JPH11164532A - Coil winding machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To realize a perfect tapless coil without burrs, which is generated by complicated cutting, to diminish the loss of a wire rod, or to make complicated postwinding cutting work unnecessary. SOLUTION: A wire rod sucking port 5 is formed on the core 22 on its peripheral surface, being connected to a vacuum pump, etc., through an inside vacuum sucking route 4. The starting end of a flat square type wire 3 having had required starting end treatment such as coat exfoliation, etc., is sucked by this wire rod sucking port and wound. It becomes possible to wind a flat square type wire, etc., without keeping a fixing margin for fixing its winding start section.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a winding machine, and more particularly to a winding machine suitable for efficiently producing a tapless coil using a flat wire.

[0002]

2. Description of the Related Art At present, a wire material used for a normal coil winding is often a thread-shaped copper wire having a round cross section, and the winding machine to be used is mostly intended for a round wire. is there.
However, some wires, such as rectangular ribbons, have a thin cross section. This is called a flat wire or a ribbon wire.

Recently, attention has been paid to a coil using the rectangular wire. In particular, demand for small motors and the like seems to be growing rapidly. According to the story heard by the inventor of the present application, when comparing a coil using a round wire and a coil using a flat wire of the same size, a motor coil using a flat wire has a larger torque and a lower efficiency than a coil using a flat wire. It seems that the demand will increase further in the future as electronic devices become smaller and smaller by 10%.

[0004] There are two possible reasons why the use of a rectangular wire improves the efficiency. One of them is FIG.
In the round wire coil as in (A), a gap is inevitably formed between the wires. On the other hand, there is no gap in the rectangular wire as shown in FIG. 3B, and the occupation ratio of the copper wire to the coil cross section increases. On the other hand, this is probably the dominant reason for the higher efficiency, but the rectangular wire has a lower DC resistance.

In the example shown in FIG. 3, both coils have 18 turns, and have substantially the same sectional area. But,
Calculating the cross-sectional area of the wire used for these two coils, the rectangular wire is about 27% larger. This means that the DC resistance of the rectangular wire is smaller than that of the rectangular wire, and the rectangular wire requires less power to obtain the same torque. In other words, if the torque and the power are the same, the coil itself can be made smaller, and the size of the entire device is further reduced.

Although the flat wire coil has the above characteristics, the flat wire itself has recently become widespread.
There are still few winding machines for flat wire, and the unit price of wire seems to be high.

[0007] These exemplified coils are used, for example, in a motor having a structure as illustrated in FIG. This is commonly called a flat motor or flat motor. Since this type of motor can be made very thin, it is widely used as a drive motor for a floppy disk, a hard disk, a video tape recorder, or the like. The development of flat motors that are smaller and more efficient is underway.

That is, a conventional coil using a round wire has been used as the stator coil a (fan-shaped coil; see FIG. 4) of this type of flat motor. The stator coil a is bonded and wired to the substrate b, operates together with an electronic circuit on the substrate b (not shown), generates a magnetic field, and rotates the rotor c. However, for the reasons described above, we are going to replace the coil using a flat wire. (Some products already use flat wire coils.)
FIG. 4B shows the stator d of FIG. 4A taken out, and FIG. 4A shows the flat motor cut vertically along the rotation axis. The hatching is omitted, and the shape is also indicated by an approximate outline.

There are roughly two types of these stator coils. One of them is shown in FIG.
This is a detailed description of a stator coil, and this type of coil is cut with a small amount of wire at the beginning and end of winding, and is called a tapped type. (Some have no tap at the end of the winding, which also comes with a tap.) And the other type is a tapless coil without any tap.

[0010] Although there is no electrical or mechanical difference between the coil with tap and the coil without tap, there are some applications for each type related to the process of mounting the coil on the substrate. Seems to have been. Although it is unknown in detail what characteristics each type of coil has, in any case, these two types of coils have a great difference from the viewpoint of winding.

That is, a winding machine for winding a coil of this type normally performs a winding operation as shown in FIG. First,
The winding jigs 1 and 1 are opened (FIG. 6A), and the starting end (start of winding) of the flat wire 3 is pulled out to the opposite side of the winding jig 1 (FIG. 6).
(B)), this is fixed to a clamp (not shown) of the winding jig 1 (FIG. 6 (C)), and the winding is executed with this. Then, the wound coil is taken out, and the start end and the end (end of winding) are cut at an arbitrary length to complete the coil. In the figure, reference numeral 2 denotes a winding core.

[0012]

By the way, a coil with a tap can be manufactured without any problem by the above-mentioned steps. However, in the case of a tapless coil, a slight uncut portion is particularly left when the starting end is cut after coil winding (winding). This is liable to occur (burrs are easily formed), and it is difficult to manufacture a tapless coil in an accurate sense.

[0013] Also, the fixed allowance cut out (Koteshiro)
There was also a problem that the yield of coils produced from one turn of the wire was poor as a result of being discarded as waste. (If one coil is produced, tens of millimeters of scrap wire are generated. Since the wire unit price is high, even a small amount significantly affects the cost.)

An object of the present invention is to solve such a problem and to make it possible to wind a flat wire or the like without taking a fixing allowance for fixing to a winding jig at the beginning of winding. This eliminates burrs generated by cutting after winding, realizes a completely tapless coil, eliminates waste of wire rods such as rectangular wires, which are expensive, and eliminates the need for complicated cutting work itself. To provide machines.

[0015]

In order to achieve the above object, the winding machine of the present invention has a wire rod suction port which is opened on the peripheral surface of the winding core and is connected to a vacuum suction device through an internal vacuum suction path. .

Thus, in the winding machine of the present invention, the coil can be wound in a state where the vicinity of the wire suction port is brought into a negative pressure state by vacuum suction and the winding start end of the wire is sucked here.

Therefore, it is not necessary to take the fixing allowance of the wire rod leading end, and the terminal treatment of the wire rod leading end can be performed before winding. A coil can be realized. In addition, it is possible to eliminate the waste of the wire rod for removing the fixing allowance. Complex operations such as fixing the starting end and cutting the fixing margin after winding are also unnecessary.

[0018]

BEST MODE FOR CARRYING OUT THE INVENTION The winding machine of the present invention is provided with a wire suction port which is opened on the peripheral surface of a winding core and which is connected to a vacuum suction device via an internal vacuum suction path. The winding core is formed, for example, on one of a pair of winding jigs arranged to face each other at a variable interval so as to protrude by the width of a substantially rectangular wire, and rotates together with the winding jig. The vacuum suction path of the core is connected to a vacuum suction device (not shown) via a known sealing mechanism that allows the rotation.

The vacuum suction device may be any vacuum suction means as long as it can suck the starting end of the wire for about 2 to 3 turns from the start of winding of the wire, for example, using a vacuum pump, an air cylinder or the like. I can do it.

[0020]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The details of the present invention will be described below with reference to the illustrated embodiments. 1 and 2 show an embodiment of the winding machine of the present invention.
FIG. 1 is a front view showing a main part of the embodiment. FIG. 1A shows a state in which the winding jigs 1a and 1b are opened before winding is started, and FIG. The state in which the winding jig is closed after the tip is attracted to the winding core and the winding of the coil is started.
2A and 2B show the winding core in an enlarged manner, wherein FIG. 2A shows a plan view and FIG. 2B shows a front view.

In these figures, the winding jigs 1a and 1b are arranged so as to face each other, and as described above,
The space between them can be expanded or closed. Of course,
Unlike the conventional example of FIG. 6, the winding jig 1a or 1b has no mechanism for clamping the starting end of the flat wire. This is because the wire can be wound without clamping in the present invention.

Reference numeral 22 denotes a winding core of the present embodiment, which protrudes from one of the winding jigs 1a and 1b opposed to each other by substantially the width of the flat wire 3, and the flat wire 3 is wound thereon. This winding core 22 has a vacuum suction path 4 inside, unlike the winding core 2 of the conventional winding machine shown in FIG.
Wire suction port (air hole) 5 formed in the peripheral surface of the core 22
It is in communication with 5. The winding core 2 and the winding jigs 1a and 1b naturally rotate. The vacuum suction path 4 is connected to a vacuum suction device (vacuum pump, suction cylinder, etc., not shown) via a known sealing mechanism (not shown) that allows these rotations.

Next, a procedure for manufacturing a tapless coil using the winding machine of the present embodiment will be described. First, before starting the winding, the winding jigs 1a and 1b are kept open (FIG. 1).
(A)). No suction is performed by a vacuum suction device (not shown). In this state, the process of the starting end of the flat wire 3 is performed first.
The processing at the start end refers to processing required as a tap inside the coil, such as peeling of an insulating layer or solder plating. In general, the length of the wound rectangular wire is determined fairly accurately. Therefore, the rectangular wire 3 may be cut into a required number of pieces and this required length in advance, and the necessary processing as the tap may be performed in advance at each of the start and end.

In any case, the material that has been subjected to such processing of the starting end is placed so as to be located between the winding jigs 1a and 1b (FIG. 1A). Next, the winding jigs 1 a and 1 b are closed, and the flat wire 3 is fed onto the winding core 22 so that the end thereof closes the wire suction ports 5 and 5. Then, a vacuum pump (not shown) is operated. With this, the inside of the wire suction ports 5, 5 becomes negative pressure,
The tip of the flat wire 3 is sucked here and fixed to the outer periphery of the winding core 22. In this state, the winding jigs 1 and 1 and the winding core 22 are rotated. The flat wire 3 is sequentially wound around the winding core 22, and the coil is completed by the required number of windings.

When the winding is completed, the vacuum pump is rotated in the reverse direction so that air is ejected from the wire suction ports 5 and 5. In this case, the inner periphery of the coil is peeled off from the surface of the core 22, and is easily detached from the core 22. Thereafter, the space between the winding jigs 1a and 1b is opened, and the completed coil is removed from the winding core 22. The end of the removed coil is also processed into a tap by a known method. If the terminal is also processed in advance, the operation here is unnecessary. This completes the tapless coil.

When the coil is separated from the winding core 22 after the completion of the winding, it is not always necessary to reverse the vacuum suction device. It is also possible to simply stop the suction operation of the vacuum suction. Further, the present winding machine can be used, for example, for manufacturing a round wire coil, and is not limited to the type and the cross-sectional shape of the wire. That is, the shape, size, and the like of the wire suction port 5 may be various depending on the cross-sectional shape, thickness, and the like of the wire to be wound.

The position of the wire suction port 5 may be formed in a flat portion of the peripheral surface of the fan-shaped core 22 as viewed in a plane, as in the embodiment, or may be formed in a curved portion. In addition, a groove may be formed in the winding core 22 so that the starting end of the wire can be fitted in accordance with the cross-sectional shape of the wire to be wound, and the wire suction port 5 may be opened at the bottom of the groove. In this case, the coil can be wound by fitting the starting end portion of the wire material serving as the winding start tap into this groove, and can be used for manufacturing a coil with a tap.

[0028]

As described above, according to the winding machine of the present invention, the starting end of a wire such as a flat wire can be fixed to the winding core without using a clip or the like. Therefore, the fixing allowance as in the prior art is not required, and the fixing allowance cutting work after winding is not performed. A tapless coil can be realized.

Further, since the wire for the fixed allowance, which has been conventionally discarded, is not wasted, the cost can be reduced particularly for a rectangular wire having a high unit price. In addition, since the work of cutting the fixed margin after winding is more complicated than the starting end processing before winding, the operation is simplified by not doing this.

[Brief description of the drawings]

FIG. 1 is a front view of a main part of an embodiment of a winding machine of the present invention,
(A) shows the open state of the winding jig before winding, and (B) shows the state in which the winding jig is tightened and the flat wire is attracted to the winding core to start winding.

FIGS. 2A and 2B are enlarged views of a core portion of the embodiment shown in FIG. 1, wherein FIG. 2A is a plan view and FIG.

3A and 3B show examples of a cross-sectional structure of a coil, wherein FIG. 3A is a cross-sectional view of a round wire coil, and FIG. 3B is a cross-sectional view of a flat wire coil.

FIG. 4 shows a schematic structure example of a flat motor, and (A)
FIG. 3 is a longitudinal sectional view centering on a rotation axis, and FIG. 3B is a plan view of a stator portion.

FIG. 5 is a plan view showing an example of a tapped coil.

6A and 6B are plan views of an essential part of an example of a conventional flat wire coil winding machine, wherein FIG. 6A is a winding jig opened state before winding, and FIG. (C) shows a state in which the winding jig is tightened and the starting end of the flat wire is to be fixed to the winding jig.

[Explanation of symbols]

1 ... winding jig, 2 ... winding core, 3 ... rectangular wire, 4 ... vacuum suction path,
5: wire suction port, 22: winding core.

Claims (1)

[Claims] 1. A winding machine comprising a wire suction port which is opened on a peripheral surface of a winding core and which is connected to a vacuum suction device via an internal vacuum suction path.