JPS61234019A - Method and apparatus for manufacturing low voltage winding for toroidal transformer - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application, Prior Art) The present invention is based on the joint application filed on January 6, 1982 entitled "Toroidal Transformer and Method for Producing the Same". Serial No. 337.356, 1984.
Serial No. 6 entitled “Apparatus and method for producing low-voltage windings for toroidal transformers,” dated October 17, 2016.
No. 62.312, serial number 662,467 entitled "Apparatus and method for making high voltage windings for toroidal transformers" dated October 17, 1984, and 198
Serial Number Whistle 66 entitled "Apparatus and Method for Winding Magnetic Iron Cores for Toroidal Transformers" dated October 17, 2004)
This invention further constitutes an invention relative to the invention disclosed in No. 30. The entire disclosure of the above joint application is incorporated herein by reference.

Patent No. 3383.059 and No. 3.45938 issued on May 14, 1968 and August 5, 1969, respectively.
An example of a prior art toroidal coil winding machine using a rotating shuttle and magazine can be found in Patent No. 5 (inventor Fahrbach). Such machines (hereinafter referred to as general purpose machines) are commercially available under various model numbers by Universal Manufacturing Co., 1168 Grove Street, New Chassis 0711, 7-Vinton. In other words, the present application and the above-mentioned joint application are directed to a newly designed toroidal transformer and an apparatus and method for manufacturing the same, which improve the power conversion efficiency of the transformer.

SUMMARY OF THE INVENTION Although the invention as a whole is similar in efficiency to that described in the joint application, it differs from the invention in a number of important respects.

In particular, the present invention provides a novel multifill low voltage winding using round thin film insulated conductors and an apparatus and method for making a multifill low voltage winding for toroidal transformers. The method and device use a wire storage magazine and a wire take-up shuttle that rotate the winding shaft of an arc-shaped or toroidal winding mandrel to separate the radially outer legs of the winding and the radially inner legs of the winding. The multifill low voltage winding is wound on a winding mandrel with a large radial winding depth in the legs.

Winding machines for toroidal winding using a rotating winding shuttle and a storage magazine that pass through a window in a toroidal core are exemplified by the general-purpose machine described above.Although well known in the prior art, the present invention It constitutes an important modification of such a general-purpose machine and differs from the preceding machines in several important respects. In particular, the machine and method of the present invention are configured to wind a toroidal multifill winding such that the multifill conductors of the winding are arranged side by side in a single layer on the radially outer legs of the toroid. They are arranged in layers, and are stacked in large numbers on the inner legs of the toroid in the radial direction.

Multifill windings can be used to wind a group of insulated conductors at once over a winding mandrel, or by multiple passes over a winding mandrel with a single insulated conductor, or an intermediate number of insulated conductors at once. Winding can be done by making multiple passes over a winding mandrel, winding during each pass. Extra lengths of wire are provided to serve as leads at the beginning and end of each pass.

If either a single pass or multiple pass method is used, the excess length of wire forming the lead can be attached to a hook, dowel, or the like attached to a take-up mandrel. In the case of manufacturing a winding wire by multiple passes, the winding direction is reversed at the end of each pass and when connected in parallel as a multi-fill winding, the conductor is connected to the magnetic flux path through the iron core. By connecting the conductors in parallel, each conductor of the completed multifill winding will carry the same voltage.

The low voltage winding is preferably wound on an arcuate semi-circular iron core insulated tube supported and positioned by an expandable mandrel. One low-voltage winding section was completed, resulting in a conductor that was one layer deeper on the radially outer leg of the toroid and two or more layers deeper on the radially inner leg of the toroid. Thereafter, an insulating bulkhead is installed around the first winding section by wrapping insulating paper around the first winding section. Thereafter, a second portion of the low voltage winding having a similar shape is wound onto the first winding portion and the insulating bulkhead. The conductor winding is glued in place following or during the completion of the low voltage winding. Low Voltage - Part of the secondary winding connects to one half of the 120/240 volt output circuit and the other part of the low voltage winding connects to the 120/240 volt output circuit.
Preferably connected to the other half of the 240 volt output circuit. Similarly, two arc-shaped low-voltage winding assemblies are arranged with arcs concentrically forming a circular path through the low-voltage winding approximately 330a.
It is desirable to use it in each transformer so as to form a . Thereafter, the high voltage winding is assembled onto the low voltage winding and a strip of iron core material is wound into an arcuate long passage inside the low voltage winding to form a continuous winding and a continuous iron core as described in the co-pending application. It is desirable to form a toroidal transformer with both.

The features and advantages described in the specification are not all-inclusive, and many other features and advantages will occur to those skilled in the art, particularly in view of the drawings, detailed description, and claims. It should become clear. Further, the terms used in the specification are used primarily for readability and educational purposes and are not used to limit the subject matter of the invention, but rather to determine the subject matter of the invention. Please note that reference should be made to the claims.

Embodiment FIGS. 1 and 2 show a first embodiment of a low-voltage winding machine 10 according to the invention. With the exception of some important variations described below, the winder 10 is manufactured by Universal Manufacturing Co., of New Chassis, Irbyton, which was designed along the lines of the machine disclosed in the above-mentioned 7 Earlbach patents. Assume that it is a "BW" type toroidal winding machine.

The winder 10 includes a winding head assembly 12 and a rotary table assembly 14. The winding head assembly 12 is generally crescent-shaped throughout the drawings and includes a winding head frame having a jaw with a circular central opening for housing an annular wire storage magazine 18 and an annular shuttlecock 20. 1
It is equipped with 6. The wire storage magazine 18 and the shuttlecock 2o are each mounted for independent rotation with respect to the winding head frame 16 by various rotatable mounting wheels 22, 24, which mounting wheels are connected to the circular jaws of the winding head frame 16. It is distributed in a circumferential manner around the . The wire storage magazine 18 is connected by a suitable gear to an air motor which rotatably drives the wire storage magazine 18 about a horizontal winding axis. The shuttlecock 20 is connected by suitable gearing to a numerically controlled drive motor which drives the winding shuttlecock 20 in rotation about a horizontal winding axis independently of the wire storage magazine 18.

The wire storage magazine 18 is equipped with an annular U-shaped storage groove 27 (FIG. 3), and is rotatably driven to wind up electric wires 25 from an external bulk supply source, store appropriate lengths of wire in the storage groove 27, and then store the electric wires 25 in the storage groove 27. The wire #I 25 is unwound from the wire storage magazine 18 so that the wire 25 can be formed into a low voltage winding 48 by winding it onto an arcuate winding mandrel 38. The air motor driving the wire storage magazine 18 is also mounted to provide a braking force to resist rotation of the wire storage magazine 18 during unwinding of the wire storage mandrel 18 from the wire storage mandrel 18. The shuttlecock 20 is rotationally driven via a circumferential ring gear 21 to unwind the electric wire 25 stored on the electric wire storage magazine 18 and wind the electric wire around the winding mandrel 38. For this purpose, the shirttle 2o has an eyelet 26 (the third
) and a pair of guide wheels 28a rotating around an axis parallel to the winding axis.

28b and then lift the electric wire 25 and direct the electric wire 25 onto the winding mandrel 38. The guide wheel 28α is Shirttle 2
0 is used to guide the wire 25 as it rotates counterclockwise (when viewed from the right side of the machine) as shown in FIG. It is used to guide the electric wire 25 when rotating in a clockwise direction as shown by the silhouette in Figure 6.

The rotary table assembly 14 includes a mandrel support assembly 29 and a mandrel clamp 30 having an upper jaw 32 and a lower jaw 34, respectively, which grip a mounting portion of a winding mandrel 38. The take-up mandrel 38 is a circle or arc whose center is located at the axis of rotation 40 of the rotary table assembly 14 such that rotation of the rotary table assembly 14 causes rotation of the arc-shaped take-up mandrel 38 about that axis. It has an arcuate or semicircular shape.

The rotary table assembly 14 is connected to a suitable drive gear and a numerically controlled motor to ensure accurate positioning by reciprocating rotation of a take-up mandrel 38 under the control of an electronic controller 44 during rotation of the shuttlecock 20 and wire storage magazine 18. The wire is wound onto a winding mandrel 38 in a predefined manner. Various instructions to the electronic control unit can be displayed on a suitable CRT 45. Controller 44 and CRT 45 are commercially available from Universal Manufacturing Company.

In operation of the coil winder 10, the wire 25 from the bulk supply source 25 is wound onto the wire storage magazine 18 in a clockwise direction as seen in FIG. A length of electrical wire 25 is stored in the generous storage magazine 18. The wire 25 from the bulk source is then disconnected. The cut end of the wire 25 that has just been stored on the wire storage magazine is secured to a hook or dowel 64 fixedly attached to one end of the winding mandrel 38 to provide a starting lead prior to winding. As depicted in FIG. 3, the wire 25 is removed from the wire storage magazine 18 by the rotation of the shuttlecock 20, and the guide wheel 28α or 28 is removed depending on the direction of rotation of the shuttlecock 20.
b, and is wound onto a winding mandrel 38. The eyelet 26 serves to lift the wire from the storage passage 27 of the wire storage magazine 18 and guide the wire 25 to the guide wheels 28α, 28b. Since the effective winding diameter of the winding mandrel 38 is considerably smaller than the diameter of the wire storage magazine 18, the wire storage magazine 18 rotates independently of the shuttlecock 20 to accommodate the differential speed caused by the difference in diameter. I can do it.

While the wire 25 is wound onto the take-up mandrel 38 by the rotation of the shuttlecock 20 and the wire storage magazine 18, the take-up mandrel 38 rotates around its axis of rotation 40 and winds the wire 25 onto the take-up mandrel 38 in a predetermined manner. Laminate.

Regarding FIGS. 4 and 5, the winding mandrel 38
The winding pattern of the winding pass above is depicted. The winding starts at the top of the winding mandrel 38 as shown in FIG. 4 and progresses as the winding mandrel 38 rotates generally around the shaft 40 in a counterclockwise direction. Please be careful. While the take-up mandrel 38 thus rotates around the axis 40 by a clockwise amount bt in the opposite direction, the shuttlecock 20 and the wire storage magazine 18 rotate around the horizontal take-up axis (
(Regarding Fig. 2) Rotate in the opposite direction to the clockwise direction and
5 onto the winding mandrel 3B.

During such a winding operation, the winding mandrel 38 also undergoes a constant reciprocating "fine" movement, i.e., rotation back and forth about the shaft 40 under the control of the controller 44, to deposit the current m in a predetermined pattern. An example of this is depicted in Figure 5. axis 40
The total amount of clockwise and counter-clockwise reciprocating rotation of the winding mandrel 38 around is equal to the counter-clockwise rotation from FIG. 4 to FIG. Winding mandrel 3
8 will produce a spiral winding, but the desirable reciprocating fine motion of the winding mandrel 38 facilitates the production of non-spiral windings.

In Fig. g8A-8hi, the winding procedure of five conductive wires using the five-strand multifil low tension winding wheel 48 is depicted. Note that one strand is wound sequentially in each of the five passes to provide a multifill winding of five struts and lands. Prior to winding, iron core insulated tube 46 is placed on winding mandrel 38, which will be described in detail below.

In the first pass, detailed in FIG. 8A, a single wire 25 is first attached to the post 64 and wound once onto the end plate 114 (FIG. 12) of the winding mandrel 38 to form a coil. An extra length of conductor is obtained which serves as the starting lead for the line. The electric wire 25 is then broken through the iron core 17. The first nozzle ξ is wound up by the rotation of the shuttlecock 20 in the counterclockwise direction after being introduced onto the tube 46 . The solid transverse lines in FIG. 8A represent the number of turns wound across the top of the winding mandrel 38, while the dashed transverse lines represent the number of turns wound across the bottom of the winding mandrel 38. After the first winding pass is completed, the excess length of wire is removed from the winding mandrel 38.
and then loops around the second post 66 to serve as a complete lead. The wires 25 in the radially inner and radially outer legs are used to distinguish the number of turns of the first winding pass from the number of turns of the following winding pass.
Each cross-section of is represented by a small circle with a blackened half.

Thereafter, a second winding pass is reverse wound (i.e. (Shuttle 20 rotates clockwise)
be done. Upon completion of the second pass, the excess length of conductor extends outwardly from the winding mandrel 38 and returns to the starting lead of the winding.
)" k and looped around the first strut 64. The turns from the first five winding passes are interleaved in a single layer against the iron core insulation tube 46.

FIG. 8C also schematically depicts the third winding pass by solid and dashed transverse lines. In the third winding pass, the wire 25 is wound as the shuttlecock 20 rotates counterclockwise and is represented by a small circle containing two intersecting lines.

In the third winding pass, each winding is approximately evenly spaced. On the outer leg of the toroid the winding lies against the iron core insulation tube 46. However, on the inner leg of the toroid, the windings lie partially in the first layer and approximately equally proportionately in the second radially inner layer relative to the iron core insulation tube 46. In other words, to complete the inner layer of the radially inner leg of the toroidal winding 2
This means that and - windings are required. At the end of the third pass, the extra length of wire 25 extends further outwardly to provide a finished lead for the winding in a loop around the second post 66.

FIG. 8D schematically shows the winding of the fourth pass,
The winding wire is wound as the shuttlecock 20 rotates clockwise. The path of the fourth winding is depicted by a small circle containing solid and dashed transverse lines and two parallel it-lines. Furthermore, the radially outer legs of the toroid have windings lying in a first layer against the iron core insulation tube 46, while
The radially inner legs of the toroid have windings lying in the second layer. The passageway is completed by further extending the lead Ael outwardly and looping it around the strut 64 to form a starting lead.

The final winding pass to complete the low voltage winding section is shown schematically in Figure 8E. Each time the shuttlecock 20 rotates counterclockwise, the windings are wound again, each winding filling the gap left by the previous winding pass. The path of the fifth winding pass is depicted by solid and dashed transverse lines and small black circles.

The last pass approximately fills the available space in the first layer of the radially outer leg and approximately fills the space in the second layer of the radially inner leg. At the end of the fifth winding pass, the finished reed extends outwardly and is looped around the post 66. Thereafter, all of the winding pass leads of strut 64 are connected together and all of the winding pass leads of strut 66 are connected together to form a full multi-filament winding.

As an alternative to the five-pass method depicted in Figures 8A to 8E, by winding more than one conductor at a time, the winding process can be performed with fewer passes than the number of multi-fill guides. . In the first pass, the shuttlecock 20 is rotated in one direction around the winding shaft, and its reciprocating fine movement causes each turn of the two or more wires to be rotated around the winding mandrel shaft. Two or more electrical wires are wound around the winding mandrel 38 such that they are circumferentially spaced from adjacent windings on the radially outer surface of the winding mandrel. In the second pass, the shuttlecock 20 is rotated in the other direction around the winding shaft, and the winding mandrel 38'lt is rotated around the mandrel shaft 40 in the reverse reciprocating fine movement direction. 3 winding mandrels each winding one or more turns of wire
Two or more windings are stacked on the first pass of the radially inner surface of the winding mandrel 38 and arranged between adjacent windings of the first pass of the radially outer surface of the winding mandrel 38. The electric wire is wound around the winding mandrel 38.

It is preferable that the winding of the low-voltage winding 48 is not spiral-shaped. Rather, the windings are placed in the radially inner and outer legs of the winding (
an axially oriented segment (relative to axis 40);
Generally radial or non-radial transitions are provided on the top and bottom legs of the winding. The winding positions of the radially inner and outer legs are configured according to the winding pattern shown in FIGS. 8A-8E. The locations of the windings across the top and bottom legs are configured by the inner and outer leg locations for connection. This positioning is accomplished by using the fine motion paths depicted in FIGS. 6, 7A, and 7B.

The shuttlecock 20 rotates in a fixed vertical plane, which passes through the mandrel shaft 40, while the take-up man or drell 38 vibrates or slightly moves clockwise and counterclockwise around its shaft 40 to generate the electric current #25e. It is positioned on the winding mandrel 38. The four micro-movement positions A-D are depicted in Figure 6 and are provided in a commercially available program guide for general-purpose machines, the results of which are illustrated in Figures 7A and 7B. It is common knowledge. In the embodiments disclosed herein,
The fine movement positions A-D remain the same for the clockwise and counterclockwise re-rotation directions of the shuttlecock 20, but there are four fine movement positions for each winding direction and a relative fine movement position for each winding direction is the other. It is also possible to perform deformation so that it deviates slightly.

Understanding the micromotion path is not necessary for a complete understanding of the invention and the designer may modify such path as appropriate. In short, in order to wind the wire in a non-spiral manner, the winding mandrel 38 is slightly moved in the clockwise and counterclockwise directions as shown in FIGS. 7A and 7B. Electric [
25 across one leg of the winding, after the wire has contacted one edge of the winding mandrel 38, the next edge of the winding mandrel 38, e.g. The electric wire 25 is brought into contact with the edges 39A and 39B of the 7th A.
Before being projected in the non-spiral direction shown in the figure, the winding mandrel 38 rotates around the shaft 40 in the clockwise and counterclockwise directions within the fine movement path A-D. As the shuttlecock 20 continues to rotate counterclockwise around its axis, the electric wire 25 comes into contact with the outer lower edge 39B of the winding mandrel 38, positioning the electric wire 25 so as to cross the bottom surface of the winding mandrel 3B. The bottom surface terminates the fine movement path D2. The clockwise and counterclockwise fine movement paths are such that the shuttlecock 20 rotates around the take-up mandrel 38 and the wire is arranged on the take-up mandrel in the axial direction in a pattern as shown in Figures 8A to 8E. Continue as you provide the medial and lateral legs and connect the top and bottom legs. Overall, electric l1I25 is the winding mandrel 3
The position of the wire 25 as it is wound onto each edge of the winding mandrel 38 is determined by the position of the edge of the previously wound winding mandrel 38 relative to the guide wheel 28 of the shirttle 20. The electric wire 25 is formed directly between the edge of the previously wound winding mandrel 38 and the commercial wheel 28. shirttle 2
As the winding mandrel 38 rotates, the adjacent edges of the wire 25. to limit the wire position between these two edges. The purpose of each fine movement path is to determine the edge position of the winding mandrel 38t according to the winding order shown in FIGS. 8A to 8E.
8 at each edge to position the wire 25 accurately. 9 and 1q, a formed paperboard core insulation tube 46 is shown being mounted on the winding mandrel 38 during the winding of the low voltage winding 48. Low voltage winding 48 includes an inner winding group or section 50 and an outer winding group or section 52 (the latter shown only in FIG. 10) separated by an insulating bulkhead 54. The core insulating tube 46 is shaped so as to surround the wound core of the transformer, and thus has an arcuate cross section and is arranged in the same circular shape as the second such insulating tube, forming an approximately 330° toroidal core. It is designed to form a passage. Each end of the iron core insulated tube 46 carries a pair of end holders 56, 58t-, the end holders 58 are positioned on the radially outer legs of the iron core insulated tube 46, 46 and is adapted to be positioned on the radially inner leg of 46. radially outer end receiver 5
8 is an inclined slot as shown in Fig. 11)59.6)t
- comprising the leads 60 of the inner winding part 50 and the outer winding part 5;
The second lever 162 is positioned and held. The starting IJ-toe #6o of the inner winding portion 52 extends from the starting end 38A of the winding cylinder 38 and is mounted within the end receiver 58 by the upper slot 6). The final end 60 of the inner winding portion 50 is the final end 38B of the winding cylinder 38.
It extends from and is mounted within an end receiver 58 within a lower slot 59 . In a similar manner, the leads 62 of the outer winding portion 52 are installed by starting and ending the winding t-K to position the leads respectively into the remaining alternating slots 59.6).

LOW VOLTAGE WINDING IJ-)'t- When arranged as above, one obtains a reversible semi-circular winding, inside which the leads emerge from the same relative position, and an arrangement in which the coil is installed in the finished transformer. The proper winding direction is maintained regardless of the position.

Referring to FIG. 9, the winding results for the inner portion 50 of the multifilt low voltage winding 48 are depicted.

Note that the inner portion 50 has a single layer of conductor on the radially outer leg of the toroid and a double layer of conductor on the radially inner leg of the toroid. Furthermore,
It can be seen in FIG. 9 that the insulating partition 54 comprises an insulating material, in particular a piece of crepe paper wrapped around the inner winding portion 50 of the low voltage winding 48. Note that the adjacent wrappers of crepe paper are adapted to include at least a single layer of crepe paper on the radially outer legs of the substantially overlapping interlocking inner winding portions 50. The winding portion 50 has the insulating partition wall 54 inside.
After the top winding, the outer low voltage winding section 52 is wound as depicted in FIG. The outer winding section 52 has a single conductor layer on the radially outer leg of the toroid and a double conductor layer on the radially inner leg of the toroid with the inner unwinding section 50. Note that it is wound in the same manner. Either completely following or during the winding of the low voltage winding 48, the conductor winding is coated with an adhesive dry-to-touch B-stage heat cure activated by a baking step following winding. It is bonded into place using a conductive wire or alternatively by wet application of a thermosetting adhesive during winding.

Referring now to FIG. 12, the winding mandrel 38 is depicted in an exploded perspective view. The winding mandrel 38 has upper and lower arcuate support plates 70.72t connected by three expandable cross supports 74.76.78, respectively. Each cross-support member 74, 76, 78 is, for example, a first
A pair of conical washers 82.841 present on a compression bolt 86 screwed into a compression plate 88 as depicted in FIG.
- Be prepared. Compression plate 88 is mounted for movement along guide bolt 89. Conical washer 82
．． 84 are the upper and lower support members 94 and 96 of the cross support member.
each rests inwardly against the conical cam surface 90,92. The compression bolt 86 rotates and the conical washer 82.84t
- separately expanding the upper and lower arcuate support plates 70,72e by acting to bias the support members 94,96 separately when pulled together; The cross support member 74 has an opening 97
(FIG. 12) to allow tool 99 to access the head of compression bolt 86. The tool 99 engages the head of each compression bolt 86 of the three expandable cross supports 74, 76, 78 and rotates the dowel bolt 86 to remove the mandrel 3.
Expand and contract 8.

By enlarging the mandrel 38, the upper and lower arc-shaped support plates 70, 72 are forced to rest on the inner upper and lower surfaces and corners of the iron core insulating tube 46, and the iron core insulating tube 46 is forced into the winding mandrel 38. This prevents the iron core insulating tube 46 from falling or changing during winding of the low voltage winding 48. In this regard, the winding of the low voltage winding 48 is subject to considerable winding which, if not firmly supported, may cause the formed paperboard structure of the iron core insulated tube to fall or deform prior to gluing in subsequent steps. Caused by stress. Of course, insulating tubes of more substantial construction can be fabricated at somewhat higher cost to avoid such deformations. However, the expandable mandrel 3
8 provides a ready means for removably attaching the iron core insulation tube 46 during winding, while also providing structural support. Furthermore, support plate 70.72t
- Completed low voltage winding 4 by folding inward.
8 can be easily removed from the winding mandrel 38.

End plates 98, 100 are attached to the ends of the expandable take-up shim mandrel 38 to hold the insulating tube 46t in place on the spool shim mandrel 38. End plate ioo is permanently attached to cross support 78 and has slot 1o to allow tool 99 access to the head of compression bolt 86 as shown in FIG.
4f, equipped.

End plate ioo also includes mounting plate 100 and cross support 78.
Jaws 32.34 of mandrel clamp 3o fixed to
The mounting stem 106f is shaped to fit securely with the mounting stem 106f. For this purpose, the jaws 32° 34tj are provided with pins 108, while the mounting stem 106 has a corresponding recess 11
0i equipped.

The end plate 98 is removably attached to the cross support member 74 to facilitate attachment and detachment of the iron core insulating tube 46.

The end plate 98 is provided with a slot (112t) that allows a tool 99 access to the head of the bolt 86 to allow expansion and contraction of the cross support 74. The threaded fastener 116 is used to removably attach the pin attachment block 114 and end plate 98 to the cross support 74.

As depicted in FIG.
The attached plate 98 can be removed by removing the threaded fasteners 116 and inserting the insulating bulkhead 46 onto the winding mandrel 38 and similarly removing it after winding. The pin mounting block 114 carries the take-up nail 64, while the mounting stem 106 carries the take-up nail 66.

An alternative winding mandrel 120 is depicted in FIG. Since the winding mandrel 120 is rotatably attached to the mounting stem 122 using the hinge 124, a part of the winding mandrel 120 that carries the iron core insulating tube 46 rotates with respect to the mounting stem 122, and the low voltage winding 48 is rotated with respect to the mounting stem 122. This differs from the winding mandrel 38 in that the iron core insulating tube 46 can be easily attached and removed before and after winding. In particular, the hinge 124 of the iron-core insulated tube 46 must be removed from the take-up mandrel 38 in a circular motion until it is free from the take-up mandrel 38 . Easy to remove. Iron core insulation tube 4
6, it is not free from the winding mandrel 38 so close to the mounting stem 106 that it provides little clearance for the insertion and removal of the iron core insulation tube 4.6. Hinging with the mounting stem 122 allows for an outward hinge of the portion of the mandrel 1200 that carries the iron core insulating tube 46, thereby creating a considerably larger clearance for removing the iron core insulating tube 46.

16, 17 and 18 depict a second low voltage coil winding machine 130 according to the present invention. The low-voltage coil winding machine 130 is a multi-fill low-voltage winding machine that winds the coil in one pass. To facilitate single-pass winding of multifil, multiple strands of multifil wire 132 are simultaneously wound onto storage magazine 134 from a Maru F-fill wire source or a single conductor demultiplex source. After the multiple strands of conductor 132 are wound clockwise onto the storage magazine 134, the shirttle 136 and storage magazine 134 are rotated counterclockwise to unwind the multifill conductor 132 as shown in FIGS. 19A-19a. Then, it is wound onto the iron core insulating tube 46.

As the shuttlecock 136 rotates counterclockwise, the multi-strand multifilter conductor 132 rises and is unwound from the storage magazine 134 by the multifilter eyelet 138 . To facilitate this purpose, the multifill eyelet 138 is provided with multiple guide grooves, one for each strand of the multifill conductor 132.

The shuttlecock 136 has a plurality of wire tension wheels 14o-
150, each with a groove around its periphery. Each strand 9 of multifill conductor 132 is wrapped separately around at least one tension pulley 140-150. The welding strand of multifill conductor 132 rests on top of the other tension pulley. Thus, each tension pulley 140-150 serves to tension a single strand independently of the other strands. However, one or more tension pulleys may be required to properly tension a single strand.

This independent tensioning of each strand of multifill conductor 132 results in a strand configuration of multifill conductor either on storage magazine 134 or on iron core insulated tube 46 mounted on take-up mandrel 38. Accommodate heterogeneity.

To provide a single bus coil winding of the multifill in a clockwise direction, a grooved guide wheel 152α is used for each strand of multifill conductor 132. After traversing the guide wheel 152α, the multifill conductor 132 is wound onto the iron core insulation tube 46 as the shuttlecock 136 and the storage magazine 134 rotate counterclockwise. Similarly, adjacent guide wheels 152b' having grooves are used for each of the conductors of the multi-fill conductor 132, and wound in the clockwise direction.

FIGS. 19A to 19E show the multifill conductor 13
The preferred method and pattern for 2t-single pass lamination is depicted. The multiple conductors 132 are simultaneously wound on the winding mandrel 38, and the multiple conductors are stacked side by side in a single layer on the radially outer surface of the winding mandrel 38 in the radial direction of the winding mandrel 38. The inner surface is laminated in double layers to form one layer of low voltage winding 48 in one pass. Briefly, the method involves wrapping the multiconductor wire around and in contact with the winding mandrel 38 to stack one or more windings of the first type, and then stacking the multiconductor wire in all radial directions outward. The first type of windings are positioned side-by-side on the face of the take-up mandrel 38 and stacked in one or more portions of the first type winding on the radially inner face of the take-up mandrel 38. The method includes the steps of winding the second type of winding, and then alternately winding the tube and the second type of winding until the set of windings is completed.

As shown in FIG. 19A, the first step in the method of winding the multifiled conductor 132 in one noun is that all the two or three windings of the first type, the multiplex conductor 132, are all on the winding mandrel 38. It consists of a step of winding the iron core insulating tubes 46 so that they lie side by side. The multiple conductor 132, which is depicted as consisting of five conductors, is arranged in the same manner as described above, i.e., the shuttle 136k (as seen in FIG. 16) is oriented counterclockwise on its horizontal winding axis. Meanwhile, the winding mandrel 38 is rotated in a reciprocating manner around the mandrel shaft 40 so that the conductor is rotated in a radial direction of the winding mandrel 38 on the inner and outer surfaces of the winding mandrel 38.
It is desirable to wind the winding material onto a winding mandrel 38 by axially locating it with respect to the mandrel axis 40 across the top and bottom surfaces of the winding mandrel 38 . Two such first type windings are depicted in FIG. 19A.

As depicted in FIG. 19B, the second type of winding is then carried out by winding the multiple conductor wire by means of a rotating shuttle 136 on one or more of the radially inner surfaces of the winding mandrel 38. The windings are wound on the radially outer surface of the winding mandrel 38 so as to be located side by side with previously wound windings of the first type. At least two of the windings of the first type are wound on the inner surface of the winding mandrel 38 before winding #I of the second type is entirely wound thereon, and the winding of the second type is laminated thereon. It is desirable to have a wide inner layer that has a wide inner layer. If the first type windings are stacked on top of a single first type winding, then one or more strands of the second type windings will overlap the edges of the first type windings below. There is a possibility that it may slip into a position behind the winding mandrel 38 that would be occupied by the first type of winding that follows from the section. Winding of the second type of winding υ Before starting the whole winding of two or more first type of winding, multiple conductors of the second type of winding are first wound of the first type. Stacking on turn winding sections eliminates this problem.

A second type of winding is stacked on top of the first type of winding previously wound on the radially inner surface of the winding mandrel 38 and is also previously wound on the radially outer surface of the winding mandrel 38. After the first type windings are wound onto the winding mandrel 38 stacked side by side, the winding process continues by alternately winding all the first type and second type windings. .

Each winding of the first type is arranged side by side with a winding of the second type wound before the radially outer surface of the winding mandrel 38 and The first type of winding is placed next to the first type of winding that was previously wound. The second type of winding each has a winding mandrel 3
8 and wound on the radially outer surface of the take-up drum/drel 38. placed side by side with the first type of winding.

19B through 19E, the radially outer surface of the winding mandrel 38 is substantially filled with conductors that are aligned, and the radially inner surface of the winding mandrel 38 is filled with conductors that are aligned. This continues until the two layers are substantially filled to complete the inner winding set of low voltage winding 48. The outer periphery of the winding is then insulated by wrapping a piece of insulating material around the entire winding, as previously described with respect to FIGS. completely surrounds the inner winding set.

Above is the method of winding the multifilter conductor in one pass (
Although described in the example of winding in a left-handed direction (as depicted in FIG. This can also be done by winding in the circumferential direction. Additionally, although the example shown in FIGS. 19A-19E depicts the winding operation starting from the inside surface of the winding mandrel 38, the method also includes starting the winding operation from the outside surface of the winding mandrel 38. This can also be done similarly by starting. Similarly, the radially inner and outer surface conductors 132 do not extend to the axially oriented K, but could also be arranged in a spiral manner.

The foregoing discussion merely describes methods and aspects of implementing the invention. Those skilled in the art should be able to easily understand from the extensive discussion that various changes and modifications can be made therein without departing from the spirit and scope of the invention as described in the claims. be.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of the low voltage winding machine of the present invention, Fig. 2 is a side view of the winding machine shown in Fig. 1, and Fig. 3 is a front view of the wire storage magazine and shuttlecock of the winding machine shown in Fig. 1. 4 is a top view of the winding mandrel at the beginning of the winding process; FIG. 5 is a top view of the winding mandrel at a later point in the winding process; FIG. Figures 7A and 7B are perspective views of the winding mandrel during the winding process; Figures 8A and 7B are perspective views of the winding mandrel during the winding process; Figures 8E to 8E are top diagrams of the winding mandrel depicting the winding pattern of the multi-pass single sland winding method for producing all multi-fill windings, and Figure 9 is after winding the first group of windings. FIG. 10 is a top view of the winding mandrel after winding the second group of windings, partially shown in cross section, and FIG. Figure 12 is a perspective view of the winding mandrel after the winding process is completed; Figure 12 is an exploded perspective view of the enlarged winding mandrel;
The figure is a top view of the winding mandrel showing the state in which iron core insulating tubes are loaded and unloaded. Figure 14 is a detailed cross-sectional view of the cross-supporting material of the winding mandrel taken along line 14-14 in Figure 12. FIG. 15 is a top view of an alternative embodiment of the winding mandrel; FIG. 16 is a right side view of an alternative embodiment of the shirttle; FIG.
The figure is a detailed sectional view of the shirttle part in Figure 16.
Figure 18 is a view of the shuttlecock and wire storage magazine of Figure 16, taken from the side of arrow 18 in Figure L6; Figures 19A to 19E are Multifill volume #! FIG. 3 is a top view of a winding mandrel showing a winding shifter of a single-pass multi-conductor winding method for manufacturing a winding mandrel; DESCRIPTION OF SYMBOLS 10... Low voltage winding machine, 12... Winding head assembly, 18... Wire storage magazine, 20... Annular shuttle 16... Winding head frame, 38... Winding mandrel, 14...Rotary table assembly, 44...Cleaning of 2 surfaces of the control device! (Please change the content) FIG, 4 FIG
, -5゜Procedural amendment (method) 1945-#Tankasuri application No. 2vri// No. Fυida 1V
Change hill Jshi J eyes rice; i41 milk gate tzashi 1 ha J ni °to (unin-6, relationship with the case of the person making the amendment) Applicant's address A law 'r-'7- + Leman・Ku 4 - Remedy Beta 4, Agent

Claims (11)

[Claims] (1) An arc-shaped take-up mandrel and a toroidal take-up machine are used, and the toroidal take-up machine is equipped with a magazine that rotates around a take-up axis that is substantially perpendicular to the rotation axis of the take-up mandrel, and the take-up mandrel guiding means for supplying and conveying the wire to be wound on the winding mandrel, comprising a shuttle that rotates around the winding shaft, is positioned coaxially with the magazine and surrounds the winding mandrel, and the shaft is connected to itself; In a method for manufacturing a toroidal multi-filament wire that functions to guide electric wire from the magazine to the take-up mandrel, the take-up mandrel is supported around the rotation axis of the take-up mandrel and rotated freely in a reciprocating manner. the winding while winding a first pass of one or more wires onto the winding mandrel by rotating the shuttle in one direction around the winding axis; making a second pass of the one or more wires by rotating the mandrel in one direction about its axis of rotation and rotating the shuttle and magazine in the opposite direction about the take-up axis; While winding onto the take-up mandrel, the take-up mandrel is rotated about its axis of rotation in the opposite direction so that each winding of the second pass is similar to that of the first pass on the take-up mandrel. A method for manufacturing a toroidal multi-filament winding, comprising the step of positioning the winding between the windings. (2) expanding the one or more wires wound outside the winding mandrel at the end of each pass to form a lead around a dowel positioned adjacent the end of the winding mandrel; looping one or more wires; continuing to wind the one or more wires in several additional passes between previous passes until the radially inner surfaces of the winding mandrels are lined up; continuing to loop the one or more wires around the dowel until it is substantially filled with wire to form a first layer of winding; and adding the one or more wires. radially stacking target passes on the take-up mandrel between preceding passes on the radially outer surface of the take-up mandrel and over the layer of windings on the radially inner surface of the take-up mandrel; 2. The method of claim 1, further comprising the step of continuing to wind and loop the one or more wires around the dowel. (3) A method according to claim 1, characterized in that the winding mandrel has a semi-toroidal shape. (4) Electrically connect the looped wire portions together around one of the dowels, electrically connect the looped wire portions together around the other dowel, and 3. A method according to claim 2, comprising the step of increasing the number of parallel multi-film wires. (5) the magazine carries two or more strands of wire, and the step of winding the wire onto the take-up mandrel involves rolling the two or more strands of wire onto the take-up mandrel; 2. A method as claimed in claim 1, characterized in that it comprises arranging. (6) A first group of windings is manufactured by the above process, and a second group of windings is produced by rotating the shuttle and magazine in one direction around the winding shaft, and rotating the first group on the winding mandrel. windings of the first group by winding a first pass of one or more wires of the second group onto the windings of the line, while the winding mandrel is wound around the windings of the line. one on the winding mandrel at the top of the first group of windings by rotating the shuttle and magazine in opposite directions around the winding shaft. or more, winding a second pass of the wire, each winding of the second pass being disposed between the windings of the first pass on the winding mandrel and in opposite directions about its axis of rotation. The take-up mandrel is rotated to pass additional passes of the one or more wires of the second group onto the take-up mandrel between the top of the first group of windings and the previous pass. continuing to wind until the radially inner surface of the second group is substantially filled with layers of side-by-side wires of the second group, and making the one or more additional passes of the second group over the winding mandrel. on the radially outer surface of the winding mandrel between the preceding passes of the first group of windings and the second group of windings; 3. The method of manufacturing a multi-film winding having two groups of windings according to claim 2, characterized in that the wires are laminated in the radial direction on the layer of lined wires and continue to be wound. 7. The method of claim 1, further comprising the step of: (7) electrically connecting the two or more wire sections together to increase the number of parallel multifilament wires in the winding. (8) A method for manufacturing a toroidal-shaped multi-filament wire, which method uses an arc-shaped winding mandrel and a toroidal winding machine, the winding machine is equipped with a magazine and a shuttle, and the magazine is used for winding the winding wire. The shaft rotates about a winding shaft substantially perpendicular to the axis of rotation of the mandrel and conveys two or more strands of wire to be wound into the winding mandrel, and the shuttle rotates around the winding shaft to comprising guide means positioned coaxially with respect to the magazine, surrounding the take-up mandrel, and coupled to itself for guiding the electrical wire from the magazine to the take-up mandrel; supporting and rotating the winding mandrel about an axis of rotation, winding one or more windings comprising a first type of winding of two or more electrical wire strands on the winding mandrel; One turn of a second type of winding of the two or more electrical wire strands is placed on the winding mandrel side by side on the radially outer surface of the winding mandrel and in the radial direction of the winding mandrel. radially stacking and winding portions of the one or more first type windings with their inner faces, and windings of the first and second type of the two or more wire strands; The windings continue to be wound alternately on the winding mandrel, until finally a multifilar winding is completed, each winding of the first type being preceded by a winding of the first type on the radially inner surface of the winding mandrel. a second type of winding positioned in tandem with the winding line and preceding it on a radially outer surface of the winding mandrel, the second type of winding being positioned in the radial direction of the winding mandrel; stacked on one or more preceding winding portions of the first type on the inner surface and positioned radially alongside the preceding first type winding portion on the outer surface of the winding mandrel; A method for manufacturing a toroidal multi-filament wire characterized by: (9) A first group of windings is produced by the above process, and a second group of windings is one or more of the first type windings of the two or more wire strands of said second group. Winding the wire into the first group of windings on the winding mandrel, and winding one turn of a second type winding of the two or more wire strands onto the winding mandrel. side by side with the one or more first type windings on the radially outer surface of the winding mandrel and on the one or more first type winding portions on the radially inner surface of the winding mandrel. radially stacking and winding the first and second types of windings of the two or more wire strands on top of the first group of windings on the winding mandrel; continuing to wind, finally completing a second group of windings, each of the first type windings being located alongside the preceding first type winding on the radially inner surface of the winding mandrel; located side by side with a preceding second type winding on the radially outer surface of the winding mandrel, each of the second type windings being one on the radially inner surface of the winding mandrel; or a plurality of preceding windings of the first type, such that they are stacked on top of one or more preceding windings of the first type so as to be located side by side with the preceding first type windings on the radially outer surface of the winding mandrel. A method of manufacturing a multi-film winding comprising two groups of windings according to claim 8. (10) A toroidal-shaped winding mandrel, a rotation support means for supporting and positioning the winding mandrel and rotating the mandrel around its rotation axis, and a winding shaft substantially perpendicular to the mandrel axis. a magazine rotatable in both directions around the winding shaft for conveying the winding to be wound onto the winding mandrel; a magazine rotatable in both directions around the winding shaft and positioned coaxially with respect to the magazine; comprising a shuttle surrounding a winding mandrel, and a guiding means connected to the shuttle for guiding the electric wire from the magazine to the winding mandrel, the electric wire being wound on the winding mandrel and connected to the magazine and the shuttle. While rotating the mandrel in a certain direction around the take-up axis while rotating the mandrel in a certain direction around the mandrel axis, rotating the magazine and shuttle in the other direction around the take-up axis, 1. An apparatus for manufacturing a toroidal multifilar winding, characterized in that the multifilar winding is formed by rotating the winding mandrel in the other direction around the mandrel axis. (11) The magazine serves to transport two or more strands of wire, and the shuttle serves to place the two or more strands of wire side by side on the winding mandrel. 11. The device according to claim 10, characterized in that: