JP2006339407A - Automatic winding machine and manufacturing method of air-core coil using it - Google Patents
Automatic winding machine and manufacturing method of air-core coil using it Download PDFInfo
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- JP2006339407A JP2006339407A JP2005162320A JP2005162320A JP2006339407A JP 2006339407 A JP2006339407 A JP 2006339407A JP 2005162320 A JP2005162320 A JP 2005162320A JP 2005162320 A JP2005162320 A JP 2005162320A JP 2006339407 A JP2006339407 A JP 2006339407A
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- 238000004804 winding Methods 0.000 title claims abstract description 380
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 230000002093 peripheral effect Effects 0.000 claims abstract description 126
- 238000003780 insertion Methods 0.000 claims abstract description 38
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- 230000007246 mechanism Effects 0.000 claims abstract description 33
- 239000013067 intermediate product Substances 0.000 claims description 40
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- 238000009751 slip forming Methods 0.000 claims description 4
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- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 description 12
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- 239000002356 single layer Substances 0.000 description 9
- 230000008569 process Effects 0.000 description 8
- 230000007704 transition Effects 0.000 description 6
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- 238000003475 lamination Methods 0.000 description 4
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Abstract
Description
本発明は、各種交流機器における整流回路、雑音防止回路、共振回路等に装備される空芯コイルを作製するための自動巻線機、及びこれを用いた空心コイルの製造方法に関するものである。 The present invention relates to an automatic winding machine for producing an air-core coil equipped in a rectifier circuit, a noise prevention circuit, a resonance circuit, etc. in various AC devices, and an air-core coil manufacturing method using the same.
従来、図１１及び図１２に示す如く、ボビン(10)の周囲に空芯コイル(２a)を巻装してなるトロイダル型のコイル装置が知られている。該空芯コイル(２a)は、導線(40)の巻き軸方向とは直交する方向に最内周から最外周へ向けて、第１層(21)、第２層(22)及び第３層(23)からなる積層構造を有している。
該空芯コイル(２a)は、図１２中に番号１〜２９で示す巻線順序で１本の導線を巻回して形成されており、連続する複数の番号(１〜３)、(４〜６)、・・・、(２５〜２７)、(２８〜２９)の巻線によってそれぞれ単位コイル部が形成され、これらの単位コイル部が巻き軸方向へ１０列に並んでいる。
各単位コイル部は、それぞれ巻数１の最大内周長の単位巻部、中間内周長の単位巻部、及び最小内周長の単位巻部から形成され、最大内周長の単位巻部の内側に中間内周長の単位巻部が押し込まれ、更に中間内周長の単位コイル部の内側に最小内周長の単位巻部が押し込まれている。
Conventionally, as shown in FIGS. 11 and 12, a toroidal type coil device in which an air-core coil (2a) is wound around a bobbin (10) is known. The air-core coil (2a) includes a first layer (21), a second layer (22), and a third layer in a direction perpendicular to the winding axis direction of the conducting wire (40) from the innermost circumference to the outermost circumference. It has a laminated structure consisting of (23).
The air-core coil (2a) is formed by winding one conducting wire in the winding order indicated by
Each unit coil portion is formed of a unit winding portion having a maximum inner peripheral length of 1 turn, a unit winding portion having an intermediate inner peripheral length, and a unit winding portion having a minimum inner peripheral length. A unit winding portion having an intermediate inner circumferential length is pushed inside, and a unit winding portion having a minimum inner circumferential length is pushed inside a unit coil portion having an intermediate inner circumferential length.
該空芯コイル(２a)を製造する方法として、出願人は、図２１に示す巻線治具(61)を用いた製造方法を提案している(特許文献１参照)。該巻線治具(61)は、平板部材(62)の両面の両端部にそれぞれ有段部材(63)を着脱可能に固定して構成される。有段部材(63)は、図２２及び図２３(ａ)(ｂ)に示す如く、低位段部(65)、中位段部(66)、高位段部(67)、中位段部(66)及び低位段部(65)の配列を１周期として、これらの段部を繰り返し形成したものである。尚、図２３(ａ)は有段部材(63)の平面図、図２３(ｂ)は有段部材(63)の側面図を表わしており、該有段部材(63)の各段部には、導線を巻き付ける際の順序を表わす番号１〜２９を付している。 As a method for manufacturing the air-core coil (2a), the applicant has proposed a manufacturing method using a winding jig (61) shown in FIG. 21 (see Patent Document 1). The winding jig (61) is configured by detachably fixing a stepped member (63) to both ends of both surfaces of the flat plate member (62). As shown in FIGS. 22 and 23 (a) (b), the stepped member (63) includes a lower step portion (65), a middle step portion (66), a higher step portion (67), a middle step portion ( 66) and the lower step (65) are arranged as one cycle, and these steps are repeatedly formed. 23 (a) is a plan view of the stepped member (63), and FIG. 23 (b) is a side view of the stepped member (63). In each step of the stepped member (63), FIG. Are numbered 1 to 29 representing the order in which the conductors are wound.
図２４(ａ)(ｂ)は、前記巻線治具(61)の周囲に導線(40)を巻回してなるコイル中間製品(29a)を表わしており、導線(40)は、図２１に示す巻線治具(61)の端部に位置する低位段部(65)から巻き初め、順次、隣接する中位段部(66)、高位段部(67)、中位段部(66)及び低位段部(65)へと巻線を進める。尚、中位段部(66)はそれぞれ導線(40)を１回だけ巻回するための幅を有しているのに対し、低位段部(65)及び高位段部(67)は導線(40)を２回だけ巻回するための幅を有している。 24 (a) and 24 (b) show a coil intermediate product (29a) formed by winding a conducting wire (40) around the winding jig (61). The conducting wire (40) is shown in FIG. Starting from the lower level step (65) located at the end of the winding jig (61) shown, the middle step (66), the higher level step (67), the middle step (66) adjacent to each other And advance the winding to the lower step (65). The middle step (66) has a width for winding the conductive wire (40) only once, whereas the lower step (65) and the high step (67) are conductors ( 40) has a width for winding only twice.
導線(40)を低位段部(65)の周囲に巻き付けることによって最小内周長の第１単位巻部(25)が形成され、導線(40)を中位段部(66)の周囲に巻き付けることによって中間内周長の第２単位巻部(26)が形成され、導線(40)を高位段部(67)の周囲に巻き付けることによって最大内周長の第１単位巻部(27)が形成される。この過程で、巻線治具(61)の１つの段部から隣りの段部へ巻線を進める際、巻線治具(61)の一方の側面にて導線(40)を斜め方向へ延ばしながら段部間を移行せしめる。尚、巻線治具(61)の他方の側面では、図２４(ａ)(ｂ)に示す如く導線(20)は同じ高さの段部間を真っ直ぐ伸びることになる。 By winding the conducting wire (40) around the lower step portion (65), the first unit winding portion (25) having the minimum inner peripheral length is formed, and the conducting wire (40) is wound around the middle step portion (66). As a result, a second unit winding portion (26) having an intermediate inner peripheral length is formed, and the first unit winding portion (27) having the maximum inner peripheral length is formed by winding the lead wire (40) around the higher step portion (67). It is formed. In this process, when the winding is advanced from one step portion of the winding jig (61) to the adjacent step portion, the conductive wire (40) is extended obliquely on one side surface of the winding jig (61). While moving between the steps. Incidentally, on the other side surface of the winding jig (61), as shown in FIGS. 24 (a) and 24 (b), the conductive wire (20) extends straight between the step portions of the same height.
巻線治具(61)の周囲に必要回数だけ導線(40)を巻き付けた後、巻線治具(61)を分解することによって、図１３(ａ)に示すコイル中間製品(29a)を得る。その後、該コイル中間製品(29a)を巻き軸方向に圧縮することによって、図１３(ｂ)に示す如く第３単位巻部(27)の内側に第２単位巻部(26)を押し込み、該第２単位巻部(26)の内側に第１単位巻部(25)を押し込む。これによって、３層の空芯コイル(２a)が得られることになる。
しかしながら、上述の空芯コイルの製造方法によって、例えば図１９に示す様な巻き軸方向の途中位置に単層及び２層の単位コイル部を有する空芯コイル(２ｂ)を作製する場合には、図２３に示す巻線治具(61)の有段部材(63)の形状を、図２５に示す有段部材(63a)の如く変更する必要がある。従って、上述の空芯コイルの製造方法によると、同一形状であってもその巻順が異なるだけで、新たに有段部材を用意する必要があるばかりでなく、空芯コイルの製造工程においては、製造すべき空芯コイルの形状や巻順に応じて、これに合った有段部材を巻線治具(61)に取り付ける煩雑な作業が必要となり、空芯コイルの製造工程の自動化を阻害する要因となっていた。
そこで本発明の目的は、巻線治具を交換することなく、積層状態の異なる様々な構成の空芯コイルを作製することが出来る自動巻線機及びこれを用いた空芯コイルの製造方法を提供することである。
However, when producing the air-core coil (2b) having single-layer and two-layer unit coil portions at the midway position in the winding axis direction, for example, as shown in FIG. It is necessary to change the shape of the stepped member (63) of the winding jig (61) shown in FIG. 23 as the stepped member (63a) shown in FIG. Therefore, according to the manufacturing method of the air core coil described above, not only the winding order is different even in the same shape, it is not only necessary to prepare a stepped member, but also in the manufacturing process of the air core coil. Depending on the shape and winding order of the air-core coil to be manufactured, a complicated operation of attaching a stepped member suitable for this to the winding jig (61) is required, which hinders automation of the air-core coil manufacturing process. It was a factor.
Accordingly, an object of the present invention is to provide an automatic winding machine capable of producing air core coils having various configurations with different lamination states without changing the winding jig, and an air core coil manufacturing method using the same. Is to provide.
本発明の自動巻線機は、少なくとも１本の導線を渦巻き状に巻回して形成される単位コイル部が、巻き軸方向に繰り返し並んでおり、各単位コイル部は、互いに内周長の異なる複数の単位巻部から形成され、内周長の大きな単位巻部の内側に内周長の小さな単位巻部の少なくとも一部が押し込まれている空芯コイルを作製するためのものであって、回転駆動機構(72)と、該回転駆動機構(72)によって回転駆動される巻芯部材(５)と、該巻芯部材(５)の回転軸と同軸上に対向配備され該回転軸を中心に回転可能な対向部材(３)と、前記巻芯部材(５)及び対向部材(３)の内、少なくとも何れか一方の部材を他方の部材に対して接近離間する方向に駆動する往復移動機構とを具えている。 In the automatic winding machine of the present invention, unit coil portions formed by spirally winding at least one conducting wire are repeatedly arranged in the winding axis direction, and each unit coil portion has a different inner peripheral length. It is formed from a plurality of unit winding parts, and for producing an air-core coil in which at least a part of a unit winding part having a small inner peripheral length is pushed inside a unit winding part having a large inner peripheral length, A rotational drive mechanism (72), a core member (5) that is rotationally driven by the rotational drive mechanism (72), and disposed coaxially with the rotational axis of the core member (5) and centered on the rotational axis And a reciprocating mechanism for driving at least one of the core member (5) and the facing member (3) in a direction to approach and separate from the other member. And has.
前記対向部材(３)の巻芯部材(５)との対向面には、導線をガイドするための導線ガイド面(35)が形成され、該導線ガイド面(35)には、前記巻芯部材(５)が挿入されるべき挿入孔(31)が凹設され、該挿入孔(31)の外側には、前記挿入孔(31)の外側には、該挿入孔(31)に挿入された巻芯部材(５)の外周面の一部を覆う形状を有する巻線補助部材(32)が配備され、該巻線補助部材(32)は、駆動機構に連結されて、該駆動機構により、前記導線ガイド面(35)から前記巻芯部材(５)に向けて突出した第１位置と、対向部材(３)の内部に収容された第２位置との間で、前記回転軸に沿って往復移動が可能である。 A conductive wire guide surface (35) for guiding a conductive wire is formed on a surface of the opposing member (3) facing the core member (5), and the conductive wire guide surface (35) includes the core member. An insertion hole (31) into which (5) is to be inserted is recessed, and the insertion hole (31) is inserted into the insertion hole (31) outside the insertion hole (31). A winding auxiliary member (32) having a shape covering a part of the outer peripheral surface of the core member (5) is provided, and the winding auxiliary member (32) is connected to the drive mechanism, Along the rotation axis between a first position protruding from the conductor guide surface (35) toward the core member (5) and a second position accommodated in the opposing member (3). Reciprocal movement is possible.
上記本発明の自動巻線機(７)を用いて、互いに内周長の異なる２つの単位巻部からなる２層の積層構造を有する空芯コイルを作製する場合には、先ず、自動巻線機(７)の往復移動機構により、巻芯部材(５)を対向部材(３)の挿入孔(31)に挿入させると共に、駆動機構により、巻線補助部材(32)を前記第２位置に移動させる。この状態で、巻線補助部材(32)は、対向部材(３)の内部に収容されているため、自動巻線機(７)の導線巻回位置には、巻芯部材(５)の外周面が露出することになる。そして、回転駆動機構(72)により、巻芯部材(５)及び対向部材(３)を回転させ、露出した巻芯部材(５)の外周面に導線を巻回することによって、空芯コイルの２つの単位巻部の内、内周長の小なる単位巻部を形成することが出来る。 In the case of producing an air-core coil having a two-layer laminated structure composed of two unit winding portions having different inner peripheral lengths using the automatic winding machine (7) of the present invention, first, the automatic winding The core member (5) is inserted into the insertion hole (31) of the opposing member (3) by the reciprocating mechanism of the machine (7), and the winding auxiliary member (32) is moved to the second position by the drive mechanism. Move. In this state, the winding auxiliary member (32) is housed inside the opposing member (3), so that the outer periphery of the core member (5) is at the winding position of the automatic winding machine (7). The surface will be exposed. Then, the core member (5) and the opposing member (3) are rotated by the rotation drive mechanism (72), and the lead wire is wound around the exposed outer peripheral surface of the core member (5). Of the two unit winding portions, a unit winding portion having a small inner peripheral length can be formed.
一方、空芯コイルの２つの単位巻部の内、内周長の大なる単位巻部を形成する場合には、駆動機構により、巻線補助部材(32)を前記第１位置に移動させる。この状態で、巻線補助部材(32)は、対向部材(３)の導線ガイド面(35)から突出し、巻芯部材(５)の外周面を覆うことになる。そして、回転駆動機構(72)により、巻芯部材(５)及び対向部材(３)を回転させ、巻線補助部材(32)の外周面に導線を巻回することによって、内周長の大なる単位巻部を形成することが出来る。 On the other hand, when forming a unit winding part having a large inner peripheral length out of the two unit winding parts of the air-core coil, the winding auxiliary member (32) is moved to the first position by the drive mechanism. In this state, the winding auxiliary member (32) protrudes from the conductive wire guide surface (35) of the opposing member (3) and covers the outer peripheral surface of the core member (5). Then, the core member (5) and the counter member (3) are rotated by the rotation drive mechanism (72), and the conductive wire is wound around the outer peripheral surface of the winding auxiliary member (32), thereby increasing the inner peripheral length. A unit winding portion can be formed.
従来、内周長の異なる複数の単位巻部の積層構造を有する空芯コイルを作製する場合には、空芯コイルの形状や巻順に応じて、巻線治具を交換する必要があったが、上記本発明の自動巻線機(７)によれば、前記巻線補助部材(32)を前記第１位置と第２位置の間で往復移動させるだけで、空芯コイルの巻き軸方向の任意の位置に、内周長の大なる単位巻部或いは内周長の小なる単位巻部を形成することが出来、これによって、積層状態の異なる様々な構成の空芯コイルを作製することが可能となる。 Conventionally, when producing an air-core coil having a laminated structure of a plurality of unit winding portions having different inner peripheral lengths, it has been necessary to replace the winding jig according to the shape and winding order of the air-core coil. According to the automatic winding machine (7) of the present invention, the winding auxiliary member (32) can be moved back and forth between the first position and the second position in the winding axis direction of the air-core coil. A unit winding part with a large inner peripheral length or a unit winding part with a small inner peripheral length can be formed at an arbitrary position, thereby making it possible to produce air core coils having various configurations with different lamination states. It becomes possible.
具体的構成において、前記巻芯部材(５)は、前記回転駆動機構(72)の回転軸に対して垂直な断面形状が略矩形状を呈し、前記対向部材(３)の挿入孔(31)は、前記巻芯部材(５)の断面形状に応じた開口形状を有し、前記巻線補助部材(32)は、前記巻芯部材(５)の断面形状を構成する４辺の内の１辺に沿ってその外側に拡がる第１外周面と、該１辺と交叉する２辺の内の１辺に沿ってその外側に拡がる第２外周面とを有している。 In a specific configuration, the core member (5) has a substantially rectangular cross section perpendicular to the rotation axis of the rotation drive mechanism (72), and the insertion hole (31) of the opposing member (3). Has an opening shape corresponding to the cross-sectional shape of the core member (5), and the winding auxiliary member (32) is one of four sides constituting the cross-sectional shape of the core member (5). A first outer peripheral surface extending outward along the side and a second outer peripheral surface extending outward along one of the two sides intersecting with the one side are provided.
該具体的構成において、前記巻線補助部材(32)が前記第２位置にあるとき、導線は対向部材(３)の挿入孔(32)に挿入された巻芯部材(５)の外周面に巻回され、これによって、内周長の小なる単位巻部が形成される。
一方、前記巻線補助部材(32)が第１位置にあるとき、巻線補助部材(32)の第１外周面及び第２外周面は、前記挿入孔(31)の矩形状の開口形状を構成する４辺の内、互いに交叉する２辺に沿って該２辺の外側に形成されているので、前記挿入孔(32)に挿入された巻芯部材(５)の外周面を覆うことになる。従って、導線は該巻線補助部材(32)の第１外周面及び第２外周面に巻回され、この結果、内周長の大なる単位巻部が形成されることになる。
In the specific configuration, when the auxiliary winding member (32) is in the second position, the conducting wire is placed on the outer peripheral surface of the core member (5) inserted into the insertion hole (32) of the opposing member (3). By winding, a unit winding portion having a small inner peripheral length is formed.
On the other hand, when the winding auxiliary member (32) is in the first position, the first outer peripheral surface and the second outer peripheral surface of the winding auxiliary member (32) have the rectangular opening shape of the insertion hole (31). Since it is formed outside the two sides along two sides that intersect each other among the four sides that constitute, it covers the outer peripheral surface of the core member (5) inserted into the insertion hole (32). Become. Therefore, the conducting wire is wound around the first outer peripheral surface and the second outer peripheral surface of the winding auxiliary member (32), and as a result, a unit winding portion having a large inner peripheral length is formed.
又、具体的構成において、前記巻線補助部材(32)は、前記対向部材(３)の挿入孔(31)の開口形状を構成する４辺の内の２辺が互いに交叉して形成される４つの角部の内、少なくとも所定の１辺の両端に形成された２つの角部にそれぞれ配備され、前記回転駆動機構(72)の回転軸に対して垂直な断面形状がＬ字状を呈している。 Further, in a specific configuration, the winding auxiliary member (32) is formed by intersecting two of the four sides constituting the opening shape of the insertion hole (31) of the facing member (3). Among the four corners, at least two corners formed at both ends of one predetermined side are respectively provided, and a cross-sectional shape perpendicular to the rotation axis of the rotation drive mechanism (72) is L-shaped. ing.
該具体的構成において、前記巻線補助部材(32)が前記第１位置にあるとき、導線は各角部に配備されたＬ字状の巻線補助部材(32)の外周面に巻回され、この結果、内周長の大なる単位巻部が形成されることになる。 In the specific configuration, when the winding auxiliary member (32) is in the first position, the conducting wire is wound around the outer peripheral surface of the L-shaped winding auxiliary member (32) arranged at each corner. As a result, a unit winding portion having a large inner peripheral length is formed.
更に具体的構成において、前記巻線補助部材(32)の外側には、該巻線補助部材(32)の外周面に沿う外周面を有する１或いは複数の巻線補助部材(33)が、内側に位置する巻線補助部材の周囲を覆う様に互いに隣接して配備され、前記対向部材(３)の挿入孔(31)に隣接して配備された巻線補助部材(32)を除く１或いは複数の巻線補助部材(33)は、それぞれ駆動機構に連結されて、該駆動機構により、前記対向部材(３)の導線ガイド面(35)から前記巻芯部材(５)に向けて突出した第１位置と、対向部材(３)の内部に収容された第２位置との間で、前記回転軸に沿って往復移動が可能である。 In a more specific configuration, one or more winding auxiliary members (33) having an outer peripheral surface along the outer peripheral surface of the winding auxiliary member (32) are provided on the outer side of the winding auxiliary member (32). 1 or 2 except for the winding auxiliary member (32) provided adjacent to each other so as to cover the periphery of the winding auxiliary member located at the position and adjacent to the insertion hole (31) of the opposing member (3). The plurality of auxiliary winding members (33) are respectively connected to a drive mechanism, and project from the conductive wire guide surface (35) of the facing member (3) toward the core member (5) by the drive mechanism. Between the first position and the second position accommodated in the opposing member (3), reciprocation is possible along the rotation axis.
該具体的構成において、例えば、前記対向部材(３)の挿入孔(31)の周囲に２つの巻線補助部材(32)(33)が隣接して配備されている場合には、内周長が互いに異なる３種類の単位巻部の積層構造を有する空芯コイルを作製することが可能となる。この様に、作製すべき空芯コイルの積層数に応じた数の巻線補助部材を対向部材(３)の挿入孔(31)の周囲に隣接して配備することによって、互いに内周長の異なる任意の数の単位巻部の積層構造を有する空芯コイルを作製することが可能となる。 In the specific configuration, for example, when two winding auxiliary members (32) and (33) are arranged adjacent to each other around the insertion hole (31) of the facing member (3), the inner circumferential length It is possible to produce an air-core coil having a laminated structure of three types of unit winding portions different from each other. In this way, by arranging the winding auxiliary members corresponding to the number of laminated air-core coils to be manufactured adjacent to the periphery of the insertion hole (31) of the opposing member (3), the inner peripheral lengths of each other can be increased. It becomes possible to produce an air-core coil having a laminated structure of an arbitrary number of different unit winding portions.
又、本発明の空芯コイルの製造方法は、少なくとも１本の導線を渦巻き状に巻回することにより、互いに異なる内周長を有する複数の単位巻部を巻き軸方向に連続して形成すると共に、該複数の単位巻部からなる単位コイル部を巻き軸方向に繰り返し形成して、空芯コイルの中間製品を作製する第１工程と、
該第１工程を経て得られた中間製品を巻き軸方向に圧縮して、各単位コイルを構成する複数の単位巻部の内、内周長の大きな単位巻部の内側に内周長の小さな単位巻部の少なくとも一部を押し込む第２工程
とを有している。
Also, in the method for manufacturing an air-core coil of the present invention, a plurality of unit winding portions having different inner peripheral lengths are continuously formed in the winding axis direction by winding at least one conducting wire in a spiral shape. And a first step of forming an intermediate product of an air-core coil by repeatedly forming a unit coil portion composed of the plurality of unit winding portions in the winding axis direction;
The intermediate product obtained through the first step is compressed in the winding axis direction, and the inner peripheral length is small inside the unit winding portion having a large inner peripheral length among the plurality of unit winding portions constituting each unit coil. And a second step of pushing at least part of the unit winding portion.
前記第１工程では、回転体の外周面に導線を巻回することにより前記中間製品を作製し、該回転体には、巻芯部材(５)と、該巻芯部材(５)の導線巻回位置に出没し該巻芯部材(５)の外周面の一部を覆う第１位置と該外周面を露出させる第２位置との間で往復移動可能な巻線補助部材(32)とが配備されている。
前記第１工程では、前記回転体を回転させ、該回転体が所定の回転角度だけ回転する毎に、前記巻線補助部材(32)を前記第１位置と第２位置との間で往復移動させると共に、該回転体が１回転する毎に、巻回した導線を前記導線巻回位置から巻芯部材(５)の回転軸方向に少なくとも導線の直径に相当する距離分だけ離間させることによって、前記導線巻回位置にて導線を巻線補助部材(32)或いは巻芯部材(５)の外周面に巻回し、互いに内周長の異なる複数の単位巻部を前記回転軸方向に連続して形成する。
In the first step, the intermediate product is manufactured by winding a conducting wire around the outer peripheral surface of the rotating body. The rotating member includes a core member (5) and a winding of the core member (5). A winding auxiliary member (32) capable of reciprocating between a first position that appears at the turning position and covers a part of the outer peripheral surface of the core member (5) and a second position that exposes the outer peripheral surface is provided. Has been deployed.
In the first step, the winding auxiliary member (32) is reciprocated between the first position and the second position each time the rotating body is rotated and the rotating body rotates by a predetermined rotation angle. And each time the rotating body makes one rotation, the wound conductor is separated from the conductor winding position by a distance corresponding to at least the diameter of the conductor in the rotation axis direction of the core member (5), A conducting wire is wound around the outer peripheral surface of the winding auxiliary member (32) or the core member (5) at the conducting wire winding position, and a plurality of unit winding portions having different inner circumferential lengths are continuously provided in the direction of the rotation axis. Form.
上記本発明の空芯コイルの製造方法を用いて、例えば互いに内周長の異なる２つの単位巻部からなる２層の積層構造を有する空芯コイルを作製する場合には、先ず、巻線補助部材(32)を前記第２位置に移動させる。この状態で、巻芯部材(５)の導線巻回位置には、巻芯部材(５)の外周面が露出することになる。そして、回転体を回転させ、該回転体が１回転する毎に、巻回した導線を前記導線巻回位置から巻芯部材(５)の回転軸方向に少なくとも導線の直径に相当する距離分だけ離間させることにより、露出した巻芯部材(５)の外周面に導線を巻回し、空芯コイルの２つの単位巻部の内、内周長の小なる単位巻部を形成する。 In the case of producing an air-core coil having a two-layer structure composed of two unit winding portions having different inner peripheral lengths, for example, using the above-described method for producing an air-core coil of the present invention, first, winding assistance The member (32) is moved to the second position. In this state, the outer peripheral surface of the core member (5) is exposed at the conducting wire winding position of the core member (5). Then, the rotating body is rotated, and each time the rotating body rotates once, the wound conducting wire is at least a distance corresponding to the diameter of the conducting wire in the direction of the axis of rotation of the core member (5) from the conducting wire winding position. By separating, the conducting wire is wound around the exposed outer peripheral surface of the core member (5) to form a unit winding portion having a smaller inner peripheral length among the two unit winding portions of the air core coil.
前記回転体が所定の回転角度だけ回転した後には、巻線補助部材(32)を前記第１位置に移動させる。この状態で、巻線補助部材(32)は、巻芯部材(５)の外周面を覆っており、導線は巻線補助部材(32)の外周面に巻回されることになる。そして、回転体が１回転する度に、巻回した導線を前記導線巻回位置から巻芯部材(５)の回転軸方向に少なくとも導線の直径に相当する距離分だけ離間させることにより、巻線補助部材(32)の外周面に導線を巻回し、空芯コイルの２つの単位巻部の内、内周長の大なる単位巻部を形成する。 After the rotating body rotates by a predetermined rotation angle, the winding auxiliary member (32) is moved to the first position. In this state, the winding auxiliary member (32) covers the outer peripheral surface of the core member (5), and the conductive wire is wound around the outer peripheral surface of the winding auxiliary member (32). Each time the rotating body makes one turn, the wound conductor is separated from the conductor winding position in the direction of the axis of rotation of the core member (5) by at least a distance corresponding to the diameter of the conductor. A conducting wire is wound around the outer peripheral surface of the auxiliary member (32) to form a unit winding portion having a large inner peripheral length among the two unit winding portions of the air-core coil.
更に上述の工程を所定回数繰り返すことによって、互いに内周長の異なる複数の単位巻部を巻き軸方向に連続して形成すると共に、該複数の単位巻部からなる単位コイル部を巻き軸方向に繰り返し形成して、前記中間製品を作製する。
その後、第２工程にて、第１工程を経て得られた中間製品を巻き軸方向に圧縮することにより、各単位コイルを構成する複数の単位巻部の内、内周長の大きな単位巻部の内側に内周長の小さな単位巻部の少なくとも一部を押し込み、この結果、複数の単位巻部の積層構造を有する空芯コイルが得られることになる。
Further, by repeating the above-described process a predetermined number of times, a plurality of unit winding portions having different inner peripheral lengths are continuously formed in the winding axis direction, and a unit coil portion composed of the plurality of unit winding portions is formed in the winding axis direction. The intermediate product is produced by repeated formation.
Thereafter, in the second step, by compressing the intermediate product obtained through the first step in the winding axis direction, a unit winding portion having a large inner peripheral length among a plurality of unit winding portions constituting each unit coil. As a result, an air-core coil having a laminated structure of a plurality of unit windings is obtained.
更に、本発明の空芯コイルは、少なくとも１本の導線を渦巻き状に巻回して形成される単位コイルが、巻き軸方向に繰り返し並んで構成される空芯コイルであって、巻き軸方向に並ぶ第１空芯コイル部と第２空芯コイルとを有し、
第１空芯コイル部を構成する複数の単位コイルはそれぞれ、互いに内周長の異なる複数の単位巻部から形成され、内周長の大きな単位巻部の内側に内周長の小さな単位巻部の少なくとも一部が押し込まれており、
第２空芯コイル部を構成する複数の単位コイルはそれぞれ、少なくとも第１空芯コイル部の最内周に位置する単位巻部に対応する最内周の単位巻部が欠落して、単一の単位巻部、若しくは第１空芯コイル部の各単位コイル部を形成する単位巻部の数よりも少ない複数の単位巻部から構成され、該複数の単位巻部は互いに内周長が異なり、内周長の大きな単位巻部の内側に内周長の小さな単位巻部の少なくとも一部が押し込まれている。
Furthermore, the air-core coil of the present invention is an air-core coil in which unit coils formed by winding at least one conducting wire in a spiral shape are repeatedly arranged in the direction of the winding axis. Having a first air core coil portion and a second air core coil lined up,
Each of the plurality of unit coils constituting the first air-core coil unit is formed of a plurality of unit winding portions having different inner circumferential lengths, and a unit winding portion having a smaller inner circumferential length is disposed inside the unit winding portion having a larger inner circumferential length. At least part of
Each of the plurality of unit coils constituting the second air-core coil portion is missing at least the innermost unit winding portion corresponding to the unit winding portion located on the innermost circumference of the first air-core coil portion. Or a plurality of unit windings less than the number of unit windings forming each unit coil part of the first air-core coil part, and the plurality of unit winding parts have different inner peripheral lengths. At least a part of the unit winding portion with a small inner peripheral length is pushed inside the unit winding portion with a large inner peripheral length.
上記本発明の空芯コイルにおいて、例えば、コアのギャップ部に対応する位置に、内周側の１或いは複数の単位巻部が欠落した複数の第２単位コイル部を連続して形成することにより、コアのギャップ部に対応する領域以外の領域では、内周の単位巻部と最外周の単位巻部との間で連続する複数の単位巻部の積層構造を有すると共に、コアのギャップ部に対応する領域では、内周側の単位巻部が欠落した空芯コイルを作製することが出来る。これによって、コアのギャップ部に生じる漏れ磁束が空芯コイルに与える影響を低減することが出来、この結果、コイル装置の高性能化を図ることが出来る。 In the above-described air-core coil of the present invention, for example, a plurality of second unit coil portions lacking one or more unit windings on the inner peripheral side are continuously formed at positions corresponding to the gap portions of the core. The region other than the region corresponding to the gap portion of the core has a laminated structure of a plurality of unit winding portions continuous between the inner peripheral unit winding portion and the outermost peripheral unit winding portion, and in the core gap portion. In the corresponding region, it is possible to produce an air-core coil lacking the unit winding portion on the inner peripheral side. As a result, the influence of the leakage magnetic flux generated in the gap portion of the core on the air-core coil can be reduced, and as a result, the performance of the coil device can be improved.
本発明の自動巻線機、及びこれを用いた空芯コイルの製造方法によれば、巻線治具を交換することなく、積層状態の異なる様々な構成の空芯コイルを作製することが出来る。 According to the automatic winding machine of the present invention and the air core coil manufacturing method using the same, it is possible to manufacture air core coils having various configurations with different lamination states without replacing the winding jig. .
以下、本発明の実施の形態につき、図面に沿って具体的に説明する。
図１に示す如く、本発明の自動巻線機(７)は、円筒状の回転体(71)と、該回転体(71)を回転駆動する回転駆動機構(72)を具えている。回転体(71)の端面には、該回転体(71)の回転軸を中心として四角柱状の巻芯部材(５)が突設されており、該巻芯部材(５)の突出方向に対向して、該巻芯部材(５)が挿入されるべき円筒状の対向部材(３)が配備され、該対向部材(３)の上方には、対向部材(３)の端面に沿って導線(40)を導くためのガイド機構(73)が配備されている。対向部材(３)及びガイド機構(73)は、同一の支持体(77)に取り付けられており、該支持体(77)には、回転体(71)の下方に配備されたエアシリンダ(76)が連結されている。該エアシリンダ(76)の駆動によって、支持体(77)は、回転体(71)に対して接近離間する方向に往復移動が可能となっている。
Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
As shown in FIG. 1, the automatic winding machine (7) of the present invention includes a cylindrical rotating body (71) and a rotation driving mechanism (72) that rotationally drives the rotating body (71). On the end surface of the rotating body (71), a quadrangular prism-shaped core member (5) is provided so as to protrude from the rotating shaft of the rotating body (71), and is opposed to the protruding direction of the core member (5). Then, a cylindrical facing member (3) into which the core member (5) is to be inserted is provided, and a conductive wire (along the end surface of the facing member (3) is provided above the facing member (3). A guide mechanism (73) for guiding 40) is provided. The opposing member (3) and the guide mechanism (73) are attached to the same support (77), and the support (77) has an air cylinder (76) disposed below the rotating body (71). ) Are connected. By driving the air cylinder (76), the support (77) can reciprocate in a direction approaching and separating from the rotating body (71).
図２(ａ)に示す如く、対向部材(３)の巻芯部材(５)との対向面には、導線をガイドするための導線ガイド面(35)が形成されると共に、該導線ガイド面(35)には、巻芯部材(５)が挿入されるべき矩形状の挿入孔(31)が凹設されている。挿入孔(31)を構成する１つの長辺と２つの短辺が互いに交叉して形成される２つの角部には、挿入孔(31)に挿入された巻芯部材(５)の外周面の一部を覆う形状を有する一対のＬ字状の巻線補助部材(32a)(32b)が配備されている。対向部材(３)の内部には、一対のエアシリンダ(75)(75)が配備され、両エアシリンダ(75)(75)は、一対の巻線補助部材(32a)(32b)にそれぞれ連結されている。これによって、一対の巻線補助部材(32a)(32b)は、図２(ｂ)に示す如く、その先端部が対向部材(３)の導線ガイド面(35)から突出した第１位置と、図２(ａ)に示す如く、各巻線補助部材(32a)(32b)が対向部材(３)の内部に収容されてその先端面と導線ガイド面(35)とが面一となった第２位置との間で、往復移動が可能となっている。 As shown in FIG. 2A, a conductive wire guide surface (35) for guiding a conductive wire is formed on a surface of the opposing member (3) facing the core member (5), and the conductive wire guide surface. In (35), a rectangular insertion hole (31) into which the core member (5) is to be inserted is recessed. The outer peripheral surface of the core member (5) inserted into the insertion hole (31) is formed at two corners formed by intersecting one long side and two short sides constituting the insertion hole (31). A pair of L-shaped winding auxiliary members (32a) and (32b) having a shape that covers a part of them are provided. A pair of air cylinders (75) and (75) are provided inside the facing member (3), and both the air cylinders (75) and (75) are connected to the pair of winding auxiliary members (32a) and (32b), respectively. Has been. As a result, the pair of winding auxiliary members (32a) and (32b), as shown in FIG. 2 (b), have their first positions protruding from the conductive wire guide surface (35) of the opposing member (3), and As shown in FIG. 2 (a), each winding auxiliary member (32a) (32b) is accommodated in the opposing member (3) so that the tip surface thereof and the conductor guide surface (35) are flush with each other. Reciprocal movement between the positions is possible.
一方、巻芯部材(５)は、図３(ａ)及び図３(ｂ)に示す如く、一対の割型(51a)(51b)と、両割型(51a)(51b)の間に挿入された楔状部材(52)とから構成され、両割型(51a)(51b)は、コイルバネ(53)によって互いに接近する方向に付勢された状態で連結されている。楔状部材(52)には、エアシリンダ(図示省略)が連結されており、これによって、楔状部材(52)は、図３(ａ)に示す前進位置と、図３(ｂ)に示す後退位置との間で往復移動が可能となっている。 On the other hand, the core member (5) is inserted between the pair of split molds (51a) (51b) and the split molds (51a) (51b) as shown in FIGS. 3 (a) and 3 (b). The split molds (51a) and (51b) are connected in a state of being biased toward each other by a coil spring (53). An air cylinder (not shown) is connected to the wedge-shaped member (52), whereby the wedge-shaped member (52) is moved forward as shown in FIG. 3 (a) and retracted as shown in FIG. 3 (b). Reciprocal movement is possible.
巻芯部材(５)を対向部材(３)の挿入孔(31)に挿入した後には、楔状部材(52)は、図３(ａ)に示す前進位置に位置しており、この状態で、楔状部材(52)の先端部は両割型(51a)(51b)に摺接し、コイルバネ(53)の付勢力に抗して両割型(51a)(51b)を互いに離間させている。これによって、巻芯部材(５)の高さｈ２は、図３(ｂ)に示す巻芯部材(５)の高さｈよりも大きくなり、この結果、図２(ｂ)に示す如く、巻芯部材(５)は対向部材(３)の挿入孔(31)に嵌合することになる。 After the core member (5) is inserted into the insertion hole (31) of the opposing member (3), the wedge-shaped member (52) is located at the forward position shown in FIG. The tip of the wedge-shaped member (52) is in sliding contact with the split molds (51a) (51b), and the split molds (51a) (51b) are separated from each other against the biasing force of the coil spring (53). As a result, the height h2 of the core member (5) becomes larger than the height h of the core member (5) shown in FIG. 3 (b). As a result, as shown in FIG. The core member (5) is fitted into the insertion hole (31) of the opposing member (3).
一方、巻芯部材(５)を対向部材(３)の挿入孔(31)に挿入し、或いは該挿入孔(31)から離脱させる際には、楔状部材(52)は、図３(ｂ)に示す後退位置に位置しており、この状態で、楔状部材(52)の先端部は両割型(51a)(51b)から離間しており、両割型(51a)(51b)はコイルバネ(53)の付勢力によって互いに接触している。この状態において、巻芯部材(５)の高さｈは、図２(ａ)に示す対向部材(３)の挿入孔(31)の高さｈ２よりも小さく、この結果、巻芯部材(５)の対向部材(３)の挿入孔(31)への挿入、或いは該挿入孔(31)からの離脱が容易となる。 On the other hand, when the core member (5) is inserted into the insertion hole (31) of the opposing member (3) or removed from the insertion hole (31), the wedge-shaped member (52) is shown in FIG. In this state, the tip of the wedge-shaped member (52) is separated from the split molds (51a) (51b), and the split molds (51a) (51b) are coil springs ( They are in contact with each other by the biasing force of 53). In this state, the height h of the core member (5) is smaller than the height h2 of the insertion hole (31) of the opposing member (3) shown in FIG. 2 (a). As a result, the core member (5 ) Can be easily inserted into or removed from the insertion hole (31) of the opposing member (3).
以下、図１に示す自動巻線機(７)を用いて空芯コイルを作製する方法について説明する。
第１実施例
図４は、本実施例において作製すべきコイル(２)を具えたチョークコイル装置を示している。該チョークコイル装置は、ギャップ(14)を有するＣ字状のコア(１)にコイル(２)を巻装して構成されている。コイル(２)を形成する導線は、コア(１)の外周側では１層に巻回され、コア(１)の内周側において２層に巻回されている。コイル(２)の両端部は同一方向に伸びて、一対のリード部(17)(18)を形成している。
Hereinafter, a method for producing an air-core coil using the automatic winding machine (7) shown in FIG. 1 will be described.
First Embodiment FIG. 4 shows a choke coil device having a coil (2) to be manufactured in this embodiment. The choke coil device is configured by winding a coil (2) around a C-shaped core (1) having a gap (14). The conducting wire forming the coil (2) is wound in one layer on the outer peripheral side of the core (1) and wound in two layers on the inner peripheral side of the core (1). Both ends of the coil (2) extend in the same direction to form a pair of lead portions (17) and (18).
コア(１)は、前記ギャップ部(14)となる隙間を有するＣ字状のコア片(11)と、ギャップ部(14)を挟む一対のコア端面を除くコア片(11)の表面を覆う絶縁層(12)とから構成されている。
コア(１)のギャップ部(14)は、コア(１)の中心軸と直交する断面における貫通方向がコア(１)の半径方向に対して傾斜して、コア(１)の中心軸からずれている。コア(１)には、ギャップ部(14)を挟む一対のコア端面の内、コア中心からの距離が短い一方のコア端面の近傍付近に、コア(１)の内側に向けて突出する凸部(15)が形成されている。
The core (1) covers the surface of the core piece (11) excluding the C-shaped core piece (11) having a gap to be the gap portion (14) and the pair of core end faces sandwiching the gap portion (14). And an insulating layer (12).
The gap portion (14) of the core (1) is displaced from the central axis of the core (1) with the penetration direction in the cross section orthogonal to the central axis of the core (1) inclined with respect to the radial direction of the core (1). ing. The core (1) has a convex portion protruding toward the inside of the core (1) in the vicinity of one core end surface having a short distance from the core center, out of a pair of core end surfaces sandwiching the gap portion (14). (15) is formed.
上記チョークコイル装置は、図５に示す如く、コア(１)に空芯コイル(４)を装着して作製する。
該空芯コイル(４)は、内周長の大なる第１単位巻部(41)と、内周長の小なる第２単位巻部(42)とを交互に配備して構成され、空芯コイル(４)の一方の側部においては、第１単位巻部(41)と第２単位巻部(42)の外周面が揃っているのに対し、他方の側部においては、第１単位巻部(41)の外周面が第２単位巻部(42)の外周面よりも外方へ突出して、凹凸形状を形成している。
As shown in FIG. 5, the choke coil device is manufactured by attaching an air-core coil (4) to a core (1).
The air-core coil (4) is configured by alternately arranging a first unit winding portion (41) having a large inner peripheral length and a second unit winding portion (42) having a small inner peripheral length. On one side of the core coil (4), the outer peripheral surfaces of the first unit winding (41) and the second unit winding (42) are aligned, while on the other side, The outer peripheral surface of the unit winding part (41) protrudes outward from the outer peripheral surface of the second unit winding part (42) to form an uneven shape.
コア(１)に空芯コイル(４)を装着する際には、空芯コイル(４)の凹凸状側部をコア(１)のギャップ部(14)に押し込む。更に空芯コイル(４)をコア(１)の奥部へ推し進めると、図６に示す如く、空芯コイル(４)の前端がコア(１)の凸部(15)に当接し、更に空芯コイル(４)を押圧することにより、空芯コイル(４)が巻き軸方向の圧縮力を受けて、コア(１)の内周側にて、空芯コイル(４)の第２単位巻部(42)が第１単位巻部(41)の内側に押し込まれる。この結果、空芯コイル(４)は、コア(１)の中央孔(13)内にて２層に形成されることになる。 When the air core coil (4) is attached to the core (1), the uneven side portion of the air core coil (4) is pushed into the gap portion (14) of the core (1). When the air-core coil (4) is further advanced to the back of the core (1), as shown in FIG. 6, the front end of the air-core coil (4) comes into contact with the convex portion (15) of the core (1), and further By pressing the core coil (4), the air core coil (4) receives the compressive force in the winding axis direction, and the second unit winding of the air core coil (4) is performed on the inner peripheral side of the core (1). The part (42) is pushed inside the first unit winding part (41). As a result, the air-core coil (4) is formed in two layers in the central hole (13) of the core (1).
上記空芯コイル(４)を図１に示す自動巻線機(７)を用いて作製する際には、先ず、エアシリンダ(76)を駆動することにより、支持体(77)を回転体(71)に接近する方向に移動させて、巻芯部材(５)を対向部材(３)の挿入孔(31)に挿入する。
この状態で、回転駆動機構(72)を駆動することにより、巻芯部材(５)及び対向部材(３)を回転させ、該回転によって、ガイド機構(73)を経て対向部材(３)の導線ガイド面(35)に沿って供給された導線(40)を、巻芯部材(５)或いは図２(ｂ)に示す対向部材(３)の一対の巻線補助部材(32a)(32b)の外周面に巻回し、空芯コイル(４)を作製する。
When the air core coil (4) is manufactured using the automatic winding machine (7) shown in FIG. 1, first, the air cylinder (76) is driven to turn the support (77) into the rotating body ( 71), the core member (5) is inserted into the insertion hole (31) of the opposing member (3).
In this state, by driving the rotation drive mechanism (72), the core member (5) and the opposing member (3) are rotated, and by this rotation, the conducting wire of the opposing member (3) is passed through the guide mechanism (73). The conducting wire (40) supplied along the guide surface (35) is connected to the winding core member (5) or the pair of winding auxiliary members (32a) (32b) of the opposing member (3) shown in FIG. It winds around an outer peripheral surface and produces an air-core coil (4).
図７(ａ)〜(ｃ)、図８(ａ)〜(ｃ)及び図９(ａ)〜(ｂ)は、巻芯部材(５)及び対向部材(３)の初期状態から、該巻芯部材(５)及び対向部材(３)が９０度回転する毎の巻線状態を、巻芯部材(５)を基準として連続的に示したものである。
図７(ａ)〜図７(ｃ)及び図８(ａ)の状態において、対向部材(３)の一対の巻線補助部材(32a)(32b)は、前記第２位置に位置しており、図１０(ａ)に示す如く、導線(40)は巻芯部材(５)の外周面に巻回され、これによって、図５に示す空芯コイル(４)の内周長の小なる第２単位巻部(42)が形成されることになる。
7 (a) to (c), FIGS. 8 (a) to (c) and FIGS. 9 (a) to (b) show the winding from the initial state of the core member (5) and the opposing member (3). The winding state every time the core member (5) and the counter member (3) rotate 90 degrees is shown continuously with the core member (5) as a reference.
7 (a) to 7 (c) and 8 (a), the pair of auxiliary winding members (32a) and (32b) of the opposing member (3) are located at the second position. As shown in FIG. 10 (a), the lead wire (40) is wound around the outer peripheral surface of the core member (5), thereby reducing the inner peripheral length of the air core coil (4) shown in FIG. A two-unit winding part (42) will be formed.
巻芯部材(５)及び対向部材(３)が、図７(ｃ)に示す状態から図８(ａ)に示す状態に遷移する過程、即ち９０度回転する過程においては、この期間に巻芯部材(５)に巻回されるべき導線(40)が、既に巻芯部材(５)の外周面に巻回した第２単位巻部(42)と重ならない様に、図１に示すエアシリンダ(76)を駆動して、支持体(77)を導線(40)の直径に相当する距離だけ回転体(71)から離間する方向に移動させる。これによって、図８(ａ)に示す如く、巻芯部材(５)の全周に亘って第２単位巻部(42)が形成されることになる。 In the process in which the core member (5) and the opposing member (3) are transitioned from the state shown in FIG. 7 (c) to the state shown in FIG. The air cylinder shown in FIG. 1 is used so that the lead wire (40) to be wound around the member (5) does not overlap the second unit winding portion (42) already wound around the outer peripheral surface of the core member (5). (76) is driven to move the support (77) in a direction away from the rotating body (71) by a distance corresponding to the diameter of the conducting wire (40). As a result, as shown in FIG. 8A, the second unit winding portion (42) is formed over the entire circumference of the core member (5).
その後、図８(ｂ)の状態において、導線(40)は巻芯部材(５)に巻回され、これによって、図５に示す空芯コイル(４)の第１単位巻部(41)の内、空芯コイル(４)の一方の側部において、第２単位巻部(42)の外周面と揃った第１単位巻部(41)の一部が形成される。
そして、巻芯部材(５)及び対向部材(３)が、図８(ｂ)に示す状態から図８(ｃ)に示す状態に遷移する過程においては、図２(ａ)に示すエアシリンダ(75)(75)を駆動することにより、対向部材(３)の一対の巻線補助部材(32a)(32b)を前記第２位置から第１位置に移動させる。この状態で、一対の巻線補助部材(32a)(32b)は、図１０(ｂ)に示す如く、巻芯部材(５)の周囲を覆っており、図８(ｃ)、図９(ａ)及び図９(ｂ)に示す状態において、導線(40)は該一対の巻線補助部材(32a)(32b)の外周面に巻回されることになる。これによって、図５に示す空芯コイル(４)の内周長の大なる第１単位巻部(41)が形成されることになる。
Thereafter, in the state of FIG. 8 (b), the conducting wire (40) is wound around the core member (5), whereby the first unit winding portion (41) of the air-core coil (4) shown in FIG. A part of the first unit winding part (41) aligned with the outer peripheral surface of the second unit winding part (42) is formed on one side of the air-core coil (4).
Then, in the process in which the core member (5) and the facing member (3) transition from the state shown in FIG. 8 (b) to the state shown in FIG. 8 (c), the air cylinder shown in FIG. 75) By driving 75, the pair of winding
巻芯部材(５)及び対向部材(３)が、図９(ａ)に示す状態から図９(ｂ)に示す状態に遷移する過程においては、この期間に巻線補助部材(32b)に巻回されるべき導線(40)が、既に巻芯部材(５)の外周面に巻回した第２単位巻部(42)と重ならない様に、図１に示すエアシリンダ(76)を駆動して、支持体(77)を導線(40)の直径に相当する距離だけ回転体(71)から離間する方向に移動させる。これによって、図８(ａ)に示す如く、巻芯部材(５)及び一対の巻線補助部材(32a)(32b)の全周に亘って、第１単位巻部(41)が形成されることになる。 In the process in which the winding core member (5) and the opposing member (3) transition from the state shown in FIG. 9 (a) to the state shown in FIG. 9 (b), the winding auxiliary member (32b) is wound during this period. The air cylinder (76) shown in FIG. 1 is driven so that the lead wire (40) to be rotated does not overlap the second unit winding portion (42) already wound around the outer peripheral surface of the core member (5). Thus, the support (77) is moved in a direction away from the rotating body (71) by a distance corresponding to the diameter of the conducting wire (40). Thus, as shown in FIG. 8A, the first unit winding portion (41) is formed over the entire circumference of the core member (5) and the pair of winding auxiliary members (32a) and (32b). It will be.
以降、上述の如き工程を複数回繰り返すことにより、図５に示す空芯コイル(４)が得られる。該空芯コイル(４)を図１に示す自動巻線機(７)から取り出す際には、エアシリンダ(76)を駆動することにより、支持体(77)を回転体(71)から離間させる方向に移動させて、巻芯部材(５)を対向部材(３)の挿入孔(31)から離脱させる。この状態で、巻芯部材(５)の楔状部材(52)は、図３(ｂ)に示す後退位置に移動しており、巻芯部材(５)の幅ｈは、図３(ａ)に示す巻芯部材(５)が対向部材(３)の挿入孔(31)に挿入された状態における巻芯部材(５)の幅ｈ１よりも小さくなっているので、空芯コイル(４)を巻芯部材(５)から容易に取り出すことが出来る。 Thereafter, the air core coil (4) shown in FIG. 5 is obtained by repeating the above-described steps a plurality of times. When taking out the air-core coil (4) from the automatic winding machine (7) shown in FIG. 1, the support (77) is separated from the rotating body (71) by driving the air cylinder (76). The core member (5) is moved away from the insertion hole (31) of the opposing member (3). In this state, the wedge-shaped member (52) of the core member (5) is moved to the retracted position shown in FIG. 3 (b), and the width h of the core member (5) is as shown in FIG. 3 (a). The winding core member (5) shown is smaller than the width h1 of the winding core member (5) in the state of being inserted into the insertion hole (31) of the opposing member (3). It can be easily removed from the core member (5).
第２実施例
図１１及び図１２は、本実施例において作製すべき空芯コイル(２a)の構造を表わしている。該空芯コイル(２a)は、導線(20)の巻き軸方向とは直交する方向に最内周から最外周へ向けて、第１層(21)、第２層(22)及び第３層(23)からなる積層構造を有している。
該空芯コイル(２a)は、図１２中に番号１〜２９で示す巻線順序で１本の導線を巻回して形成されており、連続する複数の番号(１〜３)、(４〜６)、・・・、(２５〜２７)、(２８〜２９)の巻線によってそれぞれ単位コイル部が形成され、これらの単位コイル部が巻き軸方向へ１０列に並んでいる。
各単位コイル部は、それぞれ巻数１の最大内周長の単位巻部、中間内周長の単位巻部、及び最小内周長の単位巻部から形成され、最大内周長の単位巻部の内側に中間内周長の単位巻部が押し込まれ、更に中間内周長の単位コイル部の内側に最小内周長の単位巻部が押し込まれている。
Second Embodiment FIGS. 11 and 12 show the structure of an air-core coil (2a) to be manufactured in this embodiment. The air-core coil (2a) has a first layer (21), a second layer (22) and a third layer in the direction perpendicular to the winding axis direction of the conducting wire (20) from the innermost circumference to the outermost circumference. It has a laminated structure consisting of (23).
The air-core coil (2a) is formed by winding one conducting wire in the winding order indicated by
Each unit coil portion is formed of a unit winding portion having a maximum inner peripheral length of 1 turn, a unit winding portion having an intermediate inner peripheral length, and a unit winding portion having a minimum inner peripheral length. A unit winding portion having an intermediate inner circumferential length is pushed inside, and a unit winding portion having a minimum inner circumferential length is pushed inside a unit coil portion having an intermediate inner circumferential length.
上述の空芯コイル(２a)を作製する場合には、先ず、図１３(ａ)に示すコイル中間製品(29a)を作製し、その後、該コイル中間製品(29a)を巻き軸方向に圧縮することによって、図１３(ｂ)に示す如く第３単位巻部(27)の内側に第２単位巻部(26)を押し込み、該第２単位巻部(26)の内側に第１単位巻部(25)を押し込む。これによって、３層の空芯コイル(２a)が得られることになる。
When manufacturing the above-described air-core coil (2a), first, the coil intermediate product (29a) shown in FIG. 13 (a) is manufactured, and then the coil intermediate product (29a) is compressed in the winding axis direction. Accordingly, as shown in FIG. 13B, the second
コイル中間製品(29a)は、第１実施例と同様に図１に示す自動巻線機(７)を用いて作製される。以下、図１３(ａ)に示すコイル中間製品(29a)を作製する方法について説明する。
本実施例において、対向部材(３)の巻芯部材(５)との対向面には、図１４(ａ)〜(ｃ)に示す如く、導線をガイドするための導線ガイド面(35)が形成されると共に、該導線ガイド面(35)には、巻芯部材(５)が挿入されるべき矩形状の挿入孔(31)が凹設されている。挿入孔(31)を構成する４辺の内の２辺がそれぞれ交叉して形成される４つの角部には、挿入孔(31)に挿入された巻芯部材(５)の外周面の角部を覆う形状を有する４つのＬ字状の第１巻線補助部材(32a)〜(32d)がそれぞれ配備されている。更に４つの第１巻線補助部材(32a)〜(32d)の外側には、各第１巻線補助部材(32a)〜(32d)の外周面に沿う外周面を有する４つのＬ字状の第２巻線補助部材(33a)〜(33d)が、各第１巻線補助部材(32a)〜(32d)の周囲を覆う様に互いに隣接して配備されている。
The coil intermediate product (29a) is produced using the automatic winding machine (7) shown in FIG. 1 as in the first embodiment. Hereinafter, a method for producing the coil intermediate product (29a) shown in FIG. 13 (a) will be described.
In the present embodiment, a conductor guide surface (35) for guiding a conductor is provided on the opposing surface of the opposing member (3) to the core member (5), as shown in FIGS. 14 (a) to (c). At the same time, a rectangular insertion hole (31) into which the core member (5) is to be inserted is recessed in the conductive wire guide surface (35). Four corners formed by intersecting two of the four sides constituting the insertion hole (31) are the corners of the outer peripheral surface of the core member (5) inserted into the insertion hole (31). Four L-shaped first winding auxiliary members (32a) to (32d) each having a shape covering the portion are provided. Further, outside the four first winding auxiliary members (32a) to (32d), four L-shaped members having outer peripheral surfaces along the outer peripheral surfaces of the first winding auxiliary members (32a) to (32d). The second winding auxiliary members (33a) to (33d) are arranged adjacent to each other so as to cover the periphery of the first winding auxiliary members (32a) to (32d).
第１巻線補助部材(32a)〜(32d)及び第２巻線補助部材(33a)〜(33d)は、図２(ａ)に示す第１実施例の巻線補助部材(32a)(32b)と同様に、対向部材(３)の内部に配備された一対のエアシリンダ(75)(75)にそれぞれ連結されており、これによって、第１巻線補助部材(32a)〜(32d)は、図１４(ｂ)に示す如く、その先端部が対向部材(３)の導線ガイド面(35)から突出した第１位置と、図１４(ａ)に示す如く、第１巻線補助部材(32a)〜(32d)が対向部材(３)の内部に収容されてその先端面と導線ガイド面(35)とが面一となる第２位置との間で、往復移動が可能となっている。又、第２巻線補助部材(33a)〜(33d)は、図１４(ｃ)に示す如く、その先端部が対向部材(３)の導線ガイド面(35)から突出した第１位置と、図１４(ａ)に示す如く、第２巻線補助部材(33a)〜(33d)が対向部材(３)の内部に収容されてその先端面と導線ガイド面(35)とが面一となる第２位置との間で、往復移動が可能となっている。 The first winding auxiliary members (32a) to (32d) and the second winding auxiliary members (33a) to (33d) are the winding auxiliary members (32a) (32b) of the first embodiment shown in FIG. ) Are connected to a pair of air cylinders (75) and (75) disposed inside the facing member (3), respectively, whereby the first winding auxiliary members (32a) to (32d) are connected to each other. As shown in FIG. 14 (b), the first position where the tip protrudes from the conductive wire guide surface (35) of the opposing member (3), and as shown in FIG. 14 (a), the first winding auxiliary member ( 32a) to (32d) are accommodated inside the facing member (3) and can be reciprocated between the second position where the tip surface and the conductor guide surface (35) are flush with each other. . Further, as shown in FIG. 14 (c), the second winding auxiliary members (33a) to (33d) have a first position where the tip portion protrudes from the conductive wire guide surface (35) of the opposing member (3), As shown in FIG. 14 (a), the second winding auxiliary members (33a) to (33d) are accommodated inside the opposing member (3), and the tip surface thereof and the conductor guide surface (35) are flush with each other. Reciprocal movement between the second position is possible.
上述のコイル中間製品(29a)を作製する際には、先ず、図１に示す自動巻線機(７)のエアシリンダ(76)を駆動することにより、支持体(77)を回転体(71)に接近する方向に移動させて、巻芯部材(５)は対向部材(３)の挿入孔(31)に挿入する。
この状態で、回転駆動機構(72)を駆動することにより、巻芯部材(５)及び対向部材(３)を回転させ、該回転によって、ガイド機構(73)を経て巻芯部材(５)の導線ガイド面(35)に沿って供給された導線(40)を、巻芯部材(５)、図１４(ａ)〜(ｃ)に示す対向部材(３)の第１巻線補助部材(32a)〜(32d)、或いは第２巻線補助部材(33a)〜(33d)の外周面に巻回し、コイル中間製品(29a)を作製する。
When producing the coil intermediate product (29a), first, the air cylinder (76) of the automatic winding machine (7) shown in FIG. The core member (5) is inserted into the insertion hole (31) of the opposing member (3).
In this state, by driving the rotation drive mechanism (72), the core member (5) and the opposing member (3) are rotated, and the rotation causes the core member (5) to pass through the guide mechanism (73). The lead wire (40) supplied along the lead guide surface (35) is turned into the winding core member (5), the first winding auxiliary member (32a) of the facing member (3) shown in FIGS. 14 (a) to (c). ) To (32d) or the second winding auxiliary members (33a) to (33d) are wound around the outer peripheral surface to produce a coil intermediate product (29a).
図１５(ａ)〜(ｃ)、図１６(ａ)〜(ｃ)、図１７(ａ)〜(ｃ)及び図１８(ａ)〜(ｂ)は、巻芯部材(５)及び対向部材(３)の初期状態から、該巻芯部材(５)及び対向部材(３)が９０度回転する毎の巻線状態を、巻芯部材(５)を基準として連続的に示したものである。
図１５(ａ)〜図１５(ｃ)の状態において、対向部材(３)の第１巻線補助部材(32a)〜(32d)及び第２巻線補助部材(33a)〜(33d)はそれぞれ、図１４(ａ)に示す如く前記第２位置に位置しており、これによって、巻芯部材(５)の外周面が露出している。従って、導線(40)は、巻芯部材(５)の外周面に巻回され、この結果、図１３(ａ)に示すコイル中間製品(29a)の最小内周長の第１単位巻部(25)が形成されることになる。
FIGS. 15 (a) to (c), FIGS. 16 (a) to (c), FIGS. 17 (a) to (c) and FIGS. 18 (a) to 18 (b) show the core member (5) and the opposing member. From the initial state of (3), the winding state every time the core member (5) and the opposing member (3) rotate 90 degrees is shown continuously with reference to the core member (5). .
15 (a) to 15 (c), the first winding auxiliary members (32a) to (32d) and the second winding auxiliary members (33a) to (33d) of the facing member (3) are respectively As shown in FIG. 14 (a), it is located at the second position, so that the outer peripheral surface of the core member (5) is exposed. Accordingly, the conductive wire (40) is wound around the outer peripheral surface of the core member (5), and as a result, the first unit winding portion (the minimum inner peripheral length of the coil intermediate product (29a) shown in FIG. 13 (a) ( 25) will be formed.
巻芯部材(５)及び対向部材(３)が、図１５(ｃ)に示す状態から図１６(ａ)に示す状態に遷移する過程、即ち９０度回転する過程においては、この期間に巻回されるべき導線(40)が、既に巻回した第１単位巻部(25)と重ならない様に、図１に示すエアシリンダ(76)を駆動して、支持体(77)を導線(40)の直径に相当する距離だけ回転体(71)から離間する方向に移動させる。
更に、図１４(ｂ)に示す如く、対向部材(３)の第１巻線補助部材(32a)〜(32d)を前記第２位置から、その先端部が対向部材(３)の導線ガイド面(35)から突出した第１位置に移動させる。この状態で、第１巻線補助部材(32a)〜(32d)は巻芯部材(５)の外周面を覆っており、これによって、導線(40)は第１巻線補助部材(32a)〜(32d)の外周面に巻回されることになる。
In the process in which the winding core member (5) and the opposing member (3) transition from the state shown in FIG. 15 (c) to the state shown in FIG. The air cylinder (76) shown in FIG. 1 is driven so that the conducting wire (40) to be formed does not overlap the already wound first unit winding portion (25), and the support (77) is connected to the conducting wire (40 ) In a direction away from the rotating body (71) by a distance corresponding to the diameter of.
Further, as shown in FIG. 14 (b), the first winding auxiliary members (32a) to (32d) of the facing member (3) are moved from the second position, and the leading end portion thereof is a conductive wire guide surface of the facing member (3). Move to the first position protruding from (35). In this state, the first winding auxiliary members (32a) to (32d) cover the outer peripheral surface of the core member (5), whereby the lead wire (40) is connected to the first winding auxiliary members (32a) to (32a). (32d) is wound around the outer peripheral surface.
図１６(ａ)に示す状態において、導線(40)は、第１巻線補助部材(32c)の外周面に巻回されて外側に傾斜し、これによって、コイル中間製品(29a)の最小内周長の第１単位巻部(25)から中間内周長の第２単位巻部(26)へ遷移する第１傾斜部(28a)が形成される。
更に、図１６(ｂ)〜(ｃ)、及び図１７(ａ)に示す状態において、導線(40)は該第１巻線補助部材(32b)(33a)(32d)の外周面にそれぞれ巻回され、これによって、図１３(ａ)に示すコイル中間製品(29a)の中間内周長の第２単位巻部(26)が形成されることになる。
In the state shown in FIG. 16 (a), the conducting wire (40) is wound around the outer peripheral surface of the first winding auxiliary member (32c) and is inclined outward, whereby the minimum inner diameter of the coil intermediate product (29a) is obtained. A first inclined portion (28a) is formed that transitions from the first unit winding portion (25) having a circumferential length to the second unit winding portion (26) having an intermediate inner circumferential length.
Further, in the state shown in FIGS. 16B to 16C and FIG. 17A, the
巻芯部材(５)及び対向部材(３)が、図１７(ａ)に示す状態から図１７(ｂ)に示す状態に遷移する過程においては、この期間に巻回されるべき導線(40)が、既に巻回された第２単位巻部(26)と重ならない様に、図１に示すエアシリンダ(76)を駆動して、支持体(77)を導線(40)の直径に相当する距離だけ回転体(71)から離間する方向に移動させる。
更に、図１４(ｃ)に示す如く、対向部材(３)の第２巻線補助部材(33a)〜(33d)を前記第２位置から、その先端部が対向部材(３)の導線ガイド面(35)から突出した第１位置に移動させる。この状態で、第２巻線補助部材(33a)〜(33d)は、第１巻線補助部材(32a)〜(32d)の外周面を覆っており、これによって、導線(40)は第２巻線補助部材(33a)〜(33d)の外周面に巻回されることになる。
In the process in which the core member (5) and the opposing member (3) transition from the state shown in FIG. 17 (a) to the state shown in FIG. 17 (b), the lead wire (40) to be wound during this period. However, the air cylinder (76) shown in FIG. 1 is driven so that it does not overlap with the already wound second unit winding (26), and the support (77) corresponds to the diameter of the conductor (40). It is moved in a direction away from the rotating body (71) by a distance.
Further, as shown in FIG. 14 (c), the second winding auxiliary members (33a) to (33d) of the facing member (3) are moved from the second position, and the leading end portion thereof is a conductive wire guide surface of the facing member (3). Move to the first position protruding from (35). In this state, the second winding auxiliary members (33a) to (33d) cover the outer peripheral surfaces of the first winding auxiliary members (32a) to (32d). The winding auxiliary members (33a) to (33d) are wound around the outer peripheral surface.
図１７(ｂ)に示す状態において、導線(40)は、第２巻線補助部材(33c)の外周面に巻回されて外側に傾斜し、これによって、前記コイル中間製品(29a)の中間内周長の第２単位巻部(26)から最大内周長の第２単位巻部(27)へ遷移する第２傾斜部(28b)が形成される。
更に、図１７(ｃ)、及び図１８(ａ)〜(ｂ)に示す状態において、導線(40)は該第２巻線補助部材(32b)(33a)(32d)の外周面にそれぞれ巻回され、これによって、図１３(ａ)に示すコイル中間製品(29a)の最大内周長の第３単位巻部(27)が形成されることになる。
In the state shown in FIG. 17 (b), the conducting wire (40) is wound around the outer peripheral surface of the second winding auxiliary member (33c) and inclined outward, whereby the intermediate coil product (29a) A second inclined portion (28b) is formed that transitions from the second unit winding portion (26) having the inner peripheral length to the second unit winding portion (27) having the maximum inner peripheral length.
Further, in the state shown in FIGS. 17 (c) and 18 (a)-(b), the conductive wire (40) is wound around the outer peripheral surface of the second winding auxiliary member (32b) (33a) (32d). Thus, the third unit winding portion (27) having the maximum inner peripheral length of the coil intermediate product (29a) shown in FIG. 13 (a) is formed.
以降、上記工程を逆順に繰り返すことにより、図１３(ａ)に示すコイル中間製品(29a)の第３単位巻部(27)、第２単位巻部(26)、第１単位巻部(25)の順に形成し、これらの工程を複数回繰り返して、図１３(ａ)に示すコイル中間製品(29a)が得られる。 Thereafter, by repeating the above steps in reverse order, the third unit winding part (27), the second unit winding part (26), the first unit winding part (25) of the coil intermediate product (29a) shown in FIG. ) And repeating these steps a plurality of times to obtain a coil intermediate product (29a) shown in FIG. 13 (a).
第３実施例
上記第２実施例において、空芯コイル(２ａ)は、図１２に示す如く、導線(40)の巻き軸方向の全域に亘って、第１層(21)、第２層(22)及び第３層(23)からなる３層の積層構造を有しているが、本実施例において作製すべき空芯コイル(２ｂ)は、図１９に示す如く、巻き軸方向の途中位置に、内周側の第１層(21)及び第２層(22)が欠落して２層或いは単層の単位巻部から構成される単位コイル部を有している。
該空芯コイル(２ｂ)は、ボビン(10)の周囲に巻装され、ボビン(10)の内部には、ギャップ部(14)を有するコア(１)が配備されている。コア(１)のギャップ部(14)の互いに対向する両端面の間には、図１９中矢印で示す如く、漏れ磁束が発生する。例えば、図１２に示す第２実施例の空芯コイル(２ａ)を用いてコイル装置を構成した場合、該空芯コイル(２ａ)は、巻き軸方向の全域に亘って３層の積層構造を有しているため、前記漏れ磁束が、空芯コイル(２ａ)を構成する複数の単位コイル部の内、コア(１)のギャップ部(14)に隣接する複数の単位コイル部に影響を与え、これによって、コイル装置の性能が低下する問題があった。
Third Embodiment In the second embodiment, as shown in FIG. 12, the air-core coil (2a) has a first layer (21), a second layer ( The air-core coil (2b) to be manufactured in this example has a three-layer laminated structure consisting of 22) and the third layer (23). In addition, the first layer (21) and the second layer (22) on the inner peripheral side are missing, and a unit coil portion composed of a unit winding portion of two layers or a single layer is provided.
The air-core coil (2b) is wound around the bobbin (10), and a core (1) having a gap portion (14) is disposed inside the bobbin (10). As indicated by the arrows in FIG. 19, leakage magnetic flux is generated between the opposite end faces of the gap portion (14) of the core (1). For example, when the coil device is configured using the air-core coil (2a) of the second embodiment shown in FIG. 12, the air-core coil (2a) has a three-layer laminated structure over the entire region in the winding axis direction. Therefore, the leakage magnetic flux affects a plurality of unit coil portions adjacent to the gap portion (14) of the core (1) among the plurality of unit coil portions constituting the air-core coil (2a). As a result, there has been a problem that the performance of the coil device is lowered.
これに対し、図１９に示す本実施例の空芯コイル(２ｂ)は、コア(１)のギャップ部(14)の形成位置に対応して、内周側の第１層(21)及び第２層(22)が欠落した２層或いは単層の単位巻部から構成される単位コイル部を有している。これにより、ギャップ部(14)に発生する漏れ磁束が空芯コイル(２ｂ)に与える影響を低減することが出来、この結果、コイル装置の高性能化を図ることが出来る。 On the other hand, the air-core coil (2b) of the present embodiment shown in FIG. 19 corresponds to the formation position of the gap portion (14) of the core (1), and the first layer (21) and the first layer on the inner peripheral side. It has a unit coil part composed of a unit winding part of two layers or a single layer lacking two layers (22). Thereby, the influence which the leakage magnetic flux which generate | occur | produces in a gap part (14) has on an air-core coil (2b) can be reduced, As a result, performance improvement of a coil apparatus can be achieved.
該空芯コイル(２ｂ)を作製する場合には、上述の第２実施例と同様に、先ず、図２０(ａ)に示すコイル中間製品(29b)を作製し、その後、該コイル中間製品(29b)を巻き軸方向に圧縮することによって、図２０(ｂ)に示す如く第３単位巻部(27)の内側に第２単位巻部(26)を押し込み、該第２単位巻部(26)の内側に第１単位巻部(25)を押し込む。これによって、巻き軸方向の途中位置に２層或いは単層の単位巻部から構成される単位コイル部を有すると共に、その他の領域においては３層の単位巻部の積層構造を有する空芯コイル(２b)が得られることになる。 When producing the air-core coil (2b), as in the second embodiment, first, an intermediate coil product (29b) shown in FIG. 20 (a) is produced, and then the intermediate coil product ( By compressing 29b) in the direction of the winding axis, as shown in FIG. 20 (b), the second unit winding portion (26) is pushed inside the third unit winding portion (27), and the second unit winding portion (26 ) The first unit winding part (25) is pushed inside. Thus, an air-core coil having a unit coil portion composed of a unit winding portion of two layers or a single layer at an intermediate position in the winding axis direction and having a laminated structure of unit winding portions of three layers in other regions ( 2b) is obtained.
コイル中間製品(29b)は、図１に示す自動巻線機(７)により、図２０(ｂ)中に番号１〜３０で示す巻線順序で１本の導線を巻回して形成する。コイル中間製品(29b)の３層の積層構造を有する単位コイル部、即ち図２０(ｂ)に巻線順序１〜１２及び巻線順序１９〜３０で示す部分については、第２実施例と同様にして形成する。
コイル中間製品(29b)の単層構造及び２層の積層構造を有する単位コイル部、即ち図２０(ｂ)に巻線順序１３〜１８で示す部分については、図２０(ａ)中破線で示す如く、第２実施例のコイル中間製品(29a)では形成していた第１単位巻部(25)及び第２単位巻部(26)の一部を飛ばして導線を巻回すること以外は第２実施例と同様にして形成する。
即ち、コイル中間製品(29b)の単層構造及び２層の積層構造を有する単位コイル部の内、第２単位巻部(26)は、図１４に示す第１巻線補助部材(32a)〜(32d)を前記第２位置から第１位置に移動させ、該第１巻線補助部材(32a)〜(32d)の外周面に導線を巻回することにより形成することが出来る。又、第３単位巻部(27)は、第２巻線補助部材(33a)〜(33d)を前記第２位置から第１位置に移動させ、該第２巻線補助部材(33a)〜(33d)の外周面に導線を巻回することにより形成することが出来る。これによって、巻き軸方向の途中位置に２層或いは単層の単位巻部から構成される単位コイル部を有すると共に、その他の領域においては３層の単位巻部の積層構造を有するコイル中間製品(29b)が得られることになる。
The coil intermediate product (29b) is formed by winding one conductive wire in the winding sequence indicated by
A unit coil portion having a single-layer structure and a two-layer laminated structure of the coil intermediate product (29b), that is, a portion indicated by winding
That is, among the unit coil portions having a single layer structure and a two-layer structure of the coil intermediate product (29b), the second unit winding portion (26) includes the first winding auxiliary member (32a) to It can be formed by moving (32d) from the second position to the first position and winding a conducting wire around the outer peripheral surfaces of the first winding auxiliary members (32a) to (32d). Further, the third unit winding part (27) moves the second winding auxiliary members (33a) to (33d) from the second position to the first position, and the second winding auxiliary members (33a) to (33). It can be formed by winding a conducting wire around the outer peripheral surface of 33d). As a result, a coil intermediate product having a unit coil portion composed of a unit winding portion of two layers or a single layer at an intermediate position in the winding axis direction and having a laminated structure of unit winding portions of three layers in other regions ( 29b) is obtained.
本発明の自動巻線機(７)を用いた空芯コイルの製造方法によれば、前記巻線補助部材を第１位置と第２位置との間で往復移動させるだけで、互いに内周長の異なる単位巻部を任意位置に形成することが出来るので、積層状態の異なる様々な構成の空芯コイルを作製することが可能となる。 According to the method for manufacturing an air-core coil using the automatic winding machine (7) of the present invention, the inner circumferential length of each winding auxiliary member can be simply reciprocated between the first position and the second position. Therefore, it is possible to produce air-core coils having various configurations with different lamination states.
尚、本発明の各部構成は上記実施の形態に限らず、特許請求の範囲に記載の技術的範囲内で種々の変形が可能である。例えば、空芯コイルを構成する単位巻部は、図１１に示す空芯コイル(２ａ)の如く、最大内周長の単位巻部、中間内周長の単位巻部及び最小内周長の単位巻部の３種類に限定されるものではなく、内周長が異なる３種類以上の単位巻部からなる空芯コイルを構成することも可能である。例えば、図１４(ａ)に示す各第２巻線補助部材(33a)〜(33d)の外側に、それぞれＬ字状の巻線補助部材を追加すると共に、追加した４つのＬ字状巻線補助部材を第１巻線補助部材(32a)〜(32d)及び第２巻線補助部材(32a)〜(32d)と同様に前記第１位置と第２位置との間で往復移動可能な構成とすることにより、４種類の単位巻部からなる空芯コイルを作製することが出来る。 In addition, each part structure of this invention is not restricted to the said embodiment, A various deformation | transformation is possible within the technical scope as described in a claim. For example, the unit winding part constituting the air-core coil is a unit winding part having a maximum inner peripheral length, a unit winding part having an intermediate inner peripheral length, and a unit having a minimum inner peripheral length, such as the air core coil (2a) shown in FIG. It is not limited to three types of winding parts, and it is also possible to constitute an air-core coil comprising three or more types of unit winding parts having different inner peripheral lengths. For example, an L-shaped winding auxiliary member is added to the outside of each of the second winding auxiliary members (33a) to (33d) shown in FIG. 14 (a), and four additional L-shaped windings are added. Similar to the first winding auxiliary members (32a) to (32d) and the second winding auxiliary members (32a) to (32d), the auxiliary member can reciprocate between the first position and the second position. By doing so, an air-core coil composed of four types of unit windings can be produced.
又、図１９に示す空芯コイル(２ｂ)においては、コア(１)のギャップ部(14)に対応する位置に、単層或いは２層の単位巻部からなる単位コイル部を形成したがこれに限らず、単層或いは２層の単位巻部からなる単位コイル部は、空芯コイル(２ｂ)の巻き軸方向の任意の途中位置に形成することが出来る。 Further, in the air-core coil (2b) shown in FIG. 19, a unit coil portion consisting of a single-layer or two-layer unit winding portion is formed at a position corresponding to the gap portion (14) of the core (1). However, the unit coil portion composed of a single-layer or two-layer unit winding portion can be formed at any intermediate position in the winding axis direction of the air-core coil (2b).
(１) コア
(10) ボビン
(14) ギャップ部
(２) コイル
(２ａ)(２ｂ) 空芯コイル
(21) 第１層
(22) 第２層
(23) 第３層
(25) 第１単位巻部
(26) 第２単位巻部
(27) 第３単位巻部
(28a) 第１傾斜部
(28b) 第２傾斜部
(29a)(29b) コイル中間製品
(３) 対向部材
(31) 挿入孔
(32) 巻線補助部材
(32a)〜(32d) 第１巻線補助部材
(33a)〜(33d) 第２巻線補助部材
(４) 空芯コイル
(40) 導線
(41) 第１単位巻部
(42) 第２単位巻部
(５) 巻芯部材
(51a)(51b) 割型
(52) 楔状部材
(53) コイルバネ
(７) 自動巻線機
(71) 回転体
(72) 回転駆動機構
(73) ガイド機構
(75)(76) エアシリンダ
(1) Core
(10) Bobbin
(14) Gap part
(2) Coil
(2a) (2b) Air-core coil
(21) First layer
(22) Second layer
(23) Third layer
(25) 1st unit winding part
(26) Second unit winding
(27) Third unit winding
(28a) First inclined part
(28b) Second inclined part
(29a) (29b) Coil intermediate products
(3) Opposing member
(31) Insertion hole
(32) Winding auxiliary member
(32a) to (32d) First winding auxiliary member
(33a) to (33d) Second winding auxiliary member
(4) Air core coil
(40) Conductor
(41) First unit winding
(42) Second unit winding
(5) Core member
(51a) (51b) Split type
(52) Wedge-shaped member
(53) Coil spring
(7) Automatic winding machine
(71) Rotating body
(72) Rotation drive mechanism
(73) Guide mechanism
(75) (76) Air cylinder
Claims (6)
回転駆動機構(72)と、該回転駆動機構(72)によって回転駆動される巻芯部材(５)と、該巻芯部材(５)の回転軸と同軸上に対向配備され該回転軸を中心に回転可能な対向部材(３)と、前記巻芯部材(５)及び対向部材(３)の内、少なくとも何れか一方の部材を他方の部材に対して接近離間する方向に駆動する往復移動機構とを具え、前記対向部材(３)の巻芯部材(５)との対向面には、導線をガイドするための導線ガイド面(35)が形成され、該導線ガイド面(35)には、前記巻芯部材(５)が挿入されるべき挿入孔(31)が凹設され、該挿入孔(31)の外側には、該挿入孔(31)に挿入された巻芯部材(５)の外周面の一部を覆う形状を有する巻線補助部材(32)が配備され、該巻線補助部材(32)は、駆動機構に連結されて、該駆動機構により、前記導線ガイド面(35)から前記巻芯部材(５)に向けて突出した第１位置と、対向部材(３)の内部に収容された第２位置との間で、前記回転軸に沿って往復移動が可能であることを特徴とする自動巻線機。 Unit coil portions formed by spirally winding at least one conducting wire are repeatedly arranged in the winding axis direction, and each unit coil portion is formed from a plurality of unit winding portions having different inner circumferential lengths. An automatic winding machine for producing an air-core coil in which at least a part of a unit winding portion with a small inner peripheral length is pushed inside a unit winding portion with a large inner peripheral length,
A rotational drive mechanism (72), a core member (5) that is rotationally driven by the rotational drive mechanism (72), and disposed coaxially with the rotational axis of the core member (5) and centered on the rotational axis And a reciprocating mechanism for driving at least one of the core member (5) and the facing member (3) in a direction to approach and separate from the other member. And a conductive wire guide surface (35) for guiding a conductive wire is formed on a surface of the opposing member (3) facing the core member (5), and the conductive wire guide surface (35) includes: An insertion hole (31) into which the core member (5) is to be inserted is recessed, and the core member (5) inserted into the insertion hole (31) is formed outside the insertion hole (31). A winding auxiliary member (32) having a shape covering a part of the outer peripheral surface is provided, and the winding auxiliary member (32) is connected to a drive mechanism, and the lead mechanism guide surface (35) is connected to the drive mechanism. From the core member (5) automatic, characterized in that reciprocation is possible along the rotation axis between a first position protruding toward the fifth position and a second position accommodated inside the opposing member (3). Winding machine.
該第１工程を経て得られた中間製品を巻き軸方向に圧縮して、各単位コイルを構成する複数の単位巻部の内、内周長の大きな単位巻部の内側に内周長の小さな単位巻部の少なくとも一部を押し込む第２工程
とを有する空芯コイルの製造方法において、
前記第１工程では、回転体の外周面に導線を巻回することにより前記中間製品を作製し、該回転体には、巻芯部材(５)と、該巻芯部材(５)の導線巻回位置に出没し該巻芯部材(５)の外周面の一部を覆う第１位置と該外周面を露出させる第２位置との間で往復移動可能な巻線補助部材(32)とが配備されており、前記第１工程では、前記回転体を回転させ、該回転体が所定の回転角度だけ回転する毎に、前記巻線補助部材(32)を前記第１位置と第２位置との間で往復移動させると共に、該回転体が１回転する毎に、巻回した導線を前記導線巻回位置から巻芯部材(５)の回転軸方向に少なくとも導線の直径に相当する距離分だけ離間させることによって、前記導線巻回位置にて導線を巻線補助部材(32)或いは巻芯部材(５)の外周面に巻回し、互いに内周長の異なる複数の単位巻部を前記回転軸方向に連続して形成することを特徴とする空芯コイルの製造方法。 By winding at least one conducting wire in a spiral shape, a plurality of unit winding portions having different inner peripheral lengths are continuously formed in the winding axis direction, and a unit coil portion comprising the plurality of unit winding portions Are repeatedly formed in the winding axis direction to produce an intermediate product of an air-core coil,
The intermediate product obtained through the first step is compressed in the winding axis direction, and the inner peripheral length is small inside the unit winding portion having a large inner peripheral length among the plurality of unit winding portions constituting each unit coil. In the manufacturing method of the air-core coil having the second step of pushing at least a part of the unit winding part,
In the first step, the intermediate product is manufactured by winding a conducting wire around the outer peripheral surface of the rotating body. The rotating member includes a core member (5) and a winding of the core member (5). A winding auxiliary member (32) capable of reciprocating between a first position that appears at the turning position and covers a part of the outer peripheral surface of the core member (5) and a second position that exposes the outer peripheral surface is provided. In the first step, the winding auxiliary member (32) is moved to the first position and the second position each time the rotating body is rotated and the rotating body rotates by a predetermined rotation angle. Each time the rotating body makes one revolution, the wound conductor is at least a distance corresponding to the diameter of the conductor in the direction of the axis of rotation of the core member (5) from the conductor winding position. By separating them, the conducting wire is wound around the outer peripheral surface of the winding auxiliary member (32) or the core member (5) at the conducting wire winding position, and the inner circumferential length of each other A method of manufacturing an air-core coil, wherein a plurality of different unit winding portions are formed continuously in the direction of the rotation axis.
第１空芯コイル部を構成する複数の単位コイルはそれぞれ、互いに内周長の異なる複数の単位巻部から形成され、内周長の大きな単位巻部の内側に内周長の小さな単位巻部の少なくとも一部が押し込まれており、
第２空芯コイル部を構成する複数の単位コイルはそれぞれ、少なくとも第１空芯コイル部の最内周に位置する単位巻部に対応する最内周の単位巻部が欠落して、単一の単位巻部、若しくは第１空芯コイル部の各単位コイル部を形成する単位巻部の数よりも少ない複数の単位巻部から構成され、該複数の単位巻部は互いに内周長が異なり、内周長の大きな単位巻部の内側に内周長の小さな単位巻部の少なくとも一部が押し込まれていることを特徴とする空芯コイル。 A unit coil formed by winding at least one conducting wire in a spiral shape is an air core coil configured to be repeatedly arranged in the winding axis direction, and the first air core coil portion and the second coil arranged in the winding axis direction. An air core coil,
Each of the plurality of unit coils constituting the first air-core coil unit is formed of a plurality of unit winding portions having different inner circumferential lengths, and a unit winding portion having a smaller inner circumferential length is disposed inside the unit winding portion having a larger inner circumferential length. At least part of
Each of the plurality of unit coils constituting the second air-core coil portion is missing at least the innermost unit winding portion corresponding to the unit winding portion located on the innermost circumference of the first air-core coil portion. Or a plurality of unit windings less than the number of unit windings forming each unit coil part of the first air-core coil part, and the plurality of unit winding parts have different inner peripheral lengths. An air-core coil in which at least a part of a unit winding portion having a small inner peripheral length is pushed inside a unit winding portion having a large inner peripheral length.
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| CN109103000A (en) * | 2017-06-20 | 2018-12-28 | 胜美达集团株式会社 | The manufacturing method of flat coil, reactor and reactor |
| JP7039868B2 (en) | 2017-06-20 | 2022-03-23 | スミダコーポレーション株式会社 | Reactor and reactor manufacturing method |
| CN109103000B (en) * | 2017-06-20 | 2022-09-27 | 胜美达集团株式会社 | Edgewise coil, reactor, and method for manufacturing reactor |
| CN109712803A (en) * | 2019-01-28 | 2019-05-03 | 深圳市金冠威科技有限公司 | Automatic coil winding machine and coiling are bonded all-in-one machine |
| CN109712803B (en) * | 2019-01-28 | 2023-12-26 | 深圳市金冠威科技有限公司 | Automatic winding machine and winding and laminating integrated machine |
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