding to claim 4) of the present invention. Also in this embodiment, the mechanical configuration of the coil winding device is common to that of the first embodiment.
In the present embodiment, the former 1 is also rotated by rotating the former 1 while reciprocating the conductor supply unit between the one end side a and the other end b of the former 1 in the axial direction. The coil conductor 2 is continuously wound on the outer periphery one by one. At this time, the method of forming the insulating layer 15 formed between the first layer coil 13 and the second layer coil 14 is as described above. This is different from the first embodiment and the like.

That is, when the first layer of the coil conductor 2 is wound, the tape supply section is delayed backward in the winding direction (the direction of arrow B) of the coil conductor 2 of the conductor supply section by a predetermined movement pattern P3 (FIG. 6). By repeating the inversion in (i), the first layer coil 13 is formed by the tape-shaped insulator 4.
A first insulating layer 16 having a step-like shape is formed on the outer peripheral side of the tape conductor, and after the tape-shaped insulator 4 is once cut off, when the second layer of the coil conductor 2 is wound, the winding start position is set to the coil conductor 2. While the same (the other end b), the tape supply unit is moved forward in the winding direction (the direction of arrow C) of the coil conductor 2 of the conductor supply unit, and the reversal is repeated in a predetermined movement pattern P4 to repeat the tape supply unit. The second insulating layer 1 is provided on the inner peripheral side of the two-layer coil 14.
7, the first insulating layer 16 and the second insulating layer 17
Therefore, the insulating layer 15 having a predetermined insulating thickness (step shape) is formed.

More specifically, FIGS. 6A to 6D show:
The progress of the winding work of the first layer coil 13 is shown in order. Here, first, the end insulator 5 is arranged on one end side a of the former 1 and the winding operation of the coil conductor 2 is started from the one end side a, as shown in FIG. When the winding is slightly advanced in the direction of the arrow B, the rotation of the former 1 (and the movement of the conductor supply unit in the direction of the arrow B) is once stopped, and the winding start position of the first layer coil 13 (one end side a) is stopped. The front end of the tape-shaped insulator 4 drawn from the tape supply unit is fixed to the outer peripheral portion.

From this state, the rotation of the former 1 and the movement of the conductor supply unit are resumed, and the winding operation of the coil conductor 2 is continued.
As shown in FIGS. 6B to 6D, the first layer coil 13 is formed.
It is moved in a predetermined movement pattern P3 shown in (i). This movement pattern P3 starts from one end side a and moves to position r.
And return to one end side a.
To the position t, return to the one end side a, and reach the position u, return to the one end side a.

As a result, as shown in FIG.
The layer coil 13 is formed, and the first insulating layer 16 is formed in a region near the one end side a in the outer peripheral portion. When the tape-shaped insulator 4 reaches a predetermined number of turns, the first
When the insulating layer 16 is formed, it is cut.

Next, as shown in FIGS. 6E to 6H, the winding operation of the coil conductor 2 of the second layer coil 14 is performed. At this time, as in the first embodiment, the first
On the outer peripheral portion of the winding end position (the other end b) of the layer coil 13,
The leading end of the tape-shaped insulator 4 drawn out from the tape supply unit is fixed, and the former 1 is rotated, and the conductor supply unit is moved in the direction of arrow C. Then, at this time, as shown in FIG. 6 (i), the tape supply unit is moved in a predetermined movement pattern P4.

The moving pattern P4 advances from the other end b to the position s in the direction of arrow C, and then reverses in the direction of arrow B and returns to position v. r, and further inverted to position u
When it has advanced to, it reverses and returns to the position s, and when it further reverses and advances to one end side a, it reverses and returns to the position t, reverses and proceeds to one end side a. Thereby, at the same time as the formation of the second layer coil 14, the second insulating layer 17 is formed so as to partially overlap the first insulating layer 16, so that the thickness at the other end b is small and the interlayer potential gradient is reduced. As a result, the insulating layer 15 having a predetermined insulating thickness is formed to have a larger thickness as it goes to the one end side a where the thickness is higher.

According to this embodiment, as in the case of the first embodiment, the winding operation of the coil conductor 2 and the forming operation of the insulating layer 15 can be performed at the same time. In addition to this, the winding operation can be performed continuously without cutting the coil conductor 2 for each layer, so that the workability can be improved. In addition to the fact that the insulating thickness of the insulating layer 15 formed by the tape-shaped insulator 4 can be freely changed depending on the axial position, the first insulating layer 15 formed in advance before the formation of the second layer coil 14 can be obtained. From the layer 16 and the second insulating layer 17 formed of the five,
A desired insulating layer 15 having a sufficient thickness can be formed.

(4) Fifth and Sixth Embodiments Finally, FIG. 7 shows a fifth embodiment (corresponding to claim 5) of the present invention, and FIG. 8 shows a sixth embodiment of the present invention ( (Corresponding to claim 6). Of these, in the fifth embodiment shown in FIG. 7, a plurality of tape supply units (two in this case)
The tape-shaped insulators 18 and 19 are supplied so as to partially or entirely overlap each other. According to this, the thickness of the insulating layer that can be formed with the same number of turns can be further increased. Further, although not shown, a configuration in which two narrow tape-shaped insulators are supplied side by side can be adopted, thereby making it easier to perform the reversing operation.

In the sixth embodiment shown in FIG. 8, when the tape-like insulator 20 is turned over, the winding angle θ of the tape-like insulator 20 (the plane perpendicular to the axis c (line w)
(Inclination angle with respect to the line w) and bends (matching the bending margin to the line w) to reverse the front and back. According to this, wrinkles can be prevented from being generated at the portion where the tape-shaped insulator 20 is inverted.

The present invention is not limited to the embodiments described above and shown in the drawings. For example, the winding form may be a rectangular tube, and the coil conductor may have a circular cross section. The insulating layer may be formed in the same manner for the third and subsequent coils, for example, and the coil may be appropriately modified within a range not departing from the gist.

[0055]

As is apparent from the above description, according to the method for manufacturing a multi-turn coil of the present invention, the coil conductor is not separated and joined without using the tape-like insulator for forming the insulating layer. In this way, it is possible to continuously perform the winding operation, and thus it is possible to greatly improve the workability.

[Brief description of the drawings]

FIG. 1 is a view showing a first embodiment of the present invention, showing a winding procedure (a to e) of a coil conductor and a tape-shaped insulator, together with a movement pattern (f) of a tape supply unit.

FIG. 2 is a perspective view showing a state at the beginning of winding of a second layer coil.

FIG. 3 is a view corresponding to FIG. 1, showing a second embodiment of the present invention;

FIG. 4 is a view corresponding to FIG. 2, showing a third embodiment of the present invention;

FIG. 5 is a diagram corresponding to FIG. 1;

FIG. 6 is a view showing a fourth embodiment of the present invention, showing a winding procedure (a to h) of a coil conductor and a tape-shaped insulator together with a movement pattern (i) of a tape supply unit.

FIG. 7 shows a fifth embodiment of the present invention, and is a perspective view of a tape supply unit.

FIG. 8 is a view showing a sixth embodiment of the present invention, in which a tape-shaped insulator is bent.

[Explanation of symbols]

In the drawings, 1 is a winding form, 2 is a coil conductor, 3, 10, 11,
15 is an insulating layer, 4, 18, 19, and 20 are tape-shaped insulators, 5 is an end insulator, 7, 13 is a first layer coil,
Reference numerals 9 and 14 denote second layer coils, 16 a first insulating layer, and 17 a second insulating layer.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Mitsuyoshi Horiuchi 2121 Asahi-machi, Mie-gun, Mie Prefecture 2121 Nagoya, Toshiba Mie Plant Co., Ltd. Inside the Toshiba Mie Plant (72) Inventor Hisashika Yasuda 2121 Asahimachi Oji, Mie-gun, Mie Prefecture, Japan 2121 Inside the Toshiba Mie Plant (72) Inventor Takeyoshi Maya Asahi-machi, Mie-gun, Mie Prefecture No. 2121 in the Toshiba Mie Plant Co., Ltd. (72) Masakazu Kato 2-24-24 Harumicho, Fuchu-shi, Tokyo Toshiba FA System Engineering Co., Ltd.

Claims (6)

[Claims] 1. A method of manufacturing a multi-turn coil in which a coil conductor is wound in multiple layers on a cylindrical winding form with an insulating layer interposed between layers, wherein the winding form is rotated in one direction. A driving unit, a conductor supply unit that is movable between one end and the other end in the axial direction at a side of the winding form and sequentially supplies a long coil conductor to the winding form; On the side of the winding form, it is movable independently of the conductor supply portion between one end side and the other end side in the axial direction, and sequentially supplies a long tape-shaped insulator to the winding form. An outer peripheral portion of the winding form by rotating the winding form while reciprocating the conductor supply section between one end and the other end in the axial direction of the winding form. And continuously winding the coil conductor one by one, and simultaneously with winding the n-th layer of the coil conductor, While the winding start position at one end or the other end in the axial direction is the same as that of the coil conductor, the tape supply unit is advanced ahead of the winding direction of the coil conductor of the conductor supply unit, and the inversion in the axial direction is repeated as appropriate. A multiply-wound coil, wherein an insulating layer having a predetermined insulating thickness in which the winding thickness of the tape-shaped insulator changes in the axial direction is formed on the inner peripheral side of the n-th layer of the coil conductor. Manufacturing method. 2. A method of manufacturing a multi-turn coil in which a coil conductor is wound in multiple layers with an insulating layer interposed between layers on a cylindrical winding form, wherein the winding form is rotated in one direction. A driving unit, a conductor supply unit that is movable between one end and the other end in the axial direction at a side of the winding form and sequentially supplies a long coil conductor to the winding form; A plurality of tape supplies which are movable independently of one another in the axial direction between the one end side and the other end side of the winding form and sequentially supply a long tape-shaped insulator to the winding form. The conductor supply unit, by rotating the former while reciprocating between one end side and the other end in the axial direction of the former, the outer peripheral part of the former While winding the coil conductor continuously one by one, at the same time as winding the n-th layer of the coil conductor, While the winding start position at one end or the other end in the axial direction of one tape supply unit is the same as that of the coil conductor, the plurality of tape supply units are positioned in front of the winding direction of the coil conductor of the conductor supply unit. Forming an insulating layer having a predetermined insulating thickness in which the winding thickness of the tape-shaped insulator changes in the axial direction on the inner peripheral side of the n-th layer of the coil conductor by appropriately repeating inversion in the axial direction. A method for manufacturing a multi-turn coil, comprising: 3. The method for manufacturing a multi-turn coil according to claim 2, wherein each of the tape-shaped insulators in the plurality of tape supply units has a different type such as a thickness and a width. 4. A method for manufacturing a multi-turn coil in which a coil conductor is wound in multiple layers on a cylindrical former with an insulating layer interposed between layers, the method comprising: rotating the former in one direction. A driving unit, a conductor supply unit that is movable between one end and the other end in the axial direction at a side of the winding form and sequentially supplies a long coil conductor to the winding form; On the side of the winding form, it is movable independently of the conductor supply portion between one end side and the other end side in the axial direction, and sequentially supplies a long tape-shaped insulator to the winding form. An outer peripheral portion of the winding form by rotating the winding form while reciprocating the conductor supply section between one end and the other end in the axial direction of the winding form. At the time of winding the (n-1) th layer of the coil conductor. The tape supply unit is configured to repeat the inversion in the axial direction as appropriate with a delay in the winding progression direction of the coil conductor in the conductor supply unit, so that the outer periphery side of the (n-1) th layer of the coil conductor After the tape-shaped insulator is once cut off, the winding start position at one axial end or the other end in the axial direction is the same as that of the coil conductor when the n-th layer of the coil conductor is wound. The tape supply unit is moved forward in the winding direction of the coil conductor of the conductor supply unit, and the inversion is repeated in the axial direction as appropriate, so that the second insulation is provided on the inner peripheral side of the n-th layer of the coil conductor. Forming the layers,
A method for manufacturing a multi-turn coil, comprising forming an insulating layer having a predetermined insulating thickness on the inner peripheral side of the n-th layer of the coil conductor from the insulating layer and the second insulating layer. 5. The method according to claim 1, wherein the tape supply unit supplies a plurality of tape-shaped insulators simultaneously. 6. The tape-like insulator according to claim 1, wherein the tape-like insulator is bent in accordance with a winding angle of the tape-like insulator and turned upside down when the tape supply section is turned over.
A method for producing a multi-turn coil according to any of the preceding claims.