WO2023032415A1 - コイルの製造方法及びコイル曲げ治具 - Google Patents
コイルの製造方法及びコイル曲げ治具 Download PDFInfo
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- WO2023032415A1 WO2023032415A1 PCT/JP2022/024375 JP2022024375W WO2023032415A1 WO 2023032415 A1 WO2023032415 A1 WO 2023032415A1 JP 2022024375 W JP2022024375 W JP 2022024375W WO 2023032415 A1 WO2023032415 A1 WO 2023032415A1
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- Prior art keywords
- coil
- bending
- heating
- planar coil
- jig
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- 238000005452 bending Methods 0.000 title claims abstract description 161
- 238000000034 method Methods 0.000 title claims abstract description 65
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 51
- 238000010438 heat treatment Methods 0.000 claims abstract description 92
- 238000004804 winding Methods 0.000 claims abstract description 31
- 238000003825 pressing Methods 0.000 claims description 26
- 239000002966 varnish Substances 0.000 claims description 17
- 239000000853 adhesive Substances 0.000 claims description 16
- 230000001070 adhesive effect Effects 0.000 claims description 16
- 230000004927 fusion Effects 0.000 claims description 14
- 230000006698 induction Effects 0.000 claims description 9
- 239000004020 conductor Substances 0.000 abstract description 6
- 238000000465 moulding Methods 0.000 description 11
- 238000000137 annealing Methods 0.000 description 7
- 238000001816 cooling Methods 0.000 description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical group [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 5
- 238000002844 melting Methods 0.000 description 4
- 230000008018 melting Effects 0.000 description 4
- 239000013078 crystal Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000002542 deteriorative effect Effects 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 210000003298 dental enamel Anatomy 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21F—WORKING OR PROCESSING OF METAL WIRE
- B21F3/00—Coiling wire into particular forms
- B21F3/02—Coiling wire into particular forms helically
- B21F3/06—Coiling wire into particular forms helically internally on a hollow form
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
Definitions
- the present invention is a coil for manufacturing a hook-shaped coil in which a portion of a planar coil in which a conductive wire is wound in multiple layers (or multiple rows and multiple layers) is bent at a predetermined angle in a direction perpendicular to the surface of the planar coil.
- the present invention relates to a manufacturing method and a coil bending jig.
- an irregular-shaped coil for example, a hook-shaped coil, as shown in FIG.
- a planar coil 1A with multiple layers (or multiple rows and multiple layers) of approximately rectangular shape is formed, and part of the obtained planar coil 1A is bent in the vertical direction perpendicular to the planar coil portion 1a to form an L-shaped coil 1B. method is commonly used.
- a coil manufacturing method has been proposed that includes a 90-degree bending process in which a winding (flat coil) formed in the winding process is bent (for example, Patent Document 1).
- a pair of bending dies is used to bend the winding (flat coil) formed in the winding process by bending it 90 degrees.
- a conventional multi-layer (or multi-row and multi-layer) planar coil 1A is formed, and a part of the resulting planar coil 1A is vertically bent to form an L shape.
- the wire is shifted at the end of the bent portion (vertical portion) 1b after bending (below the two-dot chain line in FIG. 1B), so the potential difference between the windings increases.
- the characteristics of the coil are negatively affected, such as the influence on the structure and assembly.
- the bent portion of the coil protrudes in the lateral direction as shown in FIG.
- the coil manufacturing method described in Patent Document 1 also has the problem that a large stress is applied between the coil wire rods at the bent portion when the planar coil is bent in the perpendicular direction.
- the spring back of the copper core wire and the insulating film layer on its surface is strong, and there is also a problem that a larger return than the intended bending position occurs.
- annealed copper wire is mainly used as a conductor wire (material) for coil winding, but there are secondary or tertiary processed wire materials.
- Such a wire is a wire material that has the above problems due to stress strain during secondary or tertiary processing.
- Another object of the present invention is to provide a coil manufacturing method and a coil bending jig capable of finishing the coil dimension after bending with high precision and suppressing stress between and inside the coil wires at the bending portion. is to provide
- a coil manufacturing method includes a planar coil forming step of winding a conductive wire in multiple layers (or multiple rows and multiple layers) to form an air-core planar coil, and a planar coil formed in the planar coil forming step. a first heating step of heating the coil to a predetermined temperature; a bending step of bending at least a portion of the planar coil heated in the first heating step at a predetermined angle in a direction perpendicular to the surface of the planar coil; and a second heating step of heating the formed bending coil at a predetermined temperature for a predetermined time.
- a portion of the planar coil is bent at a predetermined angle in a direction perpendicular to the surface of the planar coil in the bending process to form the coil.
- Annealing treatment is performed by heating the bent coil at a predetermined temperature for a predetermined period of time, so that the characteristics of the coil can be maintained without lowering the degree of alignment of the wire due to the bending process.
- the bent coil after bending there is no overhang in the lateral direction at the bent portion of the coil, and stress between the coil wires and inside the wire is suppressed, which occurs in the coil molded product. Springback can be suppressed, and the coil dimensions after bending can be finished with high accuracy.
- the planar coil has a pair of parallel portions extending parallel to each other and a pair of connecting portions that connect the ends of the pair of parallel portions. It is preferable that only one pair of parallel portions of the planar coil is wound while the adhesive varnish is applied to each layer.
- the conducting wire has a fusion layer on its surface, and the planar coil is heated to the softening temperature of the fusion layer in the first heating step.
- the first heating process and the bending process it is preferable to perform heating and bending in a plurality of different temperature zones.
- planar coil forming process when forming each layer of the planar coil, it is preferable to gradually decrease the predetermined dimension in the vertical direction at the end to be bent so as to form a step.
- the temperature of the jig in which the planar coil or the bending coil is set is increased by high-frequency induction heating, so that the planar coil or the bending coil is heated from the jig. It is preferred to use a heating method that conducts heat.
- the coil bending jig is a hook obtained by bending a portion of a planar coil in which a conductive wire is wound in multiple layers (or multiple layers and multiple rows) at a predetermined angle in a direction perpendicular to the surface of the planar coil.
- a coil bending jig for manufacturing a shaped coil comprising a holding jig for holding both side surfaces of a bent portion of a coil, wherein the holding jig is applied to both side surfaces of the bent portion during bending. It is configured to repeatedly perform the operation of loosening and tightening the presser.
- the coil bending jig includes a holding jig that holds both sides of the bent portion of the coil, and the holding jig repeatedly loosens and tightens the holding on both sides of the bent portion during bending. By doing so, there is no lateral overhang (see FIG. 14) in the bent portion of the coil unlike the conventional manufacturing method, and the coil dimensions after bending can be finished with high accuracy.
- the coil manufacturing method of the present invention after the planar coil is heated to a predetermined temperature, a portion of the planar coil is bent at a predetermined angle in a direction perpendicular to the surface of the planar coil in the bending step, and the formed bent coil is heated to a predetermined temperature.
- annealing is performed by heating at a predetermined temperature for a predetermined time.
- the planar coil forming step when forming the coils of each layer, the ends to be bent are gradually reduced in predetermined dimension in the vertical direction to form a step. As a result, the characteristics of the coil can be maintained without lowering the degree of alignment of the wire due to bending.
- the coil bending jig of the present invention includes a holding jig that holds both side surfaces of the bent portion of the coil.
- FIG. 4 is a flow chart showing steps of manufacturing a coil by the coil manufacturing method according to the first embodiment of the present invention.
- 1 is a perspective view showing an example of a hook-shaped coil manufactured by a coil manufacturing method according to the present invention
- FIG. FIG. 4 is a cross-sectional view schematically showing a winding jig used in a planar coil forming step of the coil manufacturing method according to the present invention and the formed planar coil.
- 1 is a perspective view showing an example of a coil bending jig used in a bending step of a method for manufacturing a coil according to the present invention, and a state in which the coil is bent;
- FIG. 3A and 3B are a plan view and a side view schematically showing another configuration example of a coil bending jig according to the present invention
- FIG. FIG. 4 is a cross-sectional view showing a coil obtained in a bending step of the coil manufacturing method according to the present invention
- It is a flowchart which shows the process of manufacturing a coil with the manufacturing method of the coil which concerns on the 2nd Embodiment of this invention.
- 1 is a perspective view showing an example of a molding jig used in a molding step of a coil manufacturing method according to the present invention
- FIG. FIG. 10 is a perspective view showing a state in which the coil obtained in the bending step is placed on a forming jig and pressed down in the forming step.
- FIG. 10 is a perspective view showing a state in which a jig for pressing the side surface of the coil is attached in the molding process;
- FIG. 10 is a perspective view showing a state in which a jig for pressing the hook-shaped bending end portion of the coil is attached in the forming process;
- 1 is a perspective view showing an example of a hook-shaped coil manufactured by a coil manufacturing method according to the present invention;
- FIG. 1A and 1B are cross-sectional views schematically showing a conventional coil manufacturing method, where (A) is a planar coil formed in a planar coil forming process, and (B) is a hook-shaped coil obtained in a bending process. It is a figure which shows the state of the bending part of the hook-shaped coil manufactured by the conventional coil manufacturing method.
- FIG. 1 shows the steps of manufacturing a hook-shaped coil by the coil manufacturing method according to the first embodiment of the present invention.
- FIG. 2 shows a coil 100 manufactured by the coil manufacturing method of the present invention.
- FIG. 3 shows the winding jig used in the planar coil forming step and the formed planar coil, in which (A) is a cross section of the winding jig and (B) is a cross sectional view of the planar coil. be.
- FIG. 4 shows an example of a coil bending jig used in the bending process and how the coil is bent.
- FIG. 5 shows another configuration example of a coil bending jig used in the bending process.
- FIG. 6 is a cross section showing the coil 100 obtained by the bending process.
- the coil manufacturing method includes a planar coil forming step of winding a conductive wire in multiple layers (or multiple rows and multiple layers) to form an air-core planar coil. (step S1); a first heating step (step S2) of heating the planar coil formed in the planar coil forming step to a predetermined temperature; A bending step (step S3) of bending at a predetermined angle in a direction perpendicular to the surface of the coil, a second heating step (step S4) of heating the bent coil formed in the bending step at a predetermined temperature for a predetermined time, and A cooling step (step S5) for cooling and a coil stripping step (step S6) for removing the bending coil from the bending jig are provided.
- the coil 100 manufactured by the coil manufacturing method of the present invention includes a planar coil portion 10 and a bent portion 20, as shown in FIG.
- This coil 100 is formed into a hook shape by vertically extending a portion of a planar coil having a pair of long sides and a pair of short sides in which a conductive wire is wound in multiple layers (or multiple rows and multiple layers). ing.
- the conducting wire is an enameled wire, an enameled wire coated with an insulating film (a double-coated wire having two insulating layers), a composite wire in which a plurality of enameled wires are collectively coated with an insulating outer layer, or It is an enameled wire (hereinafter referred to as a self-bonding wire) having a bonding layer made of a thermoplastic resin on its surface.
- the conductive wire is a round wire with a circular cross section or a square wire with a square cross section.
- the planar coil portion 10 has a pair of parallel portions 10a extending parallel to each other and a connecting portion 10b connecting one ends of the pair of parallel portions.
- the bent portion 20 is formed, for example, by bending one end (bent end) in the longitudinal direction of the planar coil by 90 degrees. At the upper end surface 21 of the bent portion 20, the windings of each layer are formed so as to be on the same plane (see FIG. 6). Note that the bending angle is not limited to 90 degrees.
- a self-bonding wire is wound in a plurality of layers to form a planar coil having a pair of parallel portions 10a and a connecting portion 10b connecting one ends of the pair of parallel portions.
- this planar coil forming step when an enameled wire having no fusion layer on the surface (or a double coated wire having a double insulating layer) is used, only the pair of parallel portions 10a of the planar coil are coated with adhesive varnish for each layer. Apply while rolling.
- the planar coil is heated to the curing temperature of the adhesive varnish (e.g., 230°C) for a predetermined time (e.g., 1h) after the winding to fix the winding.
- the winding is fixed by heating to the curing temperature of the bonding layer. The heating here serves both to anneal the wire itself and to remove the processing stress during winding. Then, the planar coil is cooled and removed from the winding jig T1.
- planar coil forming step winding is performed, and when forming each layer of the planar coil, a winding core (core) shown in FIG. ), the predetermined dimension ⁇ L is gradually reduced to form a step, and after bending a part of the planar coil in the vertical direction in the bending process, the upper end surface of the vertical part is parallel to the plane of the planar coil. (See FIG. 6). Also, as shown in FIG. 6, r1 is the inner radius of the bend, r2 is the outer radius, and t is the thickness of the coil.
- ⁇ is the circular constant (constant)
- t is the thickness of the planar coil
- d is the number of winding layers.
- FIG. 3B shows a cross section of a planar coil formed in the planar coil forming step of the coil manufacturing method according to the present invention.
- the planar coil is set in a coil bending jig T2 as shown in FIG. 4 or 5 and heated to a predetermined temperature.
- the planar coil obtained in the planar coil forming step is heated to the softening temperature (or melting temperature) of the bonding layer on the surface of the conductor.
- the heating temperature is 160.degree.-170.degree.
- the planar coil is heated to the softening temperature (or melting temperature) of the adhesive varnish (for example, 180°C). Since the softening temperature (or melting temperature) differs depending on the type of adhesive varnish, the heating temperature can be appropriately set.
- the heating method a method using a constant temperature bath, a method of energizing the coil to raise the temperature by self-heating of the coil, and a method of raising the temperature of the jig by high-frequency induction heating (IH) and conducting heat to the coil. can be used. Considering productivity, it is preferable to use a high-frequency induction heating method.
- the method using a constant temperature bath required about 30 minutes or longer.
- the fusion layer is softened, and the bonding between the wire rods of each layer of the planar coil is loosened, thereby minimizing the stress caused by the shifting of the wire rods during bending in the next bending step. can. Further, by softening the fusion layer, it is possible to reduce the frictional force between the wire rods during bending.
- step S3 part of the planar coil heated to a predetermined temperature is bent in the vertical direction.
- the side pressing jig T2a of the coil bending jig T2 presses both sides of the bent portion, and the pressing on both sides of the bent portion is loosened. Bending is performed while repeating the tightening operation.
- the coil bending jig T2 is provided with side pressing jigs T2a, and the side pressing jigs T2a perform operations of loosening and tightening the pressing on both side surfaces of the bent portion during bending.
- FIG. 4 shows an example of a coil bending jig T2 used in the bending process. As shown in FIG. 4, in the coil bending jig T2, the operation of manually loosening and tightening the presser can be repeatedly performed. .
- FIG. 5 shows another configuration example of the coil bending jig T2 used in the bending process. As shown in FIG. A drive mechanism having a cylinder, a servomotor, or the like can be used. The vibration width of the vibration mechanism T2b is determined within a range in which the wire does not collapse. When performing coil bending, it is necessary to be careful not to make the bending radius excessively small.
- the elongation of the coating of the coil wire is generally guaranteed up to about 30%, it is desirable to consider that the elongation due to bending should not exceed 30%.
- the bending elongation is distributed not only in the 90-degree range but also in the straight portion by about 3 to 10%, so that amount can also be taken into consideration.
- the bent coil formed in the forming step is heated at a predetermined temperature (for example, 230° C. to 240° C.) for a predetermined time (for example, 1.5 hours), and Annealing is performed on the substrate.
- a predetermined temperature for example, 230° C. to 240° C.
- a predetermined time for example, 1.5 hours
- Annealing is performed on the substrate.
- the bending coil is attached to the forming jig T3
- the bending coil and the forming jig T3 are heated together.
- the fine crystals are recrystallized and softened, and the stress in the coil bending and forming processes can be reduced, and the springback can be kept small. . Therefore, the coil dimensions after bending can be finished with high accuracy.
- the heating method a method using a constant temperature bath, a method of energizing the coil to raise the temperature by self-heating of the coil, and a method of raising the temperature of the jig by high-frequency induction heating (IH) and conducting heat to the coil.
- IH high-frequency induction heating
- the heating in the planar coil forming step (step S1) and the heating in the first heating step (step S2) may also be a heating step serving this purpose.
- step S5 the bending coil and the forming jig T3 are cooled together to room temperature.
- step S6 the bent coil is removed from the forming jig T3, and the coil 100 is obtained.
- the conducting wire is wound in a plurality of layers (or a plurality of rows and a plurality of layers), the formed planar coil is heated to a predetermined temperature, and then the bending step Annealing treatment is performed by bending a part of the coil at a predetermined angle in a direction perpendicular to the surface of the planar coil, and heating the formed bent coil at a predetermined temperature for a predetermined time.
- the planar coil forming process when forming the coils of each layer, by gradually reducing the predetermined dimension in the vertical direction at the end to be bent and forming a step, the degree of alignment of the wire rod due to bending is reduced.
- the characteristics of the coil 100 can be maintained.
- bending is performed using a coil bending jig T2 equipped with a side holding jig T2a, and after the bending, the bent coil is heated and annealed. There is no overhang in the lateral direction as shown in , and the stress between and inside the coil wires can be suppressed, the springback that occurs in the coil molded product can be suppressed, and the coil dimensions after bending can be finished with high accuracy. can be done.
- FIG. 7 shows the steps of manufacturing the hook-shaped coil 100A by the coil manufacturing method according to the second embodiment of the present invention.
- FIG. 8 shows an example of a molding jig used in the molding process.
- FIG. 9 shows a state in which the bent coil obtained in the bending process is placed on a forming jig and is press-formed in the forming process.
- FIG. 10 shows a state in which a jig is attached to hold down the sides of the coil in the molding process.
- FIG. 11 shows a state in which a jig for pressing the hook-shaped bending end portion of the coil is attached in the forming process.
- the bending angle of the L-shape is 90 degrees
- the planar coil portion 10A is curved.
- the coil manufacturing method includes a planar coil forming step (step S11) of winding a conductive wire in multiple layers (or multiple rows and multiple layers) to form an air-core planar coil.
- a first heating step step S12
- a bending step step S13) of bending at a predetermined angle in the direction of bending
- a second heating step step S14
- a forming step step S15) in which the coil is formed into a predetermined shape and size using a forming jig
- a third heating step step S16 in which the bent coil formed in the forming step is heated at a predetermined temperature for a predetermined time.
- a cooling step step S17 for cooling the bent coil
- a coil stripping step step S18
- the coil 100A manufactured by the coil manufacturing method according to the present embodiment includes a planar coil portion 10A and a bent portion 20A, and the planar coil portion 10A has a curved shape.
- the conducting wire is an enameled wire covered with an insulating film (including a double covered wire having a double insulating layer, etc.) or a self-bonding wire.
- a conductive wire for example, an enamel wire having no bonding layer on the surface, or a self-bonding wire
- a planar coil forming step step S11
- a conductive wire for example, an enamel wire having no bonding layer on the surface, or a self-bonding wire
- a planar coil forming step step S11
- a conductive wire for example, an enamel wire having no bonding layer on the surface, or a self-bonding wire
- a planar coil forming step S11 when an enameled wire having no fusion layer on the surface (or a double coated wire having a double insulating layer) is used, only the pair of parallel portions 10a of the planar coil are coated with adhesive varnish for each layer. Apply while rolling.
- the winding is fixed by heating the planar coil to the curing temperature of the adhesive varnish for a predetermined time after winding.
- the winding is fixed by heating to the curing temperature of the bonding layer.
- this planar coil forming step winding is performed, and when forming each layer of the planar coil, the predetermined dimension ⁇ L is gradually reduced in the vertical direction (bending direction) at the end to be bent to form a step. After forming and bending a portion of the planar coil vertically in a bending process, the top surface of the vertically oriented portion is made parallel to the plane of the planar coil (see FIG. 6).
- the planar coil formed in the planar coil forming step is set in a coil bending jig T2 as shown in FIGS. 4 and 5 and heated to a predetermined temperature. do.
- the planar coil obtained in the planar coil forming step is heated to the softening temperature (or melting temperature) of the bonding layer on the surface of the conductor. For example, if the fusion layer has a fusion temperature of 150.degree. C., the heating temperature is 160.degree.-170.degree.
- the planar coil is heated to the softening temperature (for example, 180 degrees) of the adhesive varnish. Since the softening temperature differs depending on the type of adhesive varnish, the heating temperature can be appropriately set.
- a heating method it is preferable to use a method of raising the temperature of the jig by high-frequency induction heating (IH) and conducting heat to the coil.
- a portion of the planar coil heated to a predetermined temperature is vertically bent with a coil bending jig T2 as shown in FIGS.
- the side pressing jig T2a of the coil bending jig T2 presses both sides of the bent portion, and the pressing on both sides of the bent portion is loosened. Bending is performed while repeating the tightening operation.
- the coil bending jig T2 is configured to repeatedly perform an operation of loosening and tightening the pressure applied to both side surfaces of the bent portion when performing the bending process.
- the mechanism for repeatedly loosening and tightening the presser is manually performed.
- a driving mechanism having an air cylinder, a servomotor, or the like can be used for the vibrating mechanism T2b that repeats the operation of loosening and tightening the presser.
- the vibration width of the vibration mechanism T2b is determined within a range in which the wire does not collapse.
- the bent coil formed in the bending step and bent into a hook shape is heated to a predetermined temperature.
- the planar coil obtained in the planar coil forming step is heated to the softening temperature of the bonding layer on the surface of the conductor.
- the heating temperature is 160.degree.-170.degree.
- the planar coil is heated to the softening temperature (for example, 180 degrees) of the adhesive varnish.
- a heating method it is preferable to use a method of raising the temperature of the jig by high-frequency induction heating (IH) and conducting heat to the coil.
- the heated L-shaped bent coil is subjected to forming processing for shape and outer dimensions using a forming jig T3 (see FIG. 8).
- a forming jig T3 see FIG. 8
- the bending coil is set in the forming jig main body T3a, and the back side pressing member T3b is mounted and pressed to form the planar coil portion 10A of the bending coil into a predetermined shape (for example, the back side). Bend it into a curved shape).
- the forming is not limited to a curved shape by bending to the back side.
- the forming jig T3 can be designed according to need.
- the side pressing member T3c for pressing the side surface of the planar coil portion 10A of the bending coil is attached so as to be pushed in the direction of the arrow in FIG. 10, and the shape and size of the side surface are adjusted.
- the upper surface pressing member T3d and end side pressing members T3e, T3f and T3g for pressing the upper surface and four side surfaces of the bent portion 20A of the bent coil are attached so as to be pushed in the direction of the arrow in FIG. arrange.
- the bent coil is heated at a predetermined temperature (for example, 230° C. to 240° C.) for a predetermined time (for example, , 1.5h) heat and anneal and cure the fusing layer or bonding varnish.
- a predetermined temperature for example, 230° C. to 240° C.
- a predetermined time for example, 1.5h
- heat and anneal and cure the fusing layer or bonding varnish for example, while the bending coil is attached to the forming jig T3, the bending coil and the forming jig T3 are heated together.
- the fine crystals are recrystallized and softened, and the stress in the coil bending and forming processes can be reduced, and the springback can be kept small. . Therefore, the coil dimensions after bending can be finished with high accuracy.
- IH high-frequency induction heating
- step S17 the bending coil and the forming jig T3 are cooled together to room temperature.
- step S18 the bent coil is removed from the forming jig T3 to obtain the coil 100A.
- the conductor wire is wound in a plurality of layers (or a plurality of rows and a plurality of layers), the formed planar coil is heated to a predetermined temperature, and then the bending step After bending a part of the coil at a predetermined angle in a direction perpendicular to the plane of the planar coil, and heating the obtained bent coil at a predetermined temperature for a predetermined time, the shape and outer dimensions are formed using a forming jig T3 in the forming process.
- bending is performed using a coil bending jig T2 equipped with a side holding jig T2a, and after the bending, the bent coil is heated and annealed. As shown in , there is no overhang in the lateral direction, and stress between and inside the coil wires can be suppressed, springback occurring in the coil molded product can be suppressed, and the coil dimensions after bending can be finished with high accuracy. be able to.
- the first heating step and the bending step are each performed once, but the present invention is not limited to this.
- heating and bending may be performed a plurality of times in a plurality of different temperature zones.
- the present invention in the coil bending process, an example in which at least part of the planar coil is bent in the vertical direction (90 degrees) has been described, but the present invention is not limited to this. It may be bent at an angle of 90 degrees or less, or at an angle of 90 degrees or more.
- An object of the present invention is to form a shape such as a hook shape in which a part of a planar coil in which a conductive wire is wound in multiple layers (or multiple rows and multiple layers) is bent at a predetermined angle in a direction perpendicular to the surface of the planar coil.
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- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
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Abstract
Description
δ=(2π×r2)/4-(2π×r1)/4 (1)
r2=r1+tであるから(1)を(2)と書き換えることができる。
δ=1/2×π×t (2)
これにより、各層間の寸法差(所定寸法)ΔLを算出することができる。
即ち、
ΔL=(1/2×π×t)/(d-1) (3)
式中、πは円周率(定数)、tは平面コイルの厚さ、dは巻き層数である。
図3(B)は本発明に係るコイルの製造方法の平面コイル形成工程で形成された平面コイルの断面を示している。
1B L字形コイル
1a、10、10A 平面コイル部
10a 平行部
10b 連結部
1b、20、20A 折り曲げ部
21 端面
100、100A コイル
T1 巻線治具
T2 コイル曲げ治具
T2a 側面押さえ治具
T2b 振動機構
T3 成形治具
T3a 成形治具本体
T3b 裏側押さえ部材
T3c 側面押さえ部材
T3d 上面押さえ部材
T3e、T3f、T3g 端部側面押さえ部材
Claims (9)
- 導線を複数層(又は複数列かつ複数層)に巻き、空芯の平面コイルを形成する平面コイル形成工程と、
前記平面コイル形成工程で形成された前記平面コイルを所定温度に加熱する第1の加熱工程と、
前記第1の加熱工程で加熱された平面コイルの少なくとも一部を前記平面コイルの面と垂直する方向へ所定角度に曲げる曲げ工程と、
前記曲げ工程で形成させた曲げコイルを所定温度で所定時間加熱する第2の加熱工程とを備えていることを特徴とするコイルの製造方法。 - 前記曲げ工程で成形させた曲げコイルを成形用治具を用いて所定形状及び寸法に成形させる成形工程と、
前記成形工程で成形させた曲げコイルを所定温度で所定時間加熱する第3の加熱工程とをさらに備えていることを特徴とする請求項1に記載のコイルの製造方法。 - 前記曲げ工程では、押さえ治具で曲げ部の両側面を押さえるようにし、前記曲げ部の両側面への押さえを緩める動作と締める動作を繰り返しながら曲げ加工を行うことを特徴とする請求項1に記載のコイルの製造方法。
- 前記平面コイルは、互いに平行に延びる1対の平行部と前記1対の平行部の端部同士を連結する1対の連結部とを有し、
前記平面コイル形成工程では、前記平面コイルの前記1対の平行部のみ各層ごとに接着ワニスを塗布しながら巻くようにすることを特徴とする請求項1から3のいずれか1項に記載のコイルの製造方法。 - 前記導線は、表面に融着層を有し、
前記第1の加熱工程では、前記平面コイルを前記融着層の軟化温度まで加熱することを特徴とする請求項1から3のいずれか1項に記載のコイルの製造方法。 - 前記第1の加熱工程と前記曲げ工程は、複数異なった温度帯に分けて加熱及び曲げ加工を行うことを特徴とする請求項1から3のいずれか1項に記載のコイルの製造方法。
- 前記平面コイル形成工程では、前記平面コイルの各層を形成する際に、曲げ加工される端において前記垂直方向に向けて次第に所定寸法を小さくし段差を付けて形成することを特徴とする請求項1から3のいずれか1項に記載のコイルの製造方法。
- 前記第1の加熱工程、前記第2の加熱工程及び前記第3の加熱工程では、高周波誘導加熱により前記平面コイル又は曲げコイルがセットされている治具を昇温させて、前記治具から前記平面コイル又は曲げコイルへ熱伝導させる加熱方法を用いることを特徴とする請求項1から3のいずれか1項に記載のコイルの製造方法。
- 導線が複数層に巻かれた平面コイルの一部を平面コイルの面と垂直する方向へ所定角度に折り曲げた鉤形を有するコイルを製造するためのコイル曲げ治具であって、
前記コイルの曲げ部の両側面を押さえる押さえ治具を備え、
前記押さえ治具は、曲げ加工を行う際に、前記曲げ部の両側面への押さえを緩める動作と締める動作を繰り返し行うように構成されていることを特徴とするコイル曲げ治具。
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