JPS63190310A - Coil winding body - Google Patents

Abstract

PURPOSE:To enable aligned winding of a coil, by using a round-type wire at its folding part so as not to deform an attitude of the coil there. CONSTITUTION:A tip of a round-type wire 4b whose cross-sectional area is circular is made to pass through a guide nozzle 7a, rollers 6a and 6b, a guide nozzle 7b, and it is tied around a bobbin 3 and fixed. In succession, a motor 1 for bobbin rotation is operated to wind the wire 4b around the bobbin 3. Simultaneously, a motor 9 for traverse guide is also operated so that a whole wire molding part (plate 5) is traversed on a ball screw at wire width pitches of a flat-type wire 4a while synchronizing with rotation of the bobbin 3 (rotation of the motor 1 for bobbin rotation). Thus, the round-type wire 4b is used before it is tied around the bobbin 3, and the flat-type wire 4a is used when it is wound around the bobbin 3. Hence, a cross-sectional attitude of the flat-type wire 4a can be easily made uniform, and since the round-type wire 4b is used, the wire 4 can be easily unwound from a drum (around which the wire 4 is wound) without being twisted.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a winding body forming, for example, a field coil of a starter or a rotor coil of an alternator.

[Traditional technique j nete]

As society's demands for smaller and lighter equipment increase, attempts are being made to increase the density of the coils that make up electromagnetic devices.

On the other hand, in the conventional type, a round wire coil is used and the coil is wound around a winding frame (bobbin).

[Problem that the invention seeks to solve]

However, in the conventional device described above, when the round wire coil 20 is wound on the bobbin 21 in layers, the directions of the leads 20c and 20d of the adjacent lower layer 20a and upper layer 20b are , since they are in opposite directions,
The wire newly wound on the upper layer 20b is connected to the lower layer 20a in the opposite direction.
A force is applied to cause the lead groove 200.20d to follow. As a result, the leads 20d of the upper layer 20b become disordered as shown in the figure, and as the layers are stacked, the disorder of the leads 20d increases.

Further, even if the winding machine is highly accurate and the alignment of the round wire coils is improved to the limit without any disturbance of the leads, it is not possible to fill up the empty spaces between adjacent round wire rods.

Therefore, as shown in FIG. 14, instead of using the A-wire coil, there are some that use a rectangular wire coil 22, but as shown in this figure, when transitioning from the lower layer to the upper layer by folding back the layer end 22a, Since the coil 22 is a rectangular wire, there is a problem that it does not fit within the winding frame 23 and the posture of the coil 23 is shifted, making it difficult to wind the upper layer.

[Means for solving problems]

Therefore, the present invention provides: a winding frame; a flat coil wound in multiple layers around the outer periphery of the winding frame;
The winding body is provided with a substantially circular coil at the end of the layer forming the folded part;

[Effect]

By forming the folded portion into an A-wire coil, the coil can be wound with a rectangular wire without changing its posture when moving from the lower layer to the upper layer, unlike in the conventional case.

〔Effect of the invention〕

As described above, in the present invention, by forming the folded portion into a round wire, there is an excellent effect that the coil can be wound in an aligned manner without changing the posture of the coil in the folded portion.

[Example] Hereinafter, an example of the present invention shown in the drawings will be described. 1st
The figure is a partially sectional perspective view showing the overall configuration of an embodiment of the coil winding device according to the present invention.

Reference numeral 1 denotes a reel frame rotation motor, and 2 a reel frame fixing jig, which is directly connected to the reel frame rotation motor 1, and is shown in half section in the figure. 3 is a winding frame, which includes a winding frame fixing jig 2 and a disc 2a.
It is clamped and fixed between. 4a and 4b are wire rods. 5 is a plate, and this plate 5 has a forming roller 6a.

6b, guide nozzles 7a, 7b for wire rods 4a, 4b.

A forming roller rotation motor 8 is provided. Reference numeral 9 denotes a traverse guide motor, which is connected to the plate 5 via a ball screw 11.

The guide nozzles 7a and 7b are fixed to the arm portion 5a of the plate 5, and are passed between the rollers 6a and 6b.
They are placed in a straight line.

Reference numeral 12 denotes a mechanical valve, which is disposed on both sides of the plate 5 in the reciprocating direction so as to be activated by being pushed by the plate 5 when the plate 5 moves to the position where the layer end folded portion of the coil is wound. The function is to switch the direction of operation.

FIG. 2 is a schematic cross-sectional view taken along line A--A in FIG. 1.

I3 is a slide flock, which is disposed in the slide groove of the plate 5 and is connected to the roller slide cylinder 1.
4 is combined. The roller 6b is rotatably attached to the slide block 13, and the roller 6a is directly connected to the molding roller rotation morph 8 and is rotatably held against the plate 5.

Next, to explain the operation of the coil winding device of the present invention having the above configuration, first, the tip of the round wire material 4b having a circular cross section is
It is passed through the guide nozzle 7a, between the rollers 6a and 6b, and through the guide nozzle 7b, and is fixed around the outer periphery of the winding frame 3.

At this time, the plate 5 is at the position where the layer end folded portion of the coil is wound, that is, at one end of the reciprocating motion (one end of the winding frame 3), and is pushing the mechanical valve 12, so the mechanical valve I2 is switched at that time. Depending on the direction, the roller slide cylinder 14 is actuated, and the roller 6b
Move the slide block 13 holding it downward (arrow B
direction), and the gap between the rollers 6a and 6b is made larger than the wire diameter of the round wire 4b.

Thereafter, the winding frame rotation motor 1 is operated to wind the wire 4b around the outer periphery of the winding frame 3. At the same time, the traverse guide motor 9 also rotates, and the entire wire molding group (plate 5) shown in FIG.
The rotation of the reel 3 (reel rotation motor I
traverse in synchronization with the rotation of When the winding frame 3 rotates once, the plate 5 separates from the mechanical valve 2. At this time, the valve switches, the roller slide cylinder 14 operates, and the slide block 13
by raising the round wire rod 4 to close the gap between the rollers 6a and 6b.
The roller 6b is moved upward (in the direction of arrow C) so as to obtain a predetermined amount of crushing b.

Further, the forming roller 6a is rotated by the operation of the forming roller rotation motor 8, and while drawing the round wire 4b between it and the roller 6b, it continuously crushes the round wire 4b to form a rectangular wire as shown in FIG. Mold 4a. During this time, the round wire 4b is stably guided to a predetermined position between the pair of forming rollers 6a and 6b through the guide nozzle 7a. Thereafter, it is formed into a rectangular shape and guided to the winding frame 3 through the guide nozzle 7b.

In this way, when the plate 5 moves to the other end (the other end of the winding frame 3) while winding the flat wire 4a, the mechanical valve 12 is pushed again, the valve is switched, and the flat wire 4a is moved to the other end (the other end of the winding frame 3).
Return to round line 4b. This operation is repeated until the end of the winding, that is, the folded end portion of the layer is wound with round wire, the other portions are wound with rectangular wire, and this process is repeated continuously.

In addition, when changing the round wire 4b to the flat wire 4a, the width of the flat wire 4a should be adjusted! , rolling ratio when other thicknesses are t -f/
According to experiments, by setting l to about 1.5 or less, wire rod 4b
The outer insulation coating will not be destroyed.

Therefore, by adopting the above-mentioned configuration, the wire 4 is initially wound around the winding frame 3 as a round wire 4b, and when it is wound around the winding frame 3, it is made into a flat wire 4a. It is easy to keep the cross-sectional posture constant, and since the wire rod 4 is a round wire rod 4b, it is easy to unwind the wire rod 4 from the drum (the wire rod 4 is wound) without twisting.

In addition, when first twisting the tip of the wire 4 around the winding frame 4, it is done with the round wire 4b, and after the tip is tied, the flat wire 4a is formed and wound around the winding frame 3, so the wire is twisted. The wire rod 4 can be wound very easily without any problems.

In addition, in order to wind the layer end folded portion with the round wire material 4b, the first
As shown in FIG. 2, there is no problem that the orientation of the rectangular wire 4a is distorted when the winding moves from the lower layer to the upper layer at the layer end folding portion.

In addition, since the rectangular wire 4a is wound around the winding frame 3, the number of lead grooves between the rectangular wires 4a is reduced, thereby eliminating the influence of the upper layer lead 4d on the lower layer lead 4e, resulting in a high degree of alignment. winding is possible.

In the second embodiment shown in FIG. 4, a first roller 6a is attached to the tip of the shaft 8a of the motor 8 for rotating the forming roller.
is fixed. Note that a first full gear I5 is fixed on the shaft 8a, and a second full gear 16 meshes with the first full gear 15. A second roller 6b is fixed to the shaft 17 to which the full gear I6 is fixed. The first and second rollers 6a and 6b are arranged at right angles.

Further, 14a is a first roller slide cylinder, 13
a is a first slide block, 6c is a third roller rotatably provided on the first slide block 13a, and this third roller 6c is arranged in a straight line with the first roller 6a, It moves in the direction of the arrow by the first roller slide cylinder 14a.

Furthermore, 14b is a second roller slide cylinder, 1
3b is a second slide block, 6d is a fourth roller rotatably provided on the second slide block 13b, and this fourth roller 6d is arranged in a straight line with the second roller 6b, It moves in the direction of arrow E by the second roller slide cylinder 14b.

Then, as shown in the fourth time, a square gap 18 is formed by the first to fourth rollers 6a to 6d.

Then, as in the first embodiment described above, the round wire rod 4b is
By inserting the wire into the gap 18, the round wire 4b can be turned into a square wire 4c. Further, when the round wire rod 4b is wound around the winding frame, the first and second roller slide cylinders 14a are used.

14b, the third and fourth rollers 6c and 6d are moved to make the gap formed by the first to fourth rollers 6a to 6d larger than the diameter of the round wire 4b. After the tip of the round wire 4b is wrapped around the winding frame, the round wire 4b is turned into a square wire 4, and the square wire 4c is wound around the winding frame 3, as shown in FIG.

Furthermore, when the degree of alignment is improved to the limit for both round wire and flat wire, the square wire-wound coil shown in Figure 5 has smaller gaps between the wires than the round wire-wound coil shown in Figure 6. It has the effect of becoming. Comparing this in terms of space factor, assuming that the cross-sectional shape of the rectangular wire is rectangular, the rectangular wire-wound coil has a space factor of 27% compared to the round wire-wound coil.
It has the advantage of being 4% more expensive. The formula below is the calculation formula.

Here, space factor - Σ (wire cross-sectional area)/(wireable space cross-sectional area).

Then, the hatched portions shown in FIGS. 7 and 8 (vertical 3a,
Calculate the space factor of the horizontal square portion (3a). Here, a
is the wire diameter of the round wire 4b.

Conventional coil space factor: (9X(π/4)a2/ (3a)”)X100-
78.5% Space factor of the coil according to the present invention = (total wire cross-sectional area)/(3a) 2xlo.

-100% +(100%-78.5%)/78.5%)xloo-
27.4% (In the coil according to the present invention, there is no empty space between adjacent wire rods, so the space factor is theoretically 100%.) Coil manufactured by the coil winding device according to the present invention Because the wire rod is rectangular, the upper layer of the coil is not affected by the lower layer leads, improving the degree of alignment. This results in a coil without a winding frame as shown in Figure 9, and a coil as shown in Figure 10. Winding of trapezoidal coils, etc. becomes easier.

In addition, in order to form the round wire 4b into the flat wire 4a,
As shown in the figure, the first to fourth rollers 6a to 6d are used, but they may be formed as in the embodiment shown below.

In FIG. 11, opposing protrusions 6e' and 6f' are formed at one end of a pair of rollers 6e and 6f, respectively, and a square gap is formed between the pair of rollers 6e and 6f.

In the one shown in FIG. 12, a pair of rollers 6g and 6h are opposed to each other, and triangular grooves 6g' and 6h' are formed on the outer peripheries of the pair of rollers 6g and 6h, respectively.
A square gap is formed between h'.

[Brief explanation of the drawing]

Fig. 1 is a partial cross-sectional perspective view showing the overall configuration of the first embodiment of the winding device of the present invention, Fig. 2 is a partial cross-sectional schematic diagram of the wire molding part shown in Fig. 1, and Fig. 3 shows the roller and wire rod. A perspective view showing,
FIG. 4 is a schematic diagram showing a second embodiment of the winding device of the present invention,
5 to 8 are schematic diagrams of coils for explaining the present invention in comparison with conventional ones, FIGS. 9 and 10 are schematic diagrams showing other embodiments of the coil according to the present invention, and FIGS. 1st
Figure 2 is a front view showing another embodiment of the roller, and Figure 1 is a front view showing another embodiment of the roller.
Figure 3 is a perspective view showing a conventional round wire rod in which the upper layer leads follow the lead grooves in the lower layer, causing the upper layer leads to become disordered, and Figure 14 shows a state in which the rectangular wire is out of position at the folded end of the layer. FIG. 1...Reeling frame rotation motor, 2...Reeling frame fixing jig, 3
...Reeling frame, 4a...Flat wire, 4b...Round wire, 5.
... play), 6a, 6b... forming roller, 7a, 7
b... Nozzle, 8... Molding roller rotation motor, 9
...Motor for traverse guide, 11...Pole screw, 12...Mechanical valve, 13...Slide block, 14...Cylinder for roller slide.

Claims (1)

[Claims] A winding frame; a flat coil wound in multiple layers around the outer periphery of the winding frame;
A winding body with a substantially circular coil at the end of the layer forming the folded part;