JPH11178291A - Winding machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a winding machine which is suitable for winding a flat wire material on an object to be wound, in which an obstacle exists around an arm or the like, especially such as a rotor core used in a small DC motor and in which the wire material is incapable of being fed from a direction at right angles to its axis. SOLUTION: A guide means is arranged so as not to collide with obstacles 2b, 2f or the like related to the rotation of an object 3a to be wound or the like or related to its own revolution with reference to the part 3a to be wound. A wire material 9 is guided to a part near the part 3a to be wound. When the wire material 9 is flat, the wire material 9 which is guided by using a turning-down means 13 is turned down toward the part 3a, to be wound, so that the distance from its unreeling position up to its winding position in the case the wire material 9 follows the left side in the width direction of the wire material 9 is equal to the distance in the case the wire material 9 follows the right side. In addition, a wire guide 10 is traversed, as required.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a winding machine and, more particularly, to a flat wire material called a flat wire or a ribbon wire, which is a small DC wire.
The present invention relates to a winding machine suitable for winding around a rotor core or the like of a motor.

[0002]

2. Description of the Related Art FIG. 5 shows an example 1 of a rotor core used in a small DC motor. The core 1 has coils wound around arms (arms) 3a to 3f of the magnetic poles 2a to 2f, and is used as a rotor of a small DC motor. The subscripts a to f are omitted unless necessary. The same applies to other items. Further, when there are a plurality of parts to which reference numerals are attached, some of them are assigned reference numerals.

When winding around each arm, for example, 3a, the magnetic poles 2b and 2f on both sides interfere. For this reason, winding cannot be performed with an ordinary winding machine. Therefore, usually, a winding machine 51 called a flyer type shown together in FIG. 5 is used. Speaking of ordinary winding machine, rotate the bobbin of the coil,
This refers to a winding machine called "axis turning type" which winds a wire on this bobbin.
1 is to fix a bobbin (arm 3), pass a wire 5 through a nozzle 6 of a fryer 4 commonly called "wing", and
To wind while rotating around the bobbin.

[0004] The flyer-type winding machine 51 is driven by this rotation, ie, the revolution of the nozzle 6 around the bobbin (3).
The middle of the wire 5 is rotated like a skipping rope. For this reason, the wire 5 is kinked inevitably, and it is difficult to wind it in alignment. However, the coil can be wound at a high speed of 10,000 rpm or more, and the coil can be wound in a short time. Therefore, it is used to wind a relay coil having a large number of turns instead of requiring a proper alignment. As another application, there is a method of covering each magnetic pole 2 with a cone-shaped cover (not shown), and winding the wire 5 by sliding the wire 5 from above the cone.

Up to now, round wires (wires having a circular cross section) have been widely used for coils. If this is the wire to be used, there is no problem with winding by these conventional methods, and in fact, most rotor coils have been wound by this method.

[0006]

However, some of the wires are
For example, there is a ribbon-shaped wire having a thin rectangular cross section. This is generally called a flat wire or a ribbon wire. (In the present specification, the flat wire is generally referred to as a "flat wire.") Recently, a coil using the flat wire has attracted attention. In particular, demand for small DC motors seems to be growing rapidly. According to the story heard by the inventor, motors using flat wire have higher torque and efficiency of several tens of percent when compared to those using round wire and those using flat wire for the same size. It seems expensive.

There are two possible reasons why the efficiency is improved. One is a difference in the occupation ratio of the wire to the coil cross section. First, in the round wire coil, a gap is formed between the wires as shown in FIG. On the other hand, in the flat wire, there is no gap between the wires as shown in FIG. Therefore, it is considered that the flat wire has a higher wire occupation ratio with respect to the coil cross section, and is advantageous in terms of a magnetic circuit.

Another is the difference in DC resistance. Perhaps this is the dominant reason for efficiency,
For example, in the case of FIG. 6, the number of turns is 18 and the cross-sectional area of the coil is almost the same. However, when calculating the cross-sectional area of the wire used for the two coils,
The flat wire (A) is about 27% larger. To say,
The flat wire has lower DC resistance, so if the same torque is obtained, the flat wire requires less power. In other words, if the same torque and electric power are sufficient, the size of the coil itself can be reduced accordingly, and the size of the entire device can be reduced accordingly. Therefore, small D
It is natural that there is a demand for the use of a flat wire for the rotor coil and the like of the C motor.

[0009] However, in the conventional winding machine, the flat wire was not so conscious. Therefore, for example, when trying to wind a flat wire with the flyer-type winding machine 51, a wire in which the wire is twisted and aligned cannot be formed. Further, it is also conceivable to wind the flat wire by rotating the arm 3a or the like, for example, as in a normal winding type winding machine. In this case, the arms 3b and 3f on both sides hinder the winding. Therefore, the flat wire cannot be supplied from a direction perpendicular to the axis of the arm 3a.

For this reason, it has been found that the flat wire has an advantage, but the conventional method cannot efficiently wind the flat wire on a rotor of a small DC motor or the like.

An object of the present invention is to solve the above-mentioned problems, and in particular, there is an obstacle around the arm or the like, such as a rotor core used for a small DC motor, and supply of a wire from a direction perpendicular to the axis is not possible. An object of the present invention is to provide a winding machine suitable for winding a flat wire around a possible winding target.

[0012]

In order to achieve the above object, according to the present invention, the winding target portion is arranged so as not to collide with an obstacle relating to the rotation of the winding target portion or its own revolution with respect to the winding target portion,
Guide means for guiding a wire near the winding target portion,
Assuming that the guided wire is flat, the guiding is performed such that the distance becomes equal between the case where the left side in the wire width direction from the feeding position to the winding position and the case where the right side is followed. Folding means for folding the wire guided by the means toward the winding target portion (claim 1).

[0013] Further, there is further provided moving means for moving the guide means along the axis of rotation or revolution.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail based on illustrated embodiments. FIG. 1 shows a main part front of the embodiment 100. 2 and 3 show the line guide 10 in an enlarged manner. FIG. 2 shows the front (A), the plane (B), the right side (C), and the left side (D), and FIG. (A) A1
The cross section along the line -A2 is shown.

In the embodiment, the line guide 10 is inclined (θ ₁ ) as shown in FIG. Since it is troublesome to express without change in 6 orthogonal views, in FIG. 2, is rotated in an amount corresponding the theta ₁ counterclockwise, are displayed mended line guide 10 horizontally. FIG. 4 is cited in the description of each angle of the line guide 10 (described later), and the solid figures 10 and 13 in FIGS.
(A) and (D) represent the same posture, and the two-dot chain line figures 10x and 13x represent the postures changed.

In FIG. 1, the core 1 is the same as that shown in FIG. Here, the flat wire 9 is wound around the arms 3 a to 3 f of the core 1. Here, these arms 3 are winding target portions referred to in the claims. Reference numeral 7 denotes a support member which sandwiches the center of the core 1 from the left and right, and rotates the core 1 as shown by the arrow RD (rotating means not shown). Thereby, the arm 3a rotates on the spot about the dashed-dotted line L1.

In the line guide 10, the guide portion 8 and the folded portion 13 are integrally formed. The details are as shown in FIGS. 2 and 3. The guide portion has a shallow square gutter shape, and
1 and a side piece 12 formed by bending both sides thereof. The guide portion corresponds to a guide means, and guides the flat wire 9 from the wire feeding portion (a bobbin (not shown) wound with a flat wire as a winding material) to the vicinity of the arm 3a.

When the arm 3a rotates, the arm 3b
And 3f form a three-dimensional body around which a substantially conical rotation is made. The line guide 10 is arranged at a position that is not included in these three-dimensional bodies, that is, does not contact the arm 3b or 3f. The solid formed by the rotation of the arms 3b and 3f is an example of the obstacle described in the claims.

The solid formed by these rotations depends on the shapes of the arms 3b, 3f and the like. Accordingly, the posture of the line guide 10, that is, the distance from the rotation axis L1, the angle θ ₁ (FIG. 1) with respect to the horizontal, and the like are adjusted according to the shape of the core and other objects to be wound at that time.

The folded portion 13 is formed so as to follow the bottom plate 11. As shown in FIGS. 2 and 3, the folded portion 13 has a gutter shape having a semi-cylindrical cross section. The gutter-shaped portion is the folded portion 13 and corresponds to the folded means.
Strictly speaking, the right side portion of the straight line connecting the right ends of the side pieces 12 shown in FIG.

The flat wire 9 extends from the upper left to the lower right in FIG.
Is guided on the bottom plate 11 while being regulated. Then, at the turning portion 13, the direction is changed with the feeling of being turned toward the near side of the bottom plate 11, and the turning is made toward the arm 3a so as to be substantially perpendicular to the rotation axis L1 of the arm 3a, where it is taken up by the arm 3a.

The flat wire 9 has a width. Therefore, if you simply change the direction of travel, both sides in the width direction will undulate like kelp. For this reason, winding cannot be performed by the flyer type or the bobbin rotation type. However, the folded portion 13 turns the so-called tape surface of the flat wire so as to be folded there. Thereby, the direction of the flat wire 9 can be changed without waving on both sides in the width direction. It is troublesome to refuse the "width direction" each time. The description is omitted hereafter.

In this conventional simple direction change, the both sides of the flat wire 9 are wavy. The distance (stroke) is different when the right and left sides in the width direction are traced over them. That's why. Therefore, in the present invention, the folded portion 13
The flat wire 9 is turned upside down by the turning means as described above to change the direction of the flat wire 9. This makes the distances when traversing on each of these sides equal.

This is well represented by the folding of the paper tape. The paper tape can be turned in any direction as long as the paper tape is folded back. Here, the inclination angle θ ₂ (FIG. 1) of the folded portion 13 is
The direction in which the flat wire 9 enters here, that is, the line guide 1
It is determined by the angle θ ₃ (FIG. 1) between the direction of 0 and the flat wire 9 going from here to the winding position 14, and θ ₂ = θ ₃
で 2 required. In the drawing, θ ₃ is shown as being moved on the rotation axis of the core 1. The alternate long and short dash line L2 shown therein is parallel to the flat wire 9 toward the winding position 14.

It is not necessary to continuously produce the same core 1, but if a rotor core having a different shape or a non-rotor core is to be wound, the wire guide 1 is not required.
Etc. 0 angle theta ₁ Relationship may want to change the angle theta ₂ of the folded portion 13. In such a case, for example, the folded portion 13 rotatably screwed to the bottom plate 11, as shown in FIG. 4 (A) when the angle theta ₅ variable may. However, the flat wire often has a width of 1 to 2 mm. When applied to such a thing, the dimensions of the guide portion 8 and the folded portion 13 become considerably small, and the production becomes complicated accordingly. Thus, the actual angle theta ₅ of the folded portion 13 is prepared the line guide 10 are different little by little several kinds, it is preferable to use those adapted for the angle theta ₂ at that time.

The line guide 10 is traversed by known moving means (not shown) in the direction of arrow TD in FIG. 1 as necessary. The flat wire 9 is spirally wound at a pitch determined by the feed amount per number of rotations by traversing the matching line guide 10 in this way with the rotation of the arm 3a. If this pitch is made to coincide with the width of the rectangular wire, a close-contact winding without overlapping will be obtained. If the traverse is performed a plurality of times, it becomes a coherent multi-layer winding. At this time, there is no gap between the wires such as round wires, and the efficiency of the small DC motor and the like is improved as described above. When the traverse is eliminated, the flat wire 9 is wrapped around the same position. This also leads to an increase in efficiency.

When the winding around the arm 3a is completed, the holding of the support member 7 is loosened, and the core 1 is rotated, for example, 60 degrees counterclockwise from the state shown in the figure. This brings the arm 3b to the position of the arm 3a shown in FIG. The core 1 again with the bearing member 7
, The arm 3b is rotated on its own axis, and winding is performed on the arm 3b. When the winding around all the arms 3 is completed, the rotor coil is completed.

Hereinafter, modified examples will be supplemented. First,
The folded portion 13 only needs to be located near the tip of the guide portion 8 and does not need to be integrated with the guide portion 8. The cross-sectional shape is also arbitrary, and it is sufficient that the direction of the rectangular wire 9 is changed there, and it is not necessary to be the gutter type (13) as in the embodiment. Specifically, for example, a rotatable roller may be arranged so as to have an outer shape close to that of the folded portion 13 of the embodiment, and this may be used to fold a flat wire or the like. Although it costs more than a gutter shape, the wire slides better. Also,
A cylinder having a similar outer shape may be fixed, or a solid cylinder may be fixed.

In short, the guide portion 8 only needs to be able to guide the flat wire 9 and the like to the turn-back portion 13. Therefore, it may be cylindrical like a wire guide of a flyer-type winding machine, or like a frame of a greenhouse, in which ring-shaped objects are arranged in a tunnel shape and connected appropriately by columns. Is also good.

The arm 3 to be wound may be stationary, and the wire guide 10 may revolve around the arm. This can be realized by attaching the wire guide 10 as in the embodiment to the rotating shaft 52 of the flyer-type winding machine. However, if it simply revolves, the flat wire will be twisted as in the conventional flyer-type winding machine 51. Therefore, in the case described here, a bobbin for feeding out the flat wire 9 is arranged on the rotating shaft 52 of the flyer-type winding machine (not shown), and is rotated together with the wire guide 10. good.

In this way, no twisting occurs. If the bobbin for feeding the flat wire 9 is large, the flat wire 9 or the like having a required length may be rewound on another small bobbin similarly to the lower thread of the sewing machine, and may be arranged on the rotary shaft 52. In this way, if the feeding bobbin is arranged on the rotating shaft, the structure becomes complicated, and it is not welcome from the viewpoint of the winding machine cost,
This is useful when the object to be wound has a shape that is difficult to rotate.

In the embodiment 100, the rotation axis L
1 or the revolution axis (52) was horizontal. The direction of this axis is arbitrary. Further, in the embodiment 100, the winding is performed so that the flat wires 9 are arranged horizontally. The rectangular wire 9 can be wound upright on the arm 3a. exactly,
A book is placed on a bookshelf, and the book is pushed in order to either side, which is also useful as a method of winding a flat wire such as a round wire coil having no gap. In this case, θ ₂ in FIG. 1 is set to 90 ° and θ ₆ in FIG.
The value is set to a value slightly less than 0 ° (the front surface of the bottom plate 11 in FIG. 1 is directed to the winding position 14).

[0033]

As described above, according to the present invention, the wire rod is provided in the vicinity of the portion to be wound by the guide means arranged so as not to collide with the obstacle relating to the rotation of the portion to be wound or its own revolution with respect to the portion to be wound. Assuming that this wire is flat, so that the distance when tracing the left side in the wire width direction and the distance when tracing the same right side from the feeding position to the winding position are equal, The wire rod guided using the folding means is folded toward the winding target portion (claim 1). Therefore, the winding of the flat wire to the rotor core of the small DC motor, which cannot be performed by the conventional winding machine, can be performed easily and at high speed.

Further, the guide means is moved along the axis of the rotation or revolution by the moving means (claim 2). This makes it possible to easily and quickly execute a multi-layer winding.

It should be noted that the winding machine of the present invention has
As described above, the present invention is particularly useful for a device in which an obstacle is formed around it when it is rotated, but is also applicable to a device in which no obstacle is generated around the device. It is also useful for flat wires, but can also be used for winding round wires, square cross-sections and other non-flat wires. As described above, the present invention is not limited to the object to be wound and the object wire, but can be dealt with by one unit.

[Brief description of the drawings]

FIG. 1 is a front view showing a main part of an embodiment 100 of a winding machine of the present invention.

FIG. 2 is an enlarged view of the line guide 10 of FIG. 1, wherein (A) is a front view, (B) is a plan view, (C) is a right side view, and (D) is a left side view. Note from the state shown in FIG. 1, in a counterclockwise direction theta ₁
Just rotate and display.

FIG. 3 is a cross-sectional view showing the line guide 10 of FIG. 1 cut along the line A1A2 and enlarged.

4A and 4B show a modification example of each angle of the line guide 10; FIG. 4A is a front view showing a modification example of an angle θ ₅ of the folded portion 13; FIG. 4D is a vertical angle θ ₆ of the line guide 10; The right view which shows the example of a change of FIG.

FIG. 5 is a front view showing an example of a rotor core and a flyer-type winding machine.

FIG. 6 shows an example of a cross section of a coil, wherein (A) is a round wire coil,
(B) is a sectional view showing an example of a rectangular wire coil.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Rotor core 2 ... Magnetic pole 3 ... Arm 4 ... Flyer 5 ... Wire rod 6 ... Nozzle 7 ... Bearing member 8 ... Guide part 9 ... Flat wire 10 ... Wire guide 11 ... Bottom plate 12 ... Side piece 13 ... Folding part 14 ... Winding position 51 ... Flyer-type winding machine 52 ... Flyer-type winding machine rotating shaft 100 ... Winding machine of the embodiment L1 ... Self-rotating shaft.

Claims (2)

[Claims] 1. A guide means which is arranged so as not to collide with an obstacle relating to the rotation of the winding target portion or its own revolution with respect to the winding target portion, and guides a wire rod near the winding target portion; Assuming that the wire rod is flat, the guide means guides such that the distance between the left side and the right side in the width direction of the wire rod from the feeding position to the winding position is equal to each other. A winding device comprising: a wrapping means for wrapping the wire rod to be wound toward the portion to be wound. 2. The winding machine according to claim 1, further comprising moving means for moving the guide means along the axis of rotation or revolution.