JP2005093852A - Method and apparatus for manufacturing rectangular coil by using rectangular conductive wire - Google Patents

Method and apparatus for manufacturing rectangular coil by using rectangular conductive wire Download PDF

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JP2005093852A
JP2005093852A JP2003327405A JP2003327405A JP2005093852A JP 2005093852 A JP2005093852 A JP 2005093852A JP 2003327405 A JP2003327405 A JP 2003327405A JP 2003327405 A JP2003327405 A JP 2003327405A JP 2005093852 A JP2005093852 A JP 2005093852A
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wire
bending
rectangular
flat wire
clamp
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JP4355547B2 (en
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Shusuke Uematsu
秀典 植松
Toshikazu Okuno
利和 奥野
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OKUNO MACHINE CO Ltd
Panasonic Holdings Corp
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OKUNO MACHINE CO Ltd
Matsushita Electric Industrial Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a new rectangular coil manufacturing apparatus capable of preventing the surface of a coat from being easily flawed. <P>SOLUTION: The rectangular coil manufacturing device is provided with a wire feeder 10 for delivering a rectangular wire w, a wire guide 20 and a bending work part 30 for bending the rectangular wire w in the width direction. The bending work pat 30 is provided with a bending mechanism in which a core bar 31 and a clamp claw 32 for holding both the side faces which are bending parts of the rectangular wire w guided from the wire guide 20 by face contact are oppositely arranged and bending work is performed around one point C of the core bar 31 by the unified state of the core bar 31, the clamp claw 32 and the rectangular wire w in the held state of the rectangular wire w between the core bar 31 and the clamp claw 32. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

本発明は、平角導通線材（以下、「平角線」という。）を用いた角形コイルの製造方法及び製造装置に関する。   The present invention relates to a method and an apparatus for manufacturing a rectangular coil using a rectangular conductive wire (hereinafter referred to as “flat wire”).

帯板状の平角線を巾方向にほぼ直角に繰り返し折り曲げて得られる矩形状コイル（以下、「角形コイル」という。）は、丸線（断面が丸状の導線）のソレノイドコイルと比較して空間の利用効率がよく大電流が流せて熱損失も小さい。このため、図６（ａ）に示すように角形コイル５０を角形のコア５２に設け、トランス製品として利用されている。   A rectangular coil (hereinafter referred to as “square coil”) obtained by repeatedly bending a strip-shaped flat wire substantially perpendicularly in the width direction is compared with a solenoid coil having a round wire (conductive wire having a round cross section). Space utilization efficiency is good, large current can flow and heat loss is small. For this reason, as shown to Fig.6 (a), the square coil 50 is provided in the square core 52, and is utilized as a transformer product.

角形コイルの製造方法として、角柱状の治具乃至鉄心（コア）に平角線を巻き付ける方式（以下、「第１の方式」という。）が知られている。図６（ｂ）は、第１の方式による、角形コイル製造方法を例示したものである（特許文献１等参照）。角柱状の鉄心６１を回転させ、ガイドローラＧ及び押圧ローラＰにより平角線を当接しながら平角線の断面の長手方向を鉄心と直角方向に巻いていく。
しかし、線材にはスプリングバック（曲げ加工後の戻り量の大きさ）があり、スプリングバック後の曲げ角を直角にするためには、９０°よりも大きく曲げなければならない。第１の方式では、角柱状の鉄心の直角部で曲げ加工するので、スプリングバック後の曲げ角は必ず９０°よりも大きくなってしまうという問題がある。また、ガイドローラＧ及び押圧ローラＰが平角線の表面に常に接触しており、擦れあいながら巻き付けていくため、表面に傷が付きやすい。巻き終わり後、鉄心をコイルから抜く必要がある場合には、鉄心を引き抜く工程でも表面に傷が付けられやすいという問題もある。 As a method of manufacturing a rectangular coil, a method of winding a rectangular wire around a prismatic jig or iron core (hereinafter referred to as “first method”) is known. FIG. 6B illustrates a square coil manufacturing method according to the first method (see Patent Document 1). The prismatic iron core 61 is rotated, and the longitudinal direction of the cross section of the rectangular wire is wound in a direction perpendicular to the iron core while the rectangular wire is brought into contact with the guide roller G and the pressing roller P.
However, the wire has a spring back (the amount of return after bending), and in order to make the bending angle after the spring back a right angle, it must be bent more than 90 °. In the first method, since bending is performed at a right angle portion of the prismatic iron core, there is a problem that the bending angle after the springback is always larger than 90 °. Further, since the guide roller G and the pressure roller P are always in contact with the surface of the flat wire and wound while being rubbed, the surface is easily damaged. When it is necessary to pull out the iron core from the coil after the end of winding, there is also a problem that the surface is easily damaged even in the step of pulling out the iron core.

角形コイルの他の製造方法としては、コイルバネを製造するためのコイリングマシンなどを利用して、円形の曲げ金型（ローラ）により線材を曲げ加工してコイリングする方式（以下、「第２の方式」という。）も知られている（特許文献２参照）。   As another method for manufacturing a rectangular coil, a coiling machine for manufacturing a coil spring is used to perform coiling by bending a wire with a circular bending die (roller) (hereinafter referred to as “second method”). Is also known (see Patent Document 2).

図７（ａ）は、第２の方式によるコイリング加工装置の曲げ加工部を示したものである。円形の曲げツール（ローラ）７１、７２が設けられ、線材を順次送ると線材がローラに接触し、一方を支点、他方を作用点として平角線の側面部と点接触しながら応力が加えられ、所定の方向に曲げられる。   FIG. 7A shows a bending section of a coiling apparatus according to the second method. Circular bending tools (rollers) 71 and 72 are provided, and when the wire is sequentially fed, the wire contacts the roller, and stress is applied while making point contact with the side surface of the flat wire with one as a fulcrum and the other as an action point. It is bent in a predetermined direction.

特開昭５３−１００４２８号公報Japanese Patent Laid-Open No. 53-100398 特開２００３−１８１５７９号公報JP 2003-181579 A

しかし、従来の方式には以下のような問題がある。   However, the conventional method has the following problems.

（１）平角線の倒れ込み
平角線を厚み方向に曲げることは容易であるが、巾方向に曲げることは困難である。一般に、素材を曲げ困難な方向に曲げるとき、外周側は引き伸ばされて厚みが薄くなる方向に組織が移動する一方で、内周側は厚みがより厚くなる方向に組織が移動する。このため、曲げ加工の際に素材に係る曲げ応力がわずかに変化しただけで組織移動バランスが崩れ、材料が曲げ方向と異なる方向に倒れ込むという現象がある。すなわち、平角線の形状が薄く（いわゆる「平たく」）なるほど、巾方向への曲げ加工時に線材が倒れやすくなる。
上記第２の方式のように、円形の曲げ金型（ローラ）により曲げ加工を行うと、ローラは円形であるため平角線の側面部と点で接触するため、応力集中点が発生し、曲げ加工時に平角線が倒れ込みやすくなる。本件発明者たちによる経験則によると、巾と厚さの比が概ね２：１より大きいときは倒れやすく、２：１以下であれば倒れにくい。曲げ加工の途中で一旦倒れ込みが始まると、倒れ込みをもとに戻すことは極めて困難である。
（２）絶縁被膜の剥離
図７（ａ）に示すように従来の円形の曲げ金型（ローラ）を用いた方式は、応力集中点Ｚが発生しやすく、この点Ｚで表面に傷が付きやすい。通常、平角線は銅などの軟らかい金属にエナメルやポリアミド系樹脂を塗布し絶縁被膜としているため、応力集中点Ｚで被膜は容易に傷つけられる。このため、応力集中点Ｚに加圧痕が形成されると、この部分から絶縁被膜が剥離して絶縁不良などの問題を引き起こす。 (1) Inclination of flat wire Although it is easy to bend a flat wire in the thickness direction, it is difficult to bend it in the width direction. In general, when a material is bent in a direction in which bending is difficult, the outer peripheral side is stretched and the tissue moves in a direction in which the thickness decreases, while the inner peripheral side moves in a direction in which the thickness increases. For this reason, there is a phenomenon in which the balance of tissue movement is lost only by a slight change in the bending stress associated with the material during bending, and the material falls in a direction different from the bending direction. That is, as the shape of the flat wire becomes thinner (so-called “flat”), the wire is more likely to fall during bending in the width direction.
When bending is performed with a circular bending die (roller) as in the second method, since the roller is circular, it contacts with the side surface of the rectangular wire at a point, and a stress concentration point is generated. The flat wire tends to fall down during processing. According to the rule of thumb by the inventors of the present invention, it is easy to fall when the ratio of width to thickness is larger than 2: 1, and it is difficult to fall when the ratio is 2: 1 or less. Once the collapse starts in the middle of bending, it is extremely difficult to restore the collapse.
(2) Peeling of insulating coating As shown in FIG. 7A, the conventional method using a circular bending die (roller) is likely to generate a stress concentration point Z, and the surface is scratched at this point Z. Cheap. Normally, since the flat wire is formed by applying enamel or polyamide-based resin to a soft metal such as copper to form an insulating film, the film is easily damaged at the stress concentration point Z. For this reason, when a pressurization mark is formed at the stress concentration point Z, the insulating film peels off from this portion, causing problems such as insulation failure.

上記第１の問題点（平角線の倒れ込みの問題）を回避するため、例えば図７（ｂ）のように、ローラの円周側部に溝を設け、溝の壁面部と平角線とを当接させることにより倒れにくくするという方法が考えられる。しかし、このように平角線が常にこの溝に挟み込まれながらローラの自転及び公転により曲げ加工を施すと、平角線の側面部が常にローラの溝壁部と擦れあうことになるため、この部分で表面に傷が付きやすくなる。
さらに、溝付きローラを用いて成形すると、完成品のピッチＬを金型の隙間以下にすることは不可能であり、密巻きすることができず、トランスの性能が低下するという新たな問題も生ずる（図６（ａ）参照。）。 In order to avoid the first problem (problem of the flat wire falling down), for example, as shown in FIG. 7B, a groove is provided on the circumferential side of the roller so that the wall surface of the groove and the flat wire are in contact with each other. The method of making it hard to fall down by making it contact is considered. However, when the flat wire is always sandwiched in this groove and bending is performed by the rotation and revolution of the roller, the side surface of the flat wire always rubs against the groove wall of the roller. The surface is easily scratched.
Furthermore, when molding is performed using a grooved roller, it is impossible to make the pitch L of the finished product below the gap of the mold, it is impossible to wind closely, and there is a new problem that the performance of the transformer deteriorates This occurs (see FIG. 6 (a)).

本発明が解決しようとする問題点は、表面に傷が付きにくい、新規な平角線の曲げ加工方法を提供することであり、本発明はこの加工方法を用いて角形コイルの製造方法及び製造装置等を提供することを目的とする。   The problem to be solved by the present invention is to provide a novel method for bending a rectangular wire that is less likely to be scratched on the surface, and the present invention uses this processing method to manufacture a rectangular coil and a manufacturing apparatus. The purpose is to provide.

本発明は、上記に鑑みてなされたものであり、曲げ加工の際に用いる曲げ金型が平角線に与える応力を分散しながら加圧する、いわゆる応力分散加圧方式を採用したことを最も主要な特徴とする。   The present invention has been made in view of the above, and it is the most important that a so-called stress dispersion pressurization method is adopted in which a bending die used in bending is pressed while dispersing stress applied to a flat wire. Features.

本発明に係る角形コイルの製造装置は、平角線ｗを送り出すための線送り装置１０と、線ガイド２０と、この平角線ｗを巾方向に曲げ加工する曲げ加工部３０とを備え、曲げ加工部３０は線ガイド２０から案内された平角線ｗの曲げ部となる両側面を面接触で狭持するための芯金３１及びクランプ爪３２が対向して設置され、芯金３１とクランプ爪３２とが平角線ｗを狭持した状態で、芯金の一点Ｃを軸に三者一体となって曲げ加工する曲げ機構を備えていることを特徴とする。
この構成によると、曲げ金型には平角線ｗとの擦れ部分が存在しない。このため平角線ｗの表面に傷が付きにくい。また、平角線ｗの側面部を面接触しながら曲げ加工するため応力が分散され、加圧痕も付かない。なお、「側面部」とは、厚み方向の面を意味する（図２（ａ）乃至（ｃ）参照）。 The rectangular coil manufacturing apparatus according to the present invention includes a wire feeding device 10 for feeding a flat wire w, a wire guide 20, and a bending portion 30 for bending the flat wire w in the width direction. The core 30 and clamp claws 32 for holding the both sides of the flat wire w guided from the wire guide 20 by the surface contact are opposed to each other, and the core 30 and the clamp claws 32 are arranged. In the state where the flat wire w is sandwiched, a bending mechanism is provided for bending the cored bar with one point C as a shaft.
According to this configuration, the bending mold does not have a rubbing portion with the flat wire w. For this reason, the surface of the flat wire w is hardly damaged. In addition, since the side surface portion of the flat wire w is bent while being in surface contact, the stress is dispersed and no pressure mark is left. The “side surface portion” means a surface in the thickness direction (see FIGS. 2A to 2C).

また、この装置の芯金３１は、平角線ｗを曲げ加工する際の曲率半径と同程度の大きさの曲率半径を持つ円弧部分と、前記平角線ｗを狭持するための平坦部分とを備えていることが好ましい。なお、芯金の円弧部分と平坦部分とは一体でも別体の組合せでもよい。   Further, the core bar 31 of this apparatus has an arc portion having a radius of curvature similar to the radius of curvature when the flat wire w is bent, and a flat portion for sandwiching the flat wire w. It is preferable to provide. The arc portion and the flat portion of the core metal may be integrated or a separate combination.

また、この装置において、芯金３１及びクランプ爪３２は芯金の一点Ｃを中心に回転する回転板３４の上に設けられていることが好ましい。クランプ爪３２が平角線ｗを狭持した状態で、回転板３４を回転させると容易に芯金の一点Ｃを中心に三者一体で回転させることができるためである。   Moreover, in this apparatus, it is preferable that the cored bar 31 and the clamp claw 32 are provided on a rotating plate 34 that rotates around one point C of the cored bar. This is because when the rotating plate 34 is rotated in a state where the clamp claw 32 holds the flat wire w, the three members can be easily rotated around the point C of the metal core.

本発明に係る角形コイルの製造方法は、線送り装置１０と、線ガイド２０と、芯金３１及びクランプ爪３２を含む曲げ加工部３０とを備えた角形コイルの製造装置において、
（ａ） 平角線ｗの一部を芯金３１及びクランプ爪３２によりクランプする工程と、
（ｂ） 平角線ｗが芯金３１及びクランプ爪３２によってクランプされた状態で三者一体となって回転させ、平角線ｗを曲げ加工する工程と、
（ｃ） クランプ爪３２のクランプを解除し、芯金３１及びクランプ爪３２を初期位置に戻すと共に、線送り装置１０により平角線ｗを所定量送出す工程と、
を含むことを特徴とする。 The square coil manufacturing method according to the present invention is a square coil manufacturing apparatus including a wire feeder 10, a wire guide 20, and a bending portion 30 including a cored bar 31 and a clamp claw 32.
(A) a step of clamping a part of the flat wire w with the core metal 31 and the clamp claw 32;
(B) a step of bending the flat wire w by rotating the flat wire w together with the core bar 31 and the clamp pawl 32, and bending the flat wire w;
(C) releasing the clamp of the clamp claw 32, returning the cored bar 31 and the clamp claw 32 to their initial positions, and sending a predetermined amount of the rectangular wire w by the wire feeder 10;
It is characterized by including.

このように平角線の一端をクランプして曲げ加工を行うと、平角線の倒れ込みが発生せず、かつ表面に傷が付かない。また、平角線の曲げ角は回転角によって決められるので、スプリングバックを考慮して精密に加工することができる。   In this way, when one end of the flat wire is clamped and bent, the flat wire does not fall down and the surface is not damaged. Further, since the bending angle of the flat wire is determined by the rotation angle, it can be precisely processed in consideration of the spring back.

なお、この角形コイル製造装置の線ガイド２０は、平角線ｗが倒れることができない程度の微小な空洞２１を有していることが好ましい。すなわち、平角線の引き込み側（曲げ加工部側）は前記芯金とクランプ爪とでクランプされ、引き込まれ側（送り出し部側）は前記線ガイドで平角線が自由に送り出されかつ倒れることができない微小な空洞（隙間）を持つ線送りロール２０で保持される構成であるため、倒れ込みなく曲げ加工ができる。   In addition, it is preferable that the wire guide 20 of this square coil manufacturing apparatus has the minute cavity 21 of the grade which cannot fall the flat wire w. That is, the drawing-in side (bending portion side) of the flat wire is clamped by the core metal and the clamp claw, and the drawing-in side (feeding-out portion side) is freely fed out by the wire guide and cannot fall down. Since it is the structure hold | maintained by the wire feed roll 20 which has a micro cavity (gap), it can be bent without falling down.

本発明に係る角形コイル製造装置は、倒れ込まずかつ表面に加圧痕が付かない。   The rectangular coil manufacturing apparatus according to the present invention does not fall down and does not have pressure marks on the surface.

以下、実施例を用いて本発明に係る角形コイル製造装置及び角形コイル製造方法について説明する。   Hereinafter, a rectangular coil manufacturing apparatus and a rectangular coil manufacturing method according to the present invention will be described using embodiments.

（角形コイル製造装置）
図１は本発明に係る角形コイル製造装置の側面図である。装置は大きく分けて、平角線を送り出すための線送り装置１０と、線ガイド２０と、曲げ加工部３０を備えている。特に、曲げ加工部３０の構成が本発明の特徴部であり、線送り装置１０及び線ガイド２０は線材加工機又はコイリングマシンなどに関する種々の公知技術を適用することができる。 (Square coil manufacturing equipment)
FIG. 1 is a side view of a square coil manufacturing apparatus according to the present invention. The apparatus is roughly divided and includes a wire feeding device 10 for feeding a flat wire, a wire guide 20, and a bending portion 30. In particular, the configuration of the bending portion 30 is a characteristic portion of the present invention, and various known techniques relating to a wire rod processing machine or a coiling machine can be applied to the wire feeding device 10 and the wire guide 20.

−線送り装置及び線ガイド−
線送り装置１０は、ボビン１１に巻かれた平角線ｗを送り出す部分である。矯正機１２は、ボビンに巻かれていたときに付いた癖を取り除くための部品であり、クランプフィーダーは平角線の送り出し量を決めるための部品（線送出量調節機構）である。クランプフィーダーは、クランプ爪１３、エアシリンダ１４、サーボモータ１５、クランプ爪１６などからなり、平角線の側面部をクランプした状態で送り方向に平行移動できる。送り出し量はコンピュータ制御されるサーボモータ１５により数値制御できる。クランプフィーダーは、線送りの際にのみクランプし、曲げ加工の際にはクランプせずフリーな状態にしておかなければならない。
なお、クランプフィーダーに代えて、一対の送りロールで平角線の両側から回転接触しながら送り出す方式や、その他の一般的な線送りに関する公知技術を適用することもできるが、特に被膜付き平角線に適用する場合には、被膜の剥離を防止するという点において、クランプフィーダー方式が最も好ましい。
また、成型される角形コイルの一辺の長さは線送り装置１０の送り出し量で決まるため、送り出す方式がいずれの場合にも、サーボモータ（不図示）などで送り出し量を正確に制御できることが好ましい。
線ガイド２０は平角線を案内するためのガイドであり、各曲げ金型（後述の芯金及びクランプ爪）の誤差を少なくし、材料にかかる曲げ応力が均等に作用するようにする働きを持つと共に、曲げ加工の際に平角線が倒れないように案内する役割を果たす。平角線ｗは線ガイド２０を通過した後、曲げ加工部３０に送られる。線ガイド２０には平角線と略同形同大の空洞２１が設けられている。なお、空洞２１は、平角線が通過でき、倒れないような形状（例えば平角線ｗと略同形同大などが考えられる。）であればよい。ただし、案内の精度を確保するためには、案内ガイド２０は、ある程度以上の長さが必要である。 -Wire feeder and wire guide-
The wire feeding device 10 is a portion that feeds a flat wire w wound around the bobbin 11. The straightening machine 12 is a part for removing wrinkles attached to the bobbin, and the clamp feeder is a part (line feed amount adjusting mechanism) for determining a flat wire feed amount. The clamp feeder is composed of a clamp claw 13, an air cylinder 14, a servo motor 15, a clamp claw 16, and the like, and can be translated in the feed direction in a state where the side surface portion of the flat wire is clamped. The feed amount can be numerically controlled by a servo motor 15 controlled by a computer. The clamp feeder must be clamped only when wire feeding and not be clamped when bending.
In addition, instead of the clamp feeder, a method of feeding while rotating from both sides of a flat wire with a pair of feed rolls, and other known techniques related to general wire feeding can also be applied, but in particular for coated rectangular wires When applied, the clamp feeder method is most preferable in terms of preventing peeling of the coating.
Further, since the length of one side of the rectangular coil to be molded is determined by the feed amount of the wire feeder 10, it is preferable that the feed amount can be accurately controlled by a servo motor (not shown) or the like in any of the feeding methods. .
The wire guide 20 is a guide for guiding a flat wire, and has a function of reducing the error of each bending die (a core metal and a clamp claw described later) so that the bending stress applied to the material acts evenly. At the same time, it plays a role of guiding so that the flat wire does not fall down during bending. After passing through the wire guide 20, the flat wire w is sent to the bending portion 30. The wire guide 20 is provided with a cavity 21 having the same shape and size as a flat wire. The cavity 21 may have a shape that allows a flat wire to pass therethrough and does not fall down (for example, a shape that is substantially the same shape and the same size as the flat wire w). However, in order to ensure the accuracy of the guide, the guide guide 20 needs to have a certain length or more.

−曲げ加工部−
図２（ａ）は図１における曲げ加工部３０の拡大図（側面図）を、図２（ｂ）は図１における曲げ加工部３０を上から見た図（平面図）を、図２（ｃ）は、（ｂ）の曲げ加工部３０におけるＡ−Ａ断面図を示している。
曲げ加工部３０は、芯金３１とクランプ爪３２とを持ち、クランプ爪３２は、エアシリンダ３３などの直線駆動機構により鉛直上下に移動でき、クランプ爪３２を平角線ｗに接触させて平角線の側面部をクランプすることができる。また、芯金３１とクランプ爪３２は回転台３４の上に設置され、これらは回転中心Ｃを軸に回転することができる。回転板３４の回転はサーボモータ（不図示）により制御でき、クランプ爪３２が芯金３１との間で平角線ｗをクランプした状態で、回転中心Ｃを軸に三者が一体となって回転し、巾方向に曲げ加工を行うことができる。
なお、回転台３４の形状は、必ずしも図２のような円盤状である必要はなく、芯金の回転中心を軸に芯金及びクランプ爪と共に回転できるものであれば、その形状はどのようなものでもよい。 -Bending part-
2A is an enlarged view (side view) of the bending portion 30 in FIG. 1, FIG. 2B is a view (plan view) of the bending portion 30 in FIG. (c) has shown AA sectional drawing in the bending process part 30 of (b).
The bending portion 30 has a metal core 31 and a clamp claw 32. The clamp claw 32 can be moved vertically up and down by a linear drive mechanism such as an air cylinder 33, and the clamp claw 32 is brought into contact with the flat wire w to make a flat wire. Can be clamped on the side. Further, the cored bar 31 and the clamp claw 32 are installed on a turntable 34, and these can rotate around the rotation center C. The rotation of the rotating plate 34 can be controlled by a servo motor (not shown), and the three members rotate integrally around the rotation center C with the clamp claw 32 clamping the flat wire w between the core bar 31 and the rotation. And it can be bent in the width direction.
The shape of the turntable 34 is not necessarily a disk shape as shown in FIG. 2, and any shape can be used as long as it can be rotated together with the core metal and the clamp claws about the center of rotation of the core metal. It may be a thing.

（角形コイルの製造方法）
上記角形コイル製造装置により角形コイルを製造する方法について、図３（ａ）乃至図３（ｄ）及び図４（ｅ）乃至図４（ｇ）を用いて説明する。 (Manufacturing method of square coil)
A method of manufacturing a rectangular coil by the above rectangular coil manufacturing apparatus will be described with reference to FIGS. 3 (a) to 3 (d) and FIGS. 4 (e) to 4 (g).

図３（ａ）は、平角線ｗが線ガイド２０から案内され、平角線ｗの一部が芯金３１とクランプ爪３２によってクランプされた状態を示している。このとき、平角線ｗに作用する応力は平角線ｗの両側面における芯金３１及びクランプ爪３２の接触面全体から均一な力を受けている（これを本明細書では「応力分散加圧」という。）。この状態でクランプフィーダーなどの線送り装置はクランプを解除する。   FIG. 3A shows a state in which the flat wire w is guided from the wire guide 20 and a part of the flat wire w is clamped by the core metal 31 and the clamp claws 32. At this time, the stress acting on the flat wire w receives a uniform force from the entire contact surface of the cored bar 31 and the clamp pawl 32 on both side surfaces of the flat wire w (this is referred to as “stress dispersion pressurization” in this specification). That said.) In this state, a wire feeder such as a clamp feeder releases the clamp.

この状態から、図３（ｂ）のように、回転台（不図示）を矢印イの方向に約９０°回転させると、回転中心Ｃを軸に芯金３１と平角線ｗとクランプ爪３２とが三者一体となって回転する。引き込み側の一部がしっかりとクランプされた状態でクランプ部分が回転すると、他方の引き込まれ側は回転板の回転に伴って引き込まれ、必要な量だけ順送りされる。この動作によって、平角線は巾方向に約９０°に曲げられる。   From this state, as shown in FIG. 3B, when the turntable (not shown) is rotated about 90 ° in the direction of the arrow A, the cored bar 31, the rectangular wire w, the clamp claw 32, Rotate as a trio. When the clamp portion rotates while a part of the pull-in side is firmly clamped, the other pull-in side is pulled in as the rotating plate rotates, and is sequentially fed by a necessary amount. By this operation, the flat wire is bent to about 90 ° in the width direction.

なお、この平角線の両側面のクランプは、応力分散可能な長さ及び面積をもつ芯金３１とクランプ爪３２とで接触しなければならない。接触面積が小さいと（つまり、芯金３１又はクランプ爪３２の面積の少なくともいずれか一方が小さいと）、クランプした部分に圧力が集中し、抉れ傷ができるおそれがあるためである。クランプ部分の面積及びクランプ圧については、当業者が絶縁被膜の材質や塗布する厚さなどによって適宜調整できる設計的事項である。   It should be noted that the clamps on both sides of the rectangular wire must be in contact with the cored bar 31 and the clamp claws 32 having a length and area capable of stress dispersion. This is because if the contact area is small (that is, if at least one of the areas of the cored bar 31 and the clamp claw 32 is small), pressure may concentrate on the clamped part and there is a risk of scuffing. The area of the clamp portion and the clamp pressure are design matters that can be appropriately adjusted by those skilled in the art depending on the material of the insulating coating, the thickness to be applied, and the like.

次に、図３（ｃ）のように、エアシリンダ３３を操作してクランプ爪３２を平角線ｗから離し、クランプを解除すると共に回転台を逆回転（矢印イと逆方向に回転）させて芯金３１及びクランプ爪３２を初期位置（曲げ加工前の位置）に戻す。その後、クランプフィーダー又は線送りロール等の線送出量調節機構（不図示）を動作させ、角形コイルの一辺に相当する量だけ線送りして停止する。以上の図３（ａ）〜図３（ｃ）が曲げ加工の基本動作である。   Next, as shown in FIG. 3C, the air cylinder 33 is operated to move the clamp pawl 32 away from the flat wire w, release the clamp, and rotate the turntable in the reverse direction (rotate in the direction opposite to the arrow A). The metal core 31 and the clamp claw 32 are returned to the initial position (position before bending). Thereafter, a wire feed amount adjusting mechanism (not shown) such as a clamp feeder or a wire feed roll is operated to feed the wire by an amount corresponding to one side of the rectangular coil and stop. FIGS. 3A to 3C described above are the basic operations of bending.

次に、図３（ｄ）のように、再びエアシリンダ３３を操作してクランプ爪３２を平角線ｗに接触させ、平角線ｗをクランプする。次に、図４（ｅ）のように、回転台（不図示）を矢印イの方向に回転させ、回転中心Ｃを軸に芯金３１と平角線ｗとクランプ爪３２とが三者一体となるように約９０°回転させて停止する。その後、クランプを解除し、回転台を逆回転（矢印イと逆方向に回転）させて芯金３１及びクランプ爪３２を初期位置に戻す。   Next, as shown in FIG. 3D, the air cylinder 33 is operated again to bring the clamp pawl 32 into contact with the flat wire w, and the flat wire w is clamped. Next, as shown in FIG. 4E, the turntable (not shown) is rotated in the direction of the arrow A, and the core 31, the rectangular wire w, and the clamp claw 32 are integrally formed around the rotation center C. Turn about 90 ° to stop. Thereafter, the clamp is released, and the turntable is rotated in the reverse direction (rotated in the direction opposite to the arrow A) to return the cored bar 31 and the clamp pawl 32 to the initial positions.

次に、図４（ｆ）のように、クランプフィーダーを操作して線送りを行い（矢印イ）、クランプ爪３２を下降させこれから曲げ加工を行う引き込み側の一部をクランプする（矢印ロ）と共にクランプフィーダーのクランプを解除して引き込まれ側の平角線をフリーにする。次に、回転台を矢印ハの方向に約９０°回転させると、回転中心Ｃを軸に芯金３１と平角線ｗとクランプ爪３２とが三者一体となって約９０°回転し、図４（ｇ）のような状態となる。   Next, as shown in FIG. 4 (f), line feed is performed by operating the clamp feeder (arrow a), and the clamp claw 32 is lowered and a part of the drawing side to be bent is clamped (arrow b). At the same time, the clamp of the clamp feeder is released and the rectangular wire on the side is pulled free. Next, when the turntable is rotated about 90 ° in the direction of arrow C, the core 31, the rectangular wire w and the clamp claw 32 are rotated about 90 ° around the rotation center C as a unit. 4 (g) is obtained.

以下、これらの動作を順次繰り返し、角形コイルを形成していく。なお、コイルの連結結合部など特殊な部位を除き、曲げ角は通常直角（すなわち９０°）である。このため、上記説明において曲げ角度は約９０°としたが、実際にはスプリングバックを考慮して曲げ角度を９０°以上に設定することが必要である。線送り量及び曲げ角度はいずれもサーボ機構等のコンピュータ制御により精密に制御されることが好ましい。   Thereafter, these operations are sequentially repeated to form a square coil. Note that the bending angle is usually a right angle (ie, 90 °), except for special parts such as a coupling and coupling portion of the coil. For this reason, although the bending angle is set to about 90 ° in the above description, it is actually necessary to set the bending angle to 90 ° or more in consideration of the springback. It is preferable that both the wire feed amount and the bending angle are precisely controlled by computer control such as a servo mechanism.

（作用）
上述のように芯金３１、平角線ｗ、クランプ爪３２が三者一体となって回転すると、溝付きの円形の曲げ金型（ローラ）などで線送りする場合のように平角線の被膜と擦れる部分がないため、平角線の被膜の表面に傷が付きにくい。
また、線ガイド２０が平角線の一端をしっかりと案内保持していることにより、平角線の曲げ加工時においても平角線の倒れ込みが発生しない。また、この方法によるとコイルにほとんどピッチをつけることなく密に巻くことができる。 (Function)
As described above, when the core 31, the rectangular wire w, and the clamp claw 32 rotate together, the rectangular wire coating and the wire are fed with a grooved circular bending die (roller) or the like. Since there is no rubbing part, the surface of the flat wire film is hardly scratched.
Moreover, since the wire guide 20 firmly guides and holds one end of the flat wire, the flat wire does not fall down even when the flat wire is bent. Further, according to this method, the coil can be wound closely with almost no pitch.

図５（ａ）は、本発明に係る角形コイル製造装置によって製造した角形コイル４０の一例を示している。従来よりもピッチが狭く、かつ、絶縁被膜の表面に傷が付いていない点が特徴である。また、本製造装置で製造すると角形コイルの辺長を自由な長さに設定できる。
図５（ｂ）は、本発明に係る角形コイルの製造方法を応用し、途中結合部４２を設け、２つの角形コイル４０、４０を連結した角形コイルを示している。これ以外にも、図５（ａ）に示す角形コイルを基本形とし、これを組み合わせて適宜連結した種々の角形コイルを形成することもできる。 Fig.5 (a) has shown an example of the square coil 40 manufactured with the square coil manufacturing apparatus which concerns on this invention. It is characterized in that the pitch is narrower than before and the surface of the insulating coating is not scratched. Further, when manufactured by this manufacturing apparatus, the side length of the rectangular coil can be set to any length.
FIG. 5 (b) shows a rectangular coil obtained by applying the rectangular coil manufacturing method according to the present invention, providing a midway coupling portion 42, and connecting two rectangular coils 40, 40. In addition to this, it is also possible to form various rectangular coils which are appropriately connected by combining the rectangular coils shown in FIG.

なお、使用した平角線の絶縁用被膜はポリアミドイミロースを用いたが、この材料は、塗られている導線が概ね２５％以上伸びると剥がれやすくなることが分かっている。曲げの内径が小さくなりすぎると、曲げられる外周側が伸びが大きくなるため、被膜が剥がれやすくなる。このため、この材料を被膜として用いた場合、最小曲げＲはこれらの点を考慮して適正に選定することが好ましい。   In addition, although the coating for insulation of the rectangular wire used used the polyamide amylose, it turned out that this material will become easy to peel when the conducting wire currently coated is extended about 25% or more. If the inner diameter of the bending becomes too small, the outer peripheral side to be bent increases in elongation, so that the coating is easily peeled off. For this reason, when this material is used as a coating, it is preferable that the minimum bend R is appropriately selected in consideration of these points.

本発明に係る角形コイル製造装置によると、巾と厚さの比が２：１以上の平角線であっても倒れ込みが全く起こることがなく、かつ、絶縁被膜の表面に傷が付きにくいために絶縁不良などを起こしにくい。しかも、コイルを密に巻くことができるので、高性能な角形コイルを製造することができる。   According to the rectangular coil manufacturing apparatus according to the present invention, even if a rectangular wire having a width to thickness ratio of 2: 1 or more, no collapse occurs and the surface of the insulating coating is not easily damaged. Insufficient insulation failure. In addition, since the coil can be tightly wound, a high-performance rectangular coil can be manufactured.

本発明に係る角形コイル製造装置は、主として小型かつ高性能なトランス製品などに用いられる角形コイル（角形電磁コイル）を製造する用途に用いることができる。   The square coil manufacturing apparatus according to the present invention can be used for the purpose of manufacturing a square coil (square electromagnetic coil) mainly used in a small and high-performance transformer product.

本発明に係る角形コイル製造装置の側面図を示している。The side view of the square coil manufacturing apparatus concerning the present invention is shown. （ａ）は、本発明に係る角形コイル製造装置における曲げ加工部３０の側面図を拡大した図である。（ｂ）は、（ａ）における曲げ加工部３０を上から見た図（平面図）である。（ｃ）は、（ａ）の曲げ加工部３０のＡ−Ａ断面である。(A) is the figure which expanded the side view of the bending process part 30 in the square coil manufacturing apparatus concerning this invention. (B) is the figure (plan view) which looked at the bending process part 30 in (a) from the top. (C) is the AA cross section of the bending process part 30 of (a). 本発明に係る角形コイルの製造方法における曲げ加工の各工程を示す図である。It is a figure which shows each process of the bending process in the manufacturing method of the square coil which concerns on this invention. 本発明に係る角形コイルの製造方法における曲げ加工の各工程を示す図である。It is a figure which shows each process of the bending process in the manufacturing method of the square coil which concerns on this invention. （ａ）及び（ｂ）は、本発明に係る角形コイル製造装置によって製造した角形コイルの一例を示す図である。(A) And (b) is a figure which shows an example of the square coil manufactured with the square coil manufacturing apparatus which concerns on this invention. （ａ）は、角形コイルを用いたトランス製品の一例を示す図である。（ｂ）は、従来の角形コイル製造方法の一例を示した図である。(A) is a figure showing an example of a transformer product using a square coil. (B) is the figure which showed an example of the conventional square coil manufacturing method. （ａ）は、従来の角形コイル製造方法の他の例を示した図である。（ｂ）は、（ａ）のＢ−Ｂで切断した断面図を示している。(A) is the figure which showed the other example of the conventional square coil manufacturing method. (B) has shown sectional drawing cut | disconnected by BB of (a).

符号の説明Explanation of symbols

１０ 線送り装置
２０ 線ガイド
３０ 曲げ加工部
３１ 芯金
３２ クランプ爪
ｗ 平角線 10 Wire Feeder 20 Wire Guide 30 Bending Process 31 Core Bar 32 Clamp Claw w Flat Wire

Claims (4)

平角線（ｗ）を送り出すための線送り装置（１０）と、線ガイド（２０）と、この平角線（ｗ）を巾方向に曲げ加工する曲げ加工部（３０）とを備え、
前記曲げ加工部（３０）は前記線ガイド（２０）から案内された前記平角線（ｗ）の曲げ部となる両側面を面接触で狭持するための芯金（３１）及びクランプ爪（３２）が対向して設置され、
前記芯金（３１）と前記クランプ爪（３２）とが前記平角線（ｗ）を狭持した状態で、前記芯金の一点（Ｃ）を軸に三者一体となって曲げ加工する曲げ機構を備えていることを特徴とする角形コイルの製造装置。 A wire feeder (10) for feeding out the flat wire (w), a wire guide (20), and a bending portion (30) for bending the flat wire (w) in the width direction;
The bending portion (30) includes a metal core (31) and a clamp claw (32) for sandwiching both side surfaces of the flat wire (w) guided from the line guide (20) by surface contact. ) Facing each other,
A bending mechanism for bending the cored bar (31) and the clamp claw (32) with one point (C) of the cored bar as an axis, with the rectangular wire (w) held between them. An apparatus for manufacturing a rectangular coil, comprising: 前記芯金（３１）は、前記平角線（ｗ）を曲げ加工する際の曲率半径と同程度の大きさの曲率半径を持つ円弧部分と、前記平角線（ｗ）を狭持するための平坦部分とを備えていることを特徴とする請求項１記載の角形コイルの製造装置。 The cored bar (31) is a flat part for sandwiching the flat wire (w) and an arc portion having a radius of curvature similar to the radius of curvature when bending the flat wire (w). The apparatus for manufacturing a rectangular coil according to claim 1, further comprising a portion. 前記芯金（３１）及び前記クランプ爪（３２）は前記芯金の一点（Ｃ）を中心に回転する回転板（３４）の上に設けられていることを特徴とする請求項１記載の角形コイルの製造装置。 2. The square according to claim 1, wherein the metal core (31) and the clamp claw (32) are provided on a rotating plate (34) that rotates about one point (C) of the metal core. Coil manufacturing equipment. 線送り装置（１０）と、線ガイド（２０）と、芯金（３１）及びクランプ爪（３２）を含む曲げ加工部（３０）とを備えた角形コイルの製造装置において、
（ａ） 前記平角線（ｗ）の一部を前記芯金（３１）及びクランプ爪（３２）によりクランプする工程と、
（ｂ） 前記平角線（ｗ）が前記芯金（３１）及びクランプ爪（３２）によってクランプされた状態で三者一体となって回転させ、前記平角線（ｗ）を曲げ加工する工程と、
（ｃ） 前記クランプ爪（３２）のクランプを解除し、前記芯金（３１）及びクランプ爪（３２）を初期位置に戻すと共に、前記線送り装置（１０）により前記平角線（ｗ）を所定量送出す工程と、
を含むことを特徴とする角形コイルの製造方法。 In a square coil manufacturing apparatus including a wire feeder (10), a wire guide (20), and a bending portion (30) including a core bar (31) and a clamp claw (32),
(A) a step of clamping a part of the flat wire (w) with the metal core (31) and the clamp claw (32);
(B) The step of bending the rectangular wire (w) by rotating the rectangular wire (w) in unison with the cored bar (31) and the clamp claw (32) in a state where the three wires are integrated.
(C) Clamping of the clamp pawl (32) is released, the core bar (31) and the clamp pawl (32) are returned to their initial positions, and the rectangular wire (w) is placed by the wire feeder (10). A process of sending a fixed amount;
The manufacturing method of the square coil characterized by including.
JP2003327405A 2003-09-19 2003-09-19 Manufacturing method and manufacturing apparatus of rectangular coil using flat conductive wire Expired - Lifetime JP4355547B2 (en)

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